ProMinent DULCODOS ULIa User manual

DULCODOS ULIa
Polymer Preparation System
Assembly and operating instructions
A3333
Target group: at least trained users, unless otherwise required.
EN
Original operating instructions (2006/42/EC)990379 Version: BA DD 002 05/23 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.
The latest version of the operating instructions are available on our homepage.

In order to make it easier to read, this document uses the male
form in grammatical structures but with an implied neutral sense.
The document is always aimed equally at women, men and
gender-neutral persons. We kindly ask readers for their under‐
standing in this simplification of the text.
Please read the supplementary information in its entirety.
Information
This provides important information relating to the
correct operation of the unit or is intended to make
your work easier.
Warning information
Warning information includes detailed descriptions of the haz‐
ardous situation, see
Ä Chapter 3.2 ‘Labelling of Warning Informa‐
tion’ on page 28 .
The following symbols are used to highlight instructions, links, lists,
results and other elements in this document:
Tab. 1: More symbols
Symbol Description
Action, step by step.
⇨Outcome of an action.
Links to elements or sections of these instructions or other applicable documents.
nList without set order.
[Button] Display element (e.g. indicators).
Operating element (e.g. button, switch).
‘Display/GUI’ Screen elements (e.g. buttons, assignment of function keys).
CODE Presentation of software elements and/or texts.
General non-discriminatory approach
Supplementary information
Supplemental directives
2

Table of contents
1 Function................................................................................ 7
1.1 Fields of application...................................................... 7
1.2 Technical details........................................................... 8
1.3 Types of polymer.......................................................... 8
1.4 Set-up versions............................................................. 8
1.5 System types................................................................ 8
1.6 Selectable components................................................ 9
1.7 Nameplate.................................................................... 9
1.8 Drawing....................................................................... 10
1.8.1 Drawing of DULCODOS ULIa 400 BASIC............... 10
1.8.2 Drawing of DULCODOS ULIa 400 BASIC with
post-dilution............................................................. 12
1.8.3 Drawing of DULCODOS ULIa 400 MEDIUM........... 14
1.8.4 Drawing of DULCODOS ULIa 400 Medium with
post-dilution............................................................. 16
1.8.5 Drawing of DULCODOS ULIa 400 COMFORT....... 18
1.8.6 Drawing of DULCODOS ULIa 400 Comfort with
post-dilution............................................................. 20
1.9 Flow chart................................................................... 22
1.9.1 P&ID: DULCODOS ULIa 400 BASIC....................... 22
1.9.2 P&ID: DULCODOS ULIa 400 BASIC with post-dilu‐
tion........................................................................... 22
1.9.3 P&ID: DULCODOS ULIa 400 MEDIUM................... 23
1.9.4 P&ID: DULCODOS ULIa 400 MEDIUM with post-
dilution..................................................................... 23
1.9.5 P&ID: DULCODOS ULIa 400 COMFORT............... 24
1.9.6 P&ID: DULCODOS ULIa 400 COMFORT with post-
dilution..................................................................... 24
2 Identity code........................................................................ 25
3 Safety and responsibility..................................................... 27
3.1 User qualification........................................................ 27
3.2 Labelling of Warning Information................................ 28
3.3 General safety information.......................................... 29
3.4 Information in the event of an emergency.................. 30
3.5 Intended use............................................................... 30
3.6 Safety information....................................................... 31
3.7 Description and testing of safety equipment............... 31
3.7.1 Safety equipment..................................................... 31
3.7.2 Warning labels......................................................... 32
3.8 Sound pressure level.................................................. 32
4 Storage and transport......................................................... 33
5 Technical data..................................................................... 34
5.1 Technical data for the system..................................... 34
5.2 Technical data for the pump....................................... 35
5.3 Technical data for the main components.................... 35
5.4 Operating conditions................................................... 35
6 Construction and function................................................... 36
6.1 Construction of the system......................................... 36
6.2 Description of the assemblies..................................... 36
6.2.1 Metering pump......................................................... 36
Table of contents
3

