ProMinent Ultromat AF Series User manual

Ultromat® AF and ATF
with Terminal Boxes and Pressure Sensor
Assembly and operating instructions
A0542
Original operating instructions (2006/42/EC)Part No. 986104 BA UL 019 06/10 EN
Please carefully read these operating instructions before use! · Do not discard!
The operator shall be liable for any damage caused by installation or operating errors!
Technical changes reserved.

986104, 2, en_GB
© 2010
ProMinent Dosiertechnik Heidelberg GmbH
Im Schuhmachergewann 5 - 11
69123 Heidelberg
Telephone: [phone]
Fax: [phone]
email: [email protected]
Internet: www.prominent.com
2

Table of contents
1Ultromat® product identification............................................. 5
1.1 Ultromat® AF with Pressure Sensor product identifi‐
cation............................................................................ 5
1.2 Ultromat® ATF with pressure sensor product identifi‐
cation............................................................................ 5
1.3 Front view Ultromat® AF/ATF with pressure sensor..... 5
1.4 Plan view Ultromat® AF/ATF with pressure sensor...... 6
1.5 About This Product....................................................... 6
2 Safety Chapter...................................................................... 7
2.1 Explanation of the safety information............................ 7
2.2 Correct and Proper Use................................................ 8
2.3 Users' Qualifications..................................................... 9
2.4 Information in the Event of an Emergency.................. 10
2.5 Description and Testing of the Safety Equipment....... 10
2.6 Ultromat® Safety Information...................................... 11
2.7 Sound Pressure Level................................................ 11
3 Transport and Storage of the System................................. 12
3.1 Transport and Storage of the System......................... 12
4 Information on the system................................................... 13
4.1 Application.................................................................. 13
4.2 Design......................................................................... 13
4.3 System dimensions..................................................... 13
5 Design and function............................................................ 16
5.1 Three-chamber reservoir............................................ 16
5.2 Flush fitting................................................................. 16
5.3 Dry Material Feeder (ATF only).................................. 16
5.4 Agitators...................................................................... 17
5.5 Power Socket for the Connection of a Conveyor (only
ATF) ........................................................................... 17
5.6 Terminal Box............................................................... 17
5.7 Crane Lifting Lugs....................................................... 17
5.8 Ultromat® options........................................................ 17
5.8.1 Agitator for Chamber 3 (Agitator 3).......................... 17
5.8.2 Overflow Protection for the Ultromat® ..................... 17
5.8.3 Vibrator ................................................................... 17
5.8.4 Discharge pipework................................................. 18
6 Assembly and Installation................................................... 19
6.1 Assembly.................................................................... 19
6.2 Installation - Hydraulic................................................ 19
6.3 Installation - Electrical................................................. 20
7 Controller............................................................................ 21
7.1 Terminal boxes AF/ATF.............................................. 21
8 Commissioning................................................................... 22
8.1 Assembly, Preparatory Work...................................... 22
8.2 Settings for Commissioning........................................ 22
8.3 Water Supply Setting.................................................. 22
8.4 Calibrating the Dry Material Feeder............................ 23
8.5 Adjusting the Concentration........................................ 23
Table of contents
3

8.5.1 Adjusting the Concentration of the Polymer Solu‐
tion in the Ultromat® AF / ATF................................. 23
8.6 Adjusting the Capacitive Sensor................................. 24
8.7 Operation of the System............................................. 24
9 Operation of the System..................................................... 26
9.1 Prerequisites for Correct and Proper Operation......... 26
9.2 Feeding the Dry Material Feeder with Powdered Pol‐
ymer (ATF).................................................................. 26
9.3 Behaviour When Switching on Mains Power and in
the Event of Mains Power Failure............................... 26
9.4 Decommissioning....................................................... 26
9.5 Disposal...................................................................... 27
10 Incorrect Operation of the System...................................... 28
11 Troubleshooting.................................................................. 29
11.1 Unspecified Malfunctions.......................................... 29
11.2 Sensors..................................................................... 29
12 Maintenance....................................................................... 30
12.1 Dry Material Feeder.................................................. 30
12.2 Cleaning the Screen Insert in the Pressure
Reducer.................................................................... 30
12.3 Dismantling the Cover of an Inspection Opening..... 30
12.4 Cleaning the Surface of the Ultromat®...................... 30
13 Spare Parts and Accessories.............................................. 31
14 Appendix............................................................................. 32
15 EC Declaration of Conformity............................................. 34
16 Commissioning report......................................................... 35
17 Index................................................................................... 36
Table of contents
4

