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ProMinent Ultromat ULFa 1000, Assembly And Operating Instructions Manual

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ProMinent Ultromat ULFa 1000 Assembly And Operating Instructions Manual Download Page 1

Ultromat

®

 ULFa

Continuous Flow System

Assembly and operating instructions

A0777

Original operating instructions (2006/42/EC)

Part no. 985956

BA UL 031 11/13 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.

Summary of Contents for Ultromat ULFa 1000

Page 1: ...A0777 Original operating instructions 2006 42 EC Part no 985956 BA UL 031 11 13 EN Please carefully read these operating instructions before use Do not discard The operator shall be liable for any dam...

Page 2: ...y The following are highlighted separately in the document n Enumerated lists Instructions Results of the instructions Information This provides important information relating to the correct operation...

Page 3: ...rate piping 23 5 2 10 Evaluation of the lack of water state for the redilution unit 23 5 2 11 Empty signal for concentrate tank 24 5 2 12 Dosing monitor for liquid concentrate 24 5 2 13 Top hopper 50...

Page 4: ...mode 66 11 1 1 Prerequisites for correct and proper operation 66 11 1 2 Refilling the feed hopper with powdered polymer 66 11 1 3 Refilling the concentrate storage tank with liquid pol ymer 66 11 2 B...

Page 5: ...16 4 Lubricating plan 82 16 5 Control sequence 82 16 6 EC Declaration of Conformity for Machinery 83 17 Index 84 Table of contents 5...

Page 6: ...0 PLC S7 1200 1 PLC S7 1200 with PROFIBUS DP DP coupler 2 PLC S7 1200 with PROFINET PN PN coupler Options 0 without options 1 Discharge pipework PVC 400 1000 2 Discharge pipework PVC 2000 3 Discharge...

Page 7: ...ter pipework for flush valve 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...

Page 8: ...Size Extraction rate ES Spanish RO Romanian ET Estonian RU Russian FI Finnish SK Slovakian FR French SL Slovenian HR Croatian SV Swedish HU Hungarian TR Turkish IT Italian ZH Chinese LT Lithuanian Pr...

Page 9: ...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 inju...

Page 10: ...tromat can result in hazardous situa tions The Ultromat is only designed to produce a polymer solution as a flocculent from powdered polymer or liquid concentrate and with drinking water All other use...

Page 11: ...sible hazards based on his her training knowledge and experience as well as knowledge of pertinent regulations The assessment of a person s technical training can also be based on several years of wor...

Page 12: ...ing 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 th...

Page 13: ...em 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...

Page 14: ...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 Safety and responsibility 14...

Page 15: ...ms 