ProMinent Ultromat ULFa User manual

Ultromat® ULFa
Continuous Flow System
Assembly and operating instructions
A0777
Original Operating Instructions (2006/42/EC)Part no. 985956 BA UL 023 05/11 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.

985956, 2, en_GB
© 2011
ProMinent Dosiertechnik GmbH
Im Schuhmachergewann 5 - 11
69123 Heidelberg
Telephone: [phone]
Fax: [phone]
email: [email protected]
Internet: www.prominent.com
2

In order to make it easier to read, this document uses the male
form in grammatical structures but with an implied neutral sense. It
is aimed equally at both men and women. We kindly ask female
readers for their understanding in this simplification of the text.
Read the following supplementary information in its entirety!
The following are highlighted separately in the document:
nEnumerated lists
Instructions
ðResults of the instructions
Information
This provides important information relating to the cor‐
rect operation of the system or is intended to make
your work easier.
Safety information
Safety information are provided with detailed descriptions of the
endangering situation, see
Ä Chapter 2.1 “Explanation of the
safety information” on page 10
General non-discriminatory approach
Supplementary information
Supplemental instructions
3

Table of contents
1Product identification............................................................. 7
1.1 Identity code ULFa ....................................................... 7
2 Safety and responsibility..................................................... 10
2.1 Explanation of the safety information.......................... 10
2.2 Correct and Proper Use.............................................. 12
2.3 Users' qualifications.................................................... 12
2.4 Ultromat® Safety Information...................................... 13
2.5 Description and testing of safety equipment............... 14
2.6 Sound Pressure Level................................................ 15
3 Transporting and storing the system................................... 16
4Information on the system................................................... 17
4.1 Design......................................................................... 17
4.2 Technical data............................................................ 17
5 Design and function............................................................ 21
5.1 System construction................................................... 21
5.2 Description of the Component Assemblies................. 21
5.2.1 Three-chamber storage tank................................... 22
5.2.2 Crane Lifting Lugs.................................................... 22
5.2.3 Water fitting with flush fitting.................................... 22
5.2.4 Powder feeder......................................................... 24
5.2.5 Vibrator ................................................................... 24
5.2.6 Stirrers..................................................................... 25
5.2.7 Control cabinet......................................................... 25
5.2.8 Power Socket for connection of a powder feeder
device...................................................................... 25
5.2.9 Concentrate piping .................................................. 25
5.2.10 Evaluation of the lack of water state for the redilu‐
tion unit.................................................................. 25
5.2.11 Empty signal for concentrate tank ........................ 26
5.2.12 Dosing monitor for liquid concentrate.................... 26
5.2.13 Top hopper 50 l, 75 l and 100 l ............................. 26
5.2.14 Powder feeder device for automatic refilling ......... 26
6 Assembly and installation................................................... 27
6.1 Assembly.................................................................... 27
6.2 Installation, hydraulic.................................................. 27
6.3 Installation, electrical.................................................. 28
6.3.1 Mains Power Connection......................................... 28
6.3.2 Adjusting the capacitive sensors............................. 29
7 Operation of the Sinamics G110 frequency converter........ 30
7.1 Function of the operating elements............................ 30
7.2 Setting the FU parameters.......................................... 31
8 General notes on operation................................................ 32
8.1 Operating Menu ULFa................................................ 33
8.2 Start screen................................................................ 34
8.3 Operating mode change............................................. 35
Table of contents
4

8.4 User administration..................................................... 36
8.4.1 User groups............................................................. 36
8.4.2 Login........................................................................ 37
8.5 Entering values on the touch panel............................ 38
8.6 Selecting the dosing product...................................... 39
8.7 Remote Operation...................................................... 40
8.8 Jump to the Archive [F3]............................................. 40
8.9 Level display............................................................... 41
8.10 Water supply............................................................. 42
8.11 Redilution.................................................................. 42
8.12 Operating mode MANUAL ....................................... 42
9 The operating menu [F2]..................................................... 44
9.1 Parameter................................................................... 44
9.1.1 Parameter [WATER]................................................ 45
9.1.2 Parameter [Stirrer]................................................... 46
9.1.3 Parameter [Powder]................................................. 47
9.1.4 Parameter [Liquid]................................................... 48
9.1.5 Parameter [Level].................................................... 49
9.2 Calibration................................................................... 50
9.2.1 Calibration Powder.................................................. 50
9.2.2 Calibration liquid concentrate.................................. 51
9.2.3 Calibration Flow monitor ("Spectra" only)................ 52
9.2.4 Calibration Water..................................................... 54
9.3 System........................................................................ 55
9.3.1 Changing the language............................................ 55
9.3.2 Setting date and time............................................... 56
9.3.3 Touch Panel............................................................. 57
9.4 Concentration............................................................. 58
9.5 Information.................................................................. 59
9.5.1 Ultromat Identity code.............................................. 59
9.5.2 Software Version..................................................... 60
9.6 Service........................................................................ 60
9.6.1 Service..................................................................... 60
10 Operation of the system...................................................... 65
10.1 Normal mode............................................................ 65
10.1.1 Prerequisites for correct and proper operation...... 65
10.1.2 Refilling the feed hopper with powdered polymer . 65
10.1.3 Refilling the concentrate storage tank with liquid
polymer.................................................................. 66
10.2 Behaviour When Switching on Mains Power and in
the Event of Mains Power Failure............................. 66
10.3 Decommissioning..................................................... 66
10.4 Disposal of used parts.............................................. 67
11 Incorrect Operation of the System...................................... 68
12 Commissioning................................................................... 69
13 Maintenance....................................................................... 70
13.1 Inspect the powder feeder and wetting apparatus.... 70
Table of contents
5