1 Ultromat® product identification
1.1 Ultromat® AF with Pressure Sensor product identification
Ultromat AF 1037294 1037295 1037296 1037297 1037298 1037299
Type AF 400 AF 1000 AF 2000 AF 4000 AF 6000 AF 8000
Reservoir
content (litre)
400 1000 2000 4000 6000 8000
1.2 Ultromat® ATF with pressure sensor product identification
Ultromat ATF 1037300 1037301 1037302 1037303 1037314 1037315
Type ATF 400 ATF 1000 ATF 2000 ATF 4000 ATF 6000 ATF 8000
Reservoir
content (litre)
400 1000 2000 4000 6000 8000
1.3 Front view Ultromat® AF/ATF with pressure sensor
A0543
1. 2. 3. 4. 5. 6.
7.
8.
9.
10.11.12.13.
Fig. 1: Front view Ultromat AF/ATF with pressure sensor
1. Agitator for chamber 1 8. Overflow
2. Dry material feeder (ATF) 9. Stopcock
3. Liquid polymer connection 10. Flow meter
4. Y-Flush inlet 11. Solenoid valve
5. Agitator for chamber 2 12. Pressure reducer
6. Terminal box 13. Shut-off valve
7. Agitator for chamber 3 (optional)
Ultromat® product identification
5

1.4 Plan view Ultromat® AF/ATF with pressure sensor
1. 2. 3.
4.
5.
6.
7.
8.9. A0548
Fig. 2: Plan view Ultromat® AF/ATF with pressure sensor
1. Dry material feeder (ATF) 6. Discharge pipework (optional)
2. Motor for dry material feeder (ATF) 7. Inspection opening for chamber 2
3. Inspection opening for chamber 3 8. Metering pipe heating (ATF)
4. Pressure sensor level measurement chamber 3 9. Inspection opening for chamber 1
5. Shut-off valves
1.5 About This Product
The Ultromat® AF/ATF from ProMinent is a preparation system for
polyelectrolytes for connection to an external control.
The Ultromat® AF can be used in any application where synthetic
liquid polymers have to be prepared for working solutions.
The Ultromat® ATF can be used in any application where free-
flowing synthetic powder polymers or liquid polymers have to be
prepared for working solutions.
Ultromat® product identification
6

2 Safety Chapter
2.1 Explanation of the safety information
These operating instructions provide information on the technical
data and functions of the product. These operating instructions pro‐
vide detailed safety information and are provided as clear step-by-
step instructions.
The safety information and notes are categorised according to the
following scheme. A number of different symbols are used to
denote different situations. The symbols shown here serve only as
examples.
DANGER!
Nature and source of the danger
Consequence: Fatal or very serious injuries.
Measure to be taken to avoid this danger
Danger!
–Denotes an immediate threatening danger. If this is
disregarded, it will result in fatal or very serious
injuries.
WARNING!
Nature and source of the danger
Possible consequence: Fatal or very serious injuries.
Measure to be taken to avoid this danger
Warning!
–Denotes a possibly hazardous situation. If this is
disregarded, it could result in fatal or very serious
injuries.
CAUTION!
Nature and source of the danger
Possible consequence: Slight or minor injuries, mate‐
rial damage.
Measure to be taken to avoid this danger
Caution!
–Denotes a possibly hazardous situation. If this is
disregarded, it could result in slight or minor inju‐
ries. May also be used as a warning about material
damage.
Ultromat® AF/ATF
Introduction
Safety Chapter
7