6.2.2 Point of injection...................................................... 38
6.2.3 Water apparatus...................................................... 39
6.2.4 Mixing chamber....................................................... 40
6.2.5 Stirrer....................................................................... 41
6.2.6 Maturing chamber.................................................... 41
6.2.7 Control cabinet......................................................... 42
6.3 Optional assemblies................................................... 43
6.3.1 Option: Post-dilution................................................ 43
6.3.2 Option: Automatic flushing....................................... 44
6.3.3 Option: Empty signal for concentrate tank............... 44
6.3.4 Option: Booster pump.............................................. 45
7 Assembly and installation................................................... 46
7.1 Assembly.................................................................... 46
7.2 Installation, hydraulic.................................................. 46
7.3 Installation, electrical.................................................. 47
7.3.1 Mains power connection.......................................... 47
8 Commissioning................................................................... 48
8.1 Leaks and Emissions.................................................. 48
8.2 Personal Protective Equipment (PPE)........................ 49
9 Operation of the system...................................................... 50
9.1 Touch panel/HMI start screen and detail screen........ 50
9.1.1 Display, detail screen, component status................ 51
9.2 Login and user administration..................................... 51
9.2.1 Login........................................................................ 51
9.2.2 User group selection of functions............................ 54
9.3 Operating menu: sub-menu construction and views... 55
9.4 Over structure of the operating menus....................... 56
9.5 Menu: Parameter........................................................ 58
9.5.1 Sub-menu: Process................................................. 58
9.5.2 Sub-menu: Motors / Valves..................................... 58
9.5.3 Sub-menu: Measurement........................................ 59
9.5.4 Sub-menu: Trends................................................... 59
9.6 Control........................................................................ 60
9.6.1 Concentration.......................................................... 60
9.6.2 Option: Capacity/System output.............................. 61
9.6.3 Option: Control of valves VC1 and VC2.................. 61
9.6.4 Option: Booster pump.............................................. 61
9.6.5 Factory settings....................................................... 61
9.7 Calibration................................................................... 62
9.7.1 Calibrating the metering pump................................. 62
9.8 Information.................................................................. 63
9.8.1 Sub-menu: System.................................................. 63
9.8.2 Sub-menu: Statistics................................................ 64
9.8.3 Sub-menu: Software................................................ 64
9.8.4 Sub-menu: Hardware............................................... 64
9.9 System........................................................................ 65
9.9.1 Sub-menu: Language.............................................. 65
9.9.2 Sub-menu: Date and time........................................ 65
9.9.3 Sub-menu: Clean screen......................................... 65
9.9.4 Sub-menu: Hardware configuration......................... 65
9.9.5 Sub-menu: Communication..................................... 66
Table of contents
4

9.10 Service...................................................................... 66
9.10.1 Inputs and outputs................................................. 66
9.10.2 Changing the identity code.................................... 66
9.10.3 Error monitoring..................................................... 66
9.10.4 Commissioning...................................................... 67
9.10.5 Maintenance display.............................................. 67
9.10.6 FAT procedure....................................................... 67
10 Operating modes................................................................ 68
10.1 HMI pre-settings....................................................... 68
10.2 Overview................................................................... 68
10.3 Operating mode: MANUAL....................................... 69
10.4 OFF operating mode................................................. 70
10.5 Operating mode: AUTO............................................ 70
10.6 Start-up: procedure depending on the type of
system...................................................................... 71
10.7 Start-up: Basic version.............................................. 73
10.8 Start-up: Medium version.......................................... 74
10.9 Start-up: Comfort version.......................................... 75
10.10 PAUSE function...................................................... 76
10.11 ARCHIVES - RESET.............................................. 77
10.12 Option: Post-dilution............................................... 77
10.13 Option: Concentrate tank empty signal................... 78
10.14 Option: Booster pump............................................. 78
10.15 Option: Modbus/Profibus/Profinet data communi‐
cation...................................................................... 78
11 Metering pump and additional components........................ 79
11.1 Setting the metering pump........................................ 79
11.2 Replacing the pump hose......................................... 79
11.3 Setting the liquid concentrate empty signal sensor.. 82
12 Operation of the system...................................................... 84
12.1 Normal mode............................................................ 84
12.1.1 Prerequisites for correct and proper operation...... 84
12.1.2 Refilling the concentrate tank with liquid polymer.. 84
12.2 Mains power switching on and mains failure behav‐
iour............................................................................ 85
12.3 Decommissioning..................................................... 85
12.4 Disposal of used parts.............................................. 86
13 Incorrect operation of the system........................................ 87
14 Maintenance....................................................................... 88
14.1 Inspecting the metering pump and injection valve.... 88
14.2 Checking the mixing chamber.................................. 88
14.3 Cleaning the filter insert in the pressure reducer...... 88
14.4 Checking and cleaning the solenoid valve................ 88
14.5 Checking the flow meter........................................... 89
15 Spare parts......................................................................... 90
15.1 Spare parts list.......................................................... 90
15.2 BASIC spare parts.................................................... 91
15.3 MEDIUM spare parts................................................ 91
15.4 COMFORT spare parts............................................. 92
Table of contents
5