13.2 Cleaning the filter insert in the pressure reducer...... 70
13.3 Checking and cleaning the solenoid valve................ 70
13.4 Remove the flow meter (turboDOS) and test............ 71
13.5 Removing the cover of an inspection opening.......... 72
13.6 Cleaning the surface of the storage tank.................. 72
14 Fault messages................................................................... 73
14.1 Troubleshooting........................................................ 73
14.2 General notes on fault messages............................. 74
14.3 Faults - Cause - Remedy.......................................... 74
15 Systems / data sheets......................................................... 78
15.1 Logical states............................................................ 78
15.2 Operating Menu ULFa.............................................. 80
15.3 Commissioning Report............................................. 81
15.4 Lubricating plan........................................................ 82
15.5 Control sequence...................................................... 82
15.6 Declaration of Conformity......................................... 83
16 Index................................................................................... 84
Table of contents
6

1 Product identification
1.1 Identity code ULFa
U
L
F
a
Type / Container Size / Extraction rate
0400 Continuous flow system / 400 l / 400 l/h
1000 Continuous flow system / 1000 l / 1000 l/h
2000 Continuous flow system / 2000 l / 2000 l/h
4000 Continuous flow system / 4000 l / 4000 l/h
6000 Continuous flow system / 6000 l / 6000 l/h
8000 Continuous flow system / 8000 l / 8000 l/h
Construction
N Normal
S Mirror imaged
Electrical connection
A 400 VAC, 50/60 Hz (3ph, N, PE)
Control
0 PLC S7-1200
1PLC S7-1200 with PROFIBUS®
Options
0 without options
Powder feeder
P
0
none
P
1
Powder feeder (0400, 1000)
P
2
Powder feeder (2000)
P
3
Powder feeder (4000, 6000)
P
4
Powder feeder (8000)
Vibrator for powder feeder
0 none
1 with vibrator for powder feeder
Powder feeder device, top hopper
0 none
1 Top hopper 50 l (0400, 1000, 2000)
2 Top hopper 75 l (4000, 6000)
Product identification
7

U
L
F
a
Type / Container Size / Extraction rate
3 Top hopper 100 l (8000)
4 Top hopper 50 l + powder feeder device FG205(0400, 1000, 2000)
5 Top hopper 75 l + powder feeder device FG205(4000, 6000)
6 Top hopper 100 l + powder feeder device FG205(8000)
7 with adapter cover + powder feeder device FG205
Liquid concentrate pump
L0 none
L1 with Sigma
L2 with Spectra
L3 prepared for Sigma
L4 prepared for Spectra
Monitoring for liquid concentrate pump
0 none
1 with float switch for concentrate tank
2 with flow monitor (Spectra only)
3 with float switch and flow monitor (Spectra only)
Water pipework for flush fitting
1 Y-flush inlet, PVC (0400,1000,2000)
2 Y-flush inlet, PVC (4000,6000)
3 Y-flush inlet, PVC (8000)
4 Wetting cone, PVC (0400,1000,2000)
5 Wetting cone, PVC (4000,6000)
6 Wetting cone, PVC (8000)
7 Wetting cone, PP (0400,1000,2000)
8 Wetting cone, PP (4000,6000)
9 Wetting cone, PP (8000)
Stirrer for 3. Chamber
0 none
1 Stirrer for storage tank 400, 0.18 kW
2 Stirrer for storage tank 1000, 0.55 kW
3 Stirrer for storage tank 2000, 0.75 kW
4 Stirrer for storage tank 4000/6000, 1.1 kW
5 Stirrer for storage tank 8000, 2.2 kW
Language
Product identification
8

U
L
F
a
Type / Container Size / Extraction rate
DE German
EN English
FR French
ES Spanish
IT Italian
CZ Czech
NL Dutch
PL Polish
PT Portuguese
RU Russian
Product identification
9