NOTICE!
Nature and source of the danger
Damage to the product or its surroundings
Measure to be taken to avoid this danger
Note!
–Denotes a possibly damaging situation. If this is
disregarded, the product or an object in its vicinity
could be damaged.
Type of information
Hints on use and additional information
Source of the information, additional measures
Information!
– Denotes hints on use and other useful information.
It does not indicate a hazardous or damaging sit‐
uation.
2.2 Correct and Proper Use
WARNING!
Danger caused by incorrect use!
Incorrect use of the Ultromat® can result in hazardous
situations.
– The Ultromat® is only designed to produce a pol‐
ymer solution as a flocculent from powdered pol‐
ymer or liquid concentrate and with drinking water.
–All other uses or a modification of the system are
only permitted with the written authorisation of
ProMinent Dosiertechnik GmbH, Heidelberg!
– The system is not designed for use in areas at risk
from explosion!
– The correct and proper operation of the system
cannot be guaranteed if non-genuine parts or third
party accessories are used.
– Please observe the relevant national regulations
and the information provided in the operating
instructions at all phases of the system's life!
– The Ultromat® may only be operated by adequately
qualified personnel
Safety Chapter
8

2.3 Users' Qualifications
WARNING!
Danger of injury with inadequately qualified personnel!
If inadequately qualified personnel work on the unit or
loiter in the hazard zone of the unit, this could result in
dangers that could cause serious injuries and material
damage.
– All work on the unit should therefore only be con‐
ducted by qualified personnel.
–Unqualified personnel should be kept away from
the hazard zone.
Activity Training
Assembly / Installation trained qualified personnel
Commissioning technical experts
Operation instructed personnel
Maintenance / Repair Customer service department
Decommissioning / Disposal technical experts
Troubleshooting instructed personnel
Explanation of the terms:
nA technical expert is deemed to be a person who is able to
assess the tasks assigned to him and recognise possible haz‐
ards based on his/her technical training and experience, as
well as knowledge of pertinent regulations.
Note: A technical qualification is typically proven by the
required completion of a technical training course. The assess‐
ment of a person's technical training can also be based on sev‐
eral years of work in the relevant field.
nA qualified employee is deemed to be a person who is able to
assess the tasks assigned to him and recognise possible haz‐
ards based on his/her technical training, knowledge and experi‐
ence, as well as knowledge of pertinent regulations.
Note: The assessment of a person's technical training can also
be based on several years of work in the relevant field.
nAn instructed person is deemed to be a person who has been
instructed and, if required, trained in the tasks assigned to him/
her and possible dangers that could result from improper
behaviour, as well as having been instructed in the required
protective equipment and protective measures.
nCustomer service department refers to service technicians,
who have received proven training and have been authorised
by ProMinent to work on the system.
Note for the system operator
The pertinent accident prevention regulations, as well
as all other generally acknowledged safety regulations,
must be adhered to!
Safety Chapter
9

2.4 Information in the Event of an Emergency
WARNING!
Information in the Event of an Emergency
Possible consequence: Fatal or very serious injuries.
Switch off the system with the red-yellow mains switch.
External control and control cabinet!
The red-yellow mains switch is located on the opera‐
tor's side. Its precise location depends on the layout on
site. The operator is responsible for labelling this
switch.
2.5 Description and Testing of the Safety Equipment
CAUTION!
Propellers are rotating in the reservoirs!
Slight or minor injuries.
Switch off the system and only then remove the
screwed cover of an inspection opening!
A0094
1
1
12
3
Fig. 3: Safety equipment
Warning labels
n1 Warning label "Warning of injury to hands"
n2 Warning label "Warning of hazardous electrical voltage"
n3 Warning label "Warning of hot surfaces" (ATF)
Test: Check whether the labels are still affixed and legible.
Safety Chapter
10