16 Fault messages................................................................... 93
16.1 Rectifying functional faults........................................ 93
16.2 General notes on fault messages............................. 93
16.3 Important faults - Cause - Remedy........................... 94
17 Data sheets......................................................................... 96
17.1 Terminal strip signals and logical statuses............... 96
17.1.1 Analogue inputs / 4 ... 20 mA................................. 96
17.1.2 Digital inputs.......................................................... 96
17.1.3 Digital inputs on the PLC and logical statuses....... 96
17.1.4 Analogue outputs / 4 ... 20 mA.............................. 97
17.1.5 Digital outputs........................................................ 97
17.1.6 Digital outputs and logical statuses....................... 97
17.2 Control sequence...................................................... 98
17.2.1 Basic version......................................................... 98
17.2.2 Medium version..................................................... 99
17.2.3 Comfort version................................................... 100
17.3 EC Declaration of Conformity................................. 101
18 Index................................................................................. 102
Table of contents
6

1 Function
A3483
Fig. 1: Polymer preparation system DULCODOS ULIa
The polymer preparation system DULCODOS ULIa (system) is
intended for the preparation of a fully activated liquid polymer solu‐
tion with an extraction rate of 50.....1800 l/h against max. 4.5 bar
Mixing with water produces a fully activated polymer solution with a
maturing time of approx. 15 minutes in the maturing chamber.
The system works directly against max. 4.5 bar back pressure, and
so there is no need for a chemical transfer pump to pump the pre‐
pared polymer solution.
The polymer preparation system DULCODOS ULIa is an inline
system and processes liquid polymers to produce a fully activated
solution. The polymer preparation system features an integrated
mixing and maturing chamber and a peristaltic metering pump.
Features:
nProcessing of liquid polymers (0.05 ... 1.5%)
nMixing chamber for emulsions/dispersions and water
nOperator-managed input of the concentration with proportional
metering
nVarious configuration options
nOptional: operator-managed specification of the polymer prep‐
aration output in l/h
1.1 Fields of application
Fields of application:
nSludge dewatering and sludge thickening.
nWaste water treatment (industrial and local authorities).
nDrinking water treatment.
Function
7

1.2 Technical details
Technical details:
nProportional metering as standard
n3 system types with different equipment can be selected
– basic: manual flow adjustment, manual flushing
– medium: automatic flow control, manual flushing
– comfort: automatic flow control, automatic flushing
nChoice of peristaltic or metering pumps:
– Peristaltic pump DFXa 0530 for back pressures of up to 3
bar, max. 5 bar
– Metering pumps gamma/ X with HV head
– Metering pumps Sigma
nCompact controller Schneider Electric TM241 and touch panel
STO735 4.3”
– Optional: fitted with Ethernet / Modbus TCP
– Optional: fitted with PROFIBUS®
nOptional: a booster pump can be integrated if the priming pres‐
sure of the raw water feed is too low.
nOptional: an integrated post-dilution unit, which can increase
the output of the system to up to 1800 l/h, although with
reduced concentration.
nOptional: a capacitive sensor for liquid level control of the on-
site liquid polymer supply can be connected.
1.3 Types of polymer
The following types of polymer can be processed:
nLiquid polymers of 0.05 ... 1.5%
nEmulsions or dispersions
1.4 Set-up versions
4 different configuration versions are available:
nStandard / vertical to the wall
nStandard / wall-side
nMirror image / wall-side
nMirror image / vertical to the wall
1.5 System types
Tab. 2: 3 system types with different functions can be selected:
Selection by iden‐
tity code
Adjustment of the raw water flow
volume > Preparation output /
Inline function
Adjustment of the pol‐
ymer preparation output
by
Flushing
Basic Manual with diaphragm valve - - Manual with ball valve
Medium Automatic with motorised control
valve
Touch panel or an
external signal
Manual with ball valve
Comfort Automatic with motorised control
valve
Touch panel or an
external signal
Automatic with motorised
control valve
Function
8