2 Safety and responsibility
The Ultromat® manufactured by ProMinent is an automatic polye‐
lectrolyte preparation system. It can be used in any application
where synthetic polymers are to be automatically prepared to form
polymer solutions to act as flocculation aids. As such a dissolving
station, the system is suitable for a large number of process engi‐
neering applications, e.g. in the water treatment sector, in waste
water treatment and paper manufacture.
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.
About this product
Introduction
Safety and responsibility
10

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.
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.
Safety and responsibility
11

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
2.3 Users' qualifications
WARNING!
Danger of injury with inadequately qualified personnel!
The operator of the plant / device is responsible for
ensuring that the qualifications are fulfilled.
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
Training Definition
Instructed personnel An 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.
Trained user A trained user is a person who fulfils the requirements made of an instructed
person and who has also received additional training specific to the system
from ProMinent or another authorised distribution partner.
Safety and responsibility
12

Training Definition
Trained qualified per‐
sonnel
A qualified employee is deemed to be a person who is able to assess the
tasks assigned to him and recognize possible hazards based on his/her
training, knowledge and experience, as well as knowledge of pertinent regula‐
tions. The assessment of a person's technical training can also be based on
several years of work in the relevant field.
Electrician Electricians are deemed to be people, who are able to complete work on elec‐
trical systems and recognize and avoid possible hazards independently based
on his/her technical training and experience, as well as knowledge of pertinent
standards and regulations.
Electricians should be specifically trained for the working environment in
which the are employed and know the relevant standards and regulations.
Electricians must comply with the provisions of the applicable statutory direc‐
tives on accident prevention.
Customer Service depart‐
ment
Customer 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!
2.4 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 ope‐
ration.
The mains switch must be set to "0" and secured
against restart before any installation or maintenance
work can begin.
Safety and responsibility
13

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!
2.5 Description and testing of safety equipment
A0427
Fig. 1: Safety Equipment
1. Main switch
2. "Warning of hazardous electrical voltage"
warning label
3. Cover of inspection opening with "Warning of
injury to hands" warning label
4. "Warning of hot surfaces" warning label
The red-yellow main switch on the right-hand side of the control
cabinet disconnects the system and any connected units.
Safety Equipment
Main switch
Safety and responsibility
14

Test: With all parts of the system are operational, switch the main
switch to
“Off” - all of the parts must stop - all the lights must go
out.
The screw covers of the inspection openings prevent persons
injuring their hands on the rotating propellers of the stirrers.
Test: Check that the covers of the inspection openings are being
used and are secured with screws
A0428
Fig. 2: Warning labels
I. Warning of injury to hands
II. Warning of hazardous electrical voltage
III. Warning of hot surfaces
Test: Check whether the labels are still affixed and legible.
2.6 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)
Covers of inspection openings
Warning labels
Safety and responsibility
15

3 Transporting and storing the system
User qualification: trained user, see
Ä Chapter 2.3 “Users' qualifi‐
cations” on page 12
WARNING!
High system weight
Possible consequence: Death or severe injuries, if the
floor cannot support the system and breaks.
Measure: Ensure that the floor of the installation site
can support the weight of both the empty and full
system.
WARNING!
Never stand under suspended loads.
Possible consequence: Fatal or very serious injuries
– It is prohibited to walk under or stand underneath
suspended loads
–When lifting and transporting the Ultromat ensure it
cannot slip or topple
– Use suitable approved lifting tackle. Observe the
information given in the lifting equipment data
sheets.
– Ultromat® systems of type 4000 and 8000 may
only be lifted with a traverse if they are fitted with
lifting lugs. The length of the traverse must be at
least 10 - 20 cm longer than the storage tank
CAUTION!
Possibility of damage to the system during transport
Improper transport can result in system damage.
– Only move the Ultromat® system when empty
–The storage tank wall must not be subjected to
point loading
– Avoid heavy vibration 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 storage tank
– If a crane is used, attach the slings, even if lifting
lugs are fitted, such that shear forces are avoided
Permissible ambient temperature: -5 °C to +50 °C.
Humidity: None. Rain and condensation not permitted.
Other: No dust, no direct sunlight.
Ambient conditions for storage and
transport
Transporting and storing the system
16

4 Information on the system
The Ultromat® manufactured by ProMinent is an automatic polye‐
lectrolyte preparation system.
It can be used in any application where synthetic polymers are to
be automatically prepared to form polymer solutions e.g. to act as
flocculation aids. As such a dissolving station, the system is suit‐
able for a large number of process engineering applications, e.g. in
the water treatment sector, in waste water treatment and paper
manufacture.
4.1 Design
The system is designed for the fully automatic batching of polymer
solutions.
Almost all commercially available polymers can be used. Under the
control of Ultromat® systems, concentrations from 0.05 to 1.0 %
can be set. The viscosity of the polymer solution produced must
not however exceed 1500 mPas. Please refer to the polymer sup‐
pliers' application data sheets 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 range. 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 extraction rate and the volumetric capacity of
the Ultromat® and is approximately 60 minutes at a maximum
extraction rate. The system capacities extend from max. 400 l
usage solution per hour for the Ultromat® 400 up to 8,000 l for the
Ultromat® 8000.
4.2 Technical data
Please refer to the dimensions sheet for the precise
dimensions of your Ultromat® system
Information on the system
17