2.6 Ultromat® Safety Information
WARNING!
Qualification of personnel
Danger due to incorrect operation of the system
The operating personnel must be instructed by a
ProMinent service technician" (When the system is first
operated)
The operating instructions must be available by the
system!
WARNING!
Danger of electric shock!
Possible consequence: Fatal or very serious injuries
The control cabinet must always be closed during
operation.
The mains switch must be set to "0" and secured
against restart before any installation or maintenance
work can begin.
CAUTION!
Propellers are rotating in the reservoirs!
Slight or minor injuries.
Switch off the system and only then remove the
screwed cover of an inspection opening!
CAUTION!
A screw conveyor and a loosening wheel are located
under the safety guard of the dry material feeder.
Slight or minor injuries. Material damage.
Do not reach into the dry material feeder.
CAUTION!
Hot surface!
Incorrectly set heating on the metering pipe may
become hot!
Ensure that the metering pipe heating is correctly set!
2.7 Sound Pressure Level
The sound pressure level is < 70 dB (A) for powdered polymer,
according to EN ISO 11202:1997 (Acoustics - Noise emission from
machinery and equipment)
Safety Chapter
11

3 Transport and Storage of the System
3.1 Transport and Storage of the System
CAUTION!
Fractures in plastic material may result from incorrect
loading
– Only move the Ultromat® system when empty
–The reservoir wall may not be subjected to point
loads
– Avoid heavy vibrations and impact loads
– Only move the system with suitable hoisting and
lifting equipment
– When using forklift trucks, use long forks, which
extend across the entire depth of the three-
chamber reservoir
– If a crane is used, fit the transport belts such that
shear stress is avoided, even if lifting lugs exist
– The support must be able to carry the weight of the
system
Ambient conditions for storage and transport
Permissible ambient temperature: -5 °C to +50 °C
Humidity: none
Other: No dust, no direct sunlight
Transport and Storage of the System
12

4 Information on the system
4.1 Application
The Ultromat® AF/ATF manufactured by ProMinent is a polyelec‐
trolyte preparation system.
4.2 Design
Almost all commercially available polymers can be used.
Concentrations of 0.05 to 0.5 % can be set. The viscosity of the
polymer solution produced may not exceed 1500 mPas. Please
refer to the application data sheets of the polymer suppliers for
information about the viscosity of the different polymer solutions.
Adjust the flow rate of the preparation water to make full use of the
preparation chamber. Concentrations of greater than 0.5 % can
reduce the capacity of the preparation performance.
The maturing time available for the production of a polymer solu‐
tion depends on the discharge quantity and the volumetric capacity
of the Ultromat® and is approximately 60 minutes at a maximum
discharge rate.
4.3 System dimensions
System dimensions
Please refer to the dimensions sheet for the precise
dimensions of the individual Ultromat® system!
Ultromat AF 400 1000 2000 4000 6000 8000
Reservoir
content (litre)
400 1000 2000 4000 6000 8000
Chamber
volume (l)
133 333 666 1333 2000 2666
Discharge
rate (l/h)
400 1000 2000 4000 6000 8000
Maturing time
(min)
60 60 60 60 60 60
Dimensions
LxWxH (mm)
1742x905x87
6
2396x970x12
26
3095x1155x1
377
3081x1433x1
923
3936x1682x1
924
4377x1895x1
929
Net weight
(kg)
140 350 400 550 850 1150
Total weight
(kg)
540 1350 2400 4550 6850 9150
Overflow
connection
DN 40 DN 50 DN 50 DN 65 DN 65 DN 80
Discharge
connection
DN 25 DN 25 DN 32 DN 40 DN 40 DN 50
Water supply
for redilution
1" 1" 1" 1 1/2" 11/2" 2"
Information on the system
13