1.6 Selectable components
Selectable components:
nPreparation output as an inline preparation station or batch
preparation station
nConfiguration versions
nElectrical connection
nControl versions with or without data communication
nOperating versions
nLiquid polymer metering pumps
– Peristaltic pump DFXa
– Metering pumps gamma/ X
– Metering pumps Sigma 1 Control
nMonitoring of low liquid polymers
nRaw water booster pump
nPost-dilution unit
nAdditional maturing tank with stirrer for batch preparation
nFeed pump for additional maturing tank
nControl operating language
1.7 Nameplate
A3617
Fig. 2: Nameplate
Function
9

1.8 Drawing
1.8.1 Drawing of DULCODOS ULIa 400 BASIC
C
E
D
A
B
800
65110 220
1830
160
780
800
755
65
110
495
65
385
320
310
840
400
50
575
A3511
Fig. 3: Drawing of DULCODOS ULIa 400 BASIC
Tab. 3: Connectors and connections
Pos. Description Material Type Dimension
A Water supply PVC/FKM Connecting nozzle DN25
B Emulsion inlet PVC/FKM Hose line DN10
C Vent nozzle PVC/FKM Hose line DN15
D Drain PVC/FKM Connecting nozzle DN25
E Outlet PVC/FKM Connecting nozzle DN25
Function
10

Description Type Dimension Material Part number
Raw water pipe DN25 Brass / PVC /
FKM
Pipes to mixing chamber DN15 PVC / FKM
Metering pump for emulsion DFXa 0565 DN10 PUR hose
PVDF / PTFE
1116369
Stirrer single-phase, P =
1.5 kW
2800 rpm Aluminium frame 1113060
Mixing chamber PP / FKM
Maturing chamber PP / FKM
Control cabinet SE 540x540x180 mm Polyester / fibre‐
glass
Function
11

1.8.2 Drawing of DULCODOS ULIa 400 BASIC with post-dilution
C
E
D
A
B
800
65110 220
1830
780
800
755
65
110
495 320 535 80
50
320
310
840
400
160
15
575
A3610
Fig. 4: Drawing of DULCODOS ULIa 400 BASIC with post-dilution
Tab. 4: Connectors and connections
Pos. Description Material Type Dimension
A Water supply PVC/FKM Connecting nozzle DN25
B Emulsion inlet PVC/FKM Hose line DN10
C Vent nozzle PVC/FKM Hose line DN15
D Drain PVC/FKM Connecting nozzle DN25
E Outlet PVC/FKM Connecting nozzle DN25
Function
12

Description Type Dimension Material Part number
Raw water pipe DN25 Brass / PVC /
FKM
Pipes to mixing chamber DN15 PVC / FKM
Metering pump for emulsion DFXa 0565 DN10 PUR hose
PVDF / PTFE
1116369
Stirrer single-phase, P =
1.5 kW
2800 rpm Aluminium frame 1113060
Mixing chamber PP / FKM
Maturing chamber PP / FKM
Control cabinet SE 540x540x180 mm Polyester / fibre‐
glass
Dilution line DN25 PVC / FKM
Function
13