Ultromat® ULFa
Ultromat® ULFa 400 1000 2000 4000 6000 8000
Storage tank volume
(l)
400 1000 2000 4000 6000 8000
Extraction rate (l/h) 400 1000 2000 4000 6000 8000
Maturing time (min) 60
Solution concentra‐
tion (%)
0.05 - 1.0
Dimensions
LxWxH (mm)
1999x918
x1390
2643x1002
x1740
3292x1186
x1890
3301x1456
x2182
4120x1651
x2182
4605x1910
x2290
Net weight (kg) 190 400 450 600 900 1,200
Total weight (kg) 590 1400 2450 4600 6900 9200
Overflow connection DN 40 DN 50 DN 50 DN 65 DN 65 DN 80
Extraction connec‐
tion
DN 25 DN 25 DN 32 DN 40 DN 40 DN 50
Water supply for
redilution
1" 1" 1" 1 1/2" 1 1/2" 2"
Liquid concentrate -
pipework
DN 15 DN 15 DN 15 DN 20 DN 20 DN 20
Max. water supply 600 l/h 1,500 l/h 3,000 l/h 6,000 l/h 9000 l/h 12,000 l/h
Electrical rating 1.5 kW 2.6 kW 3.2 kW 5.0 kW 5.0 kW 9.5 kW
External fuse 32 A 32 A 32 A 32 A 32 A 32 A
Degree of protection
control cabinet
IP 55 IP 55 IP 55 IP 55 IP 55 IP 55
Stirrer 1
Performance 0.25 kW 0.55 kW 0.75 kW 1.1 kW 1.1 kW 2.2 kW
Speed (50 Hz) 700 rpm 700 rpm 700 rpm 700 rpm 700 rpm 750 rpm
Degree of protection IP 55 IP 55 IP 55 IP 55 IP 55 IP 55
Stirrer for chambers 2 + 3 (optional)
Performance 0.18 kW 0.55 kW 0.75 kW 1.1 kW 1.1 kW 2.2 kW
Speed (50 Hz) 700 rpm 700 rpm 700 rpm 700 rpm 700 rpm 700 rpm
Degree of protection IP 55 IP 55 IP 55 IP 55 IP 55 IP 55
Powder feeder
Type TGD 11 TGD 11 TGD 18 TGD 55 TGD 55 TGD 110
Maximum capacity 11 kg/h 11 kg/h 18 kg/h 55 kg/h 55 kg/h 110 kg/h
Pressure sensor
Part number 1038273 1038273 1038273 1038273 1038273 1038273
Type dT P30 dT P30 dT P30 dT P30 dT P30 dT P30
Measuring range 0-160 mbar 0-160 mbar 0-160 mbar 0-160 mbar 0-160 mbar 0-160 mbar
Information on the system
18

Ultromat® ULFa 400 1000 2000 4000 6000 8000
Signal 1 - 6 V 1 - 6 V 1 - 6 V 1 - 6 V 1 - 6 V 1 - 6 V
Turbodos
Part number 1025379 1025379 1025379 1025379 1025379 1040023
Pulse/litre 67.5 67.5 67.5 67.5 67.5 26.6
Output PNP PNP PNP PNP PNP PNP
Metering pumps of the Ultromat® ULFa
Ultromat® ULFa 400 1000 2000 4000 6000 8000
Sigma
Type S1CaH 12017 12035 12035 10050 10050 10050
Capacity 17 l/h 35 l/h 35 l/h 50 l/h 50 l/h 50 l/h
Degree of protection IP 65 IP 65 IP 65 IP 65 IP 65 IP 65
Spectra
Type Spectra 12 / 13 F 12 / 33 F 12 / 33 F 12 / 100 F 12 / 100 F 12 / 100 F
Capacity 13 l/h 33 l/h 33 l/h 100 l/h 100 l/h 100 l/h
Degree of protection IP 55 IP 55 IP 55 IP 55 IP 55 IP 55
A0429
Fig. 3: System dimensions
I. Height (H)
II. Width (B)
III. Length (L)
Information on the system
19

Ambient conditions
Value
Storage and transport temperature - 5 °C ... + 50 °C
Operation temperature + 5 °C ... + 40 °C
Storage and operation air humidity < 92 % relative air humidity (non-condensing)
Powdered polymer air humidity Observe the instructions of the polymer manufacturer. If
necessary use an air dehumidifier
System sound pressure level < 70 dB (A)
Information on the system
20