Ultromat AF 400 1000 2000 4000 6000 8000
Liquid con‐
centrate pipe‐
work
DN 15 DN 15 DN 15 DN 20 DN 20 DN 20
Max. water
supply
1,500 l/h 1,500 l/h 3,000 l/h 6,000 l/h 8,000 l/h 12,000 l/h
Elec. power
input
1.5 kW 2.6 kW 3.2 kW 5.0 kW 5.0 kW 9.5 kW
External fuse 25 A 25 A 25 A 25 A 25 A 40 A
Agitator 1
Power 0.25 kW 0.55 kW 0.75 kW 1.10 kW 1.10 kW 2.20 kW
Speed (50
Hz)
750 rpm 750 rpm 750 rpm 750 rpm 750 rpm 750 rpm
Enclosure
rating
IP 55 IP 55 IP 55 IP 55 IP 55 IP 55
Agitator for
chambers 2 +
3 (optional)
Power 0.18 kW 0.55 kW 0.75 kW 1.10 kW 1.10 kW 1.10 kW
Speed (50
Hz)
750 rpm 750 rpm 750 rpm 750 rpm 750 rpm 750 rpm
Enclosure
rating
IP 55 IP 55 IP 55 IP 55 IP 55 IP 55
Ultromat ATF 400 1000 2000 4000 6000 8000
Reservoir
content (litre)
400 1000 2000 4000 6000 8000
Chamber
volume (l)
133 333 666 1333 2000 2666
Discharge
rate (l/h)
400 1000 2000 4000 6000 8000
Maturing time
(min)
60 60 60 60 60 60
Dimensions
LxWxH (mm)
1742x905x91
6
2396x970x12
66
3095x1155x1
416
3081x1454x1
953
3936x1682x1
953
4377x1895x2
000
Net weight
(kg)
180 390 440 590 890 1190
Total weight
(kg)
580 1390 2440 4590 6890 9190
Overflow
connection
DN 40 DN 50 DN 50 DN 65 DN 65 DN 80
Discharge
connection
DN 25 DN 25 DN 32 DN 40 DN 40 DN 50
Water supply
for redilution
1" 1" 1" 1 1/2" 11/2" 2"
Information on the system
14

Ultromat ATF 400 1000 2000 4000 6000 8000
Liquid con‐
centrate pipe‐
work
DN 15 DN 15 DN 15 DN 20 DN 20 DN 20
Max. water
supply
1,500 l/h 1,500 l/h 3,000 l/h 6,000 l/h 8,000 l/h 12,000 l/h
Elec. power
input
1.5 kW 2.6 kW 3.2 kW 5.0 kW 5.0 kW 9.5 kW
External fuse 25 A 25 A 25 A 25 A 25 A 40 A
Agitator 1
Power 0.25 kW 0.55 kW 0.75 kW 1.10 kW 1.10 kW 2.20 kW
Speed (50
Hz)
750 rpm 750 rpm 750 rpm 750 rpm 750 rpm 750 rpm
Enclosure
rating
IP 55 IP 55 IP 55 IP 55 IP 55 IP 55
Agitator for
chambers 2 +
3 (optional)
Power 0.18 kW 0.55 kW 0.75 kW 1.10 kW 1.10 kW 1.10 kW
Speed (50
Hz)
750 rpm 750 rpm 750 rpm 750 rpm 750 rpm 750 rpm
Enclosure
rating
IP 55 IP 55 IP 55 IP 55 IP 55 IP 55
Powder
feeder
Type TGD 18.13 TGD 18.13 TGD 18.13 TGD 30.13 TGD 30.13 TGD 38.13
Maximum
metering
output at 50
Hz
9 kg/h 9 kg/h 9 kg/h 28 kg/h 28 kg/h 55 kg/h
Information on the system
15

5 Design and function
5.1 Three-chamber reservoir
The PP reservoir is divided into three separate chambers, so that a
sufficient maturing time for the polymer solution can be ensured.
The division of the reservoir largely prevents the matured and
freshly prepared solution from mixing and ensures continuous dis‐
charge.
The fill level of reservoir 3 is measured by a pressure sensor (4 to
20 mA). An additional sensor is optionally available for overflow
protection.
The water pipework supplies the system with the required prepara‐
tion water. The pressure reduced with strainer ensures that the
correct operating pressure is limited and maintained. A solenoid
valve opens and closes the water inlet. A manual shut-off valve
also shuts off the supply of water for maintenance work.
5.2 Flush fitting
The flush fitting ensures that the polymer is intensively wetted with
preparation water.
1. 2. 3.
4.
6.
5.
A0547
Fig. 4: Flush fitting
1. Shut-off valve
2. Pressure reducer
3. Solenoid valve
4. Flow meter float
5. Control valve
6. Y-Flush inlet
5.3 Dry Material Feeder (ATF only)
Please refer to the separate operating instructions entitled "Dry
material feeder" in this documentation for detailed information
about the design and function of the equipment. The heating for
the metering pipe and the minimum fill level sensor for the dry
material hopper are supplied as standard.
Description of the Component Assem‐
blies
Water pipework
Design and function
16

A loosening wheel is fitted directly about the feeder screw for the
continuous discharge of the powdered polymer. A metering pipe
heating unit also removes any penetrated moisture and thus pre‐
vents any caking of the powdered polymer.
5.4 Agitators
The Ultromat® is fitted with two electrical agitators as standard. A
third agitator for chamber 3 can be supplied as an option. The elec‐
trical agitators ensure that the polymer solution is gently agitated.
The electrical agitator 1 has two propellers. The agitators can start
up suddenly as soon as they are supplied with mains power!
5.5 Power Socket for the Connection of a Conveyor (only ATF)
The Ultromat® has a power socket for the connection of a con‐
veyor. The power socket is attached to the side of the terminal box
and is secured electrically by a circuit breaker.
5.6 Terminal Box
The Ultromat® has a terminal box for connection to an external
control. The control is provided by the operator.
5.7 Crane Lifting Lugs
A suitable hoisting can be attached to the four crane lifting lugs.
5.8 Ultromat® options
The following options are available for the Ultromat®.
5.8.1 Agitator for Chamber 3 (Agitator 3)
The Ultromat® is fitted with two electrical agitators as standard. A
third agitator for chamber 3 can be supplied as an option.
5.8.2 Overflow Protection for the Ultromat®
The overflow protection signals that the Ultromat® is overflowing
5.8.3 Vibrator
The vibrator helps to prevent bridging in the dry material feeder so
that the powdered polymer matures better.
Design and function
17

5.8.4 Discharge pipework
The discharge pipework serves to combine the 3 reservoir outlets.
This enables the Ultromat® to be emptied and its contents to be fed
into a drain.
Design and function
18

6 Assembly and Installation
The system is fully pre-assembled ex works. The cabling between
the terminal box and the electrical power units is fully installed.
6.1 Assembly
WARNING!
High fill weight in the system
Possible consequence: Fatal or very serious injuries.
Ensure that the position of the system can bear the
weight of the system when full.
Accessibility of the system
The system must be easily accessible at all times for
operation, maintenance and filling.
Ambient conditions:
Permissible ambient temperature: 5 ℃ to 40 ℃
The system may not be exposed to condensation or rain.
The system may not be exposed to direct sunlight.
6.2 Installation - Hydraulic
CAUTION!
Damage to the environment by the polymer solution is
possible!
Observe the safety data sheet for the polymer and
statutory regulations for disposal when draining the
discharge lines and the overflow line!
NOTICE!
Prerequisites
– The preparation water must be of drinking water
quality
–It must be free of solids and suspended particles
– Inlet water pressure: 3 bar - 5 bar
– The preparation water, overflow and discharge
lines must have the correct dimensions
The overflow and discharge lines must be laid on a gradient and be
operable without counter-pressure!
1. Connect the line for the preparation water to the water fitting.
2. Connect the feed pump to the discharge line.
3. Connect up the discharge lines and lead into a suitable drain.
4. Connect the overflow line to the overflow union and lead into
a suitable drain.
Assembly and Installation
19

6.3 Installation - Electrical
WARNING!
Danger of electric shock!
Possible consequence: Fatal or very serious injuries
– The electrical installation may only be performed
by a qualified electrician
–Always disconnect the system from the mains
power supply and prevent it from being re-con‐
nected before undertaking any installation work in
the electrical connections
– Ensure that the cross-section of the cable is ade‐
quate
– Ensure that the terminals are assigned correctly
when connecting the units
CAUTION!
Danger of malfunction!
Material damage
Ensure that the motors are rotating in the right direc‐
tion ... when connecting the agitators, powder feeder
and motor pumps
Assembly and Installation
20