1.8.3 Drawing of DULCODOS ULIa 400 MEDIUM
C
E
D
A
B
800
65110 220
183 0
160
780
800
65
110
49 5
65
385
320
31 0
840
400
50
575
755
A3512
Fig. 5: Drawing of DULCODOS ULIa 400 MEDIUM
Tab. 5: Connectors and connections
Pos. Description Material Type Dimension
A Water supply PVC/FKM Connecting nozzle DN25
B Emulsion inlet PVC/FKM Hose line DN10
C Vent nozzle PVC/FKM Hose line DN15
D Drain PVC/FKM Connecting nozzle DN25
E Outlet PVC/FKM Connecting nozzle DN25
Function
14

Description Type Dimension Material Part number
Raw water pipe DN25 Brass / PVC /
FKM
Pipes to mixing chamber DN15 PVC / FKM
Metering pump for emulsion DFXa 0565 DN10 PUR hose
PVDF / PTFE
1116369
Stirrer single-phase, P =
1.5 kW
2800 rpm Aluminium frame 1113060
Mixing chamber PP / FKM
Maturing chamber PP / FKM
Control cabinet SE 540x540x180 mm Polyester / fibre‐
glass
Function
15

1.8.4 Drawing of DULCODOS ULIa 400 Medium with post-dilution
C
E
D
A
B
800
65110 220
1830
780
800
65
110
495 320 535 80
50
320
310
840
400
160
15
575
755
A3611
Fig. 6: Drawing of DULCODOS ULIa 400 Medium with post-dilution
Tab. 6: Connectors and connections
Pos. Description Material Type Dimension
A Water supply PVC/FKM Connecting nozzle DN25
B Emulsion inlet PVC/FKM Hose line DN10
C Vent nozzle PVC/FKM Hose line DN15
D Drain PVC/FKM Connecting nozzle DN25
E Outlet PVC/FKM Connecting nozzle DN25
Function
16

Description Type Dimension Material Part number
Raw water pipe DN25 Brass / PVC /
FKM
Pipes to mixing chamber DN15 PVC / FKM
Metering pump for emulsion DFXa 0565 DN10 PUR hose
PVDF / PTFE
1116369
Stirrer single-phase, P =
1.5 kW
2800 rpm Aluminium frame 1113060
Mixing chamber PP / FKM
Maturing chamber PP / FKM
Control cabinet SE 540x540x180 mm Polyester / fibre‐
glass
Dilution line DN25 PVC / FKM
Function
17

1.8.5 Drawing of DULCODOS ULIa 400 COMFORT
C
E
D
A
B
800
65110 220
1830
160
780
800
755
65
110
495
65
385
320
310
840
400
50
575
A3513
Fig. 7: Drawing of DULCODOS ULIa 400 COMFORT
Tab. 7: Connectors and connections
Pos. Description Material Type Dimension
A Water supply PVC/FKM Connecting nozzle DN25
B Emulsion inlet PVC/FKM Hose line DN10
C Vent nozzle PVC/FKM Hose line DN15
D Drain PVC/FKM Connecting nozzle DN25
E Outlet PVC/FKM Connecting nozzle DN25
Function
18

Description Type Dimension Material Part number
Raw water pipe DN25 Brass / PVC /
FKM
Pipes to mixing chamber DN15 PVC / FKM
Metering pump for emulsion DFXa 0565 DN10 PUR hose
PVDF / PTFE
1116369
Stirrer single-phase, P =
1.5 kW
2800 rpm Aluminium frame 1113060
Mixing chamber PP / FKM
Maturing chamber PP / FKM
Control cabinet SE 540x540x180 mm Polyester / fibre‐
glass
Function
19

1.8.6 Drawing of DULCODOS ULIa 400 Comfort with post-dilution
C
E
D
A
B
800
65
110 220
1830
780
800
755
110
495 320 535 80
320
310
840
400
160
15
575
A3612
Fig. 8: Drawing of DULCODOS ULIa 400 Comfort with post-dilution
Tab. 8: Connectors and connections
Pos. Description Material Type Dimension
A Water supply PVC/FKM Connecting nozzle DN25
B Emulsion inlet PVC/FKM Hose line DN10
C Vent nozzle PVC/FKM Hose line DN15
D Drain PVC/FKM Connecting nozzle DN25
E Outlet PVC/FKM Connecting nozzle DN25
Function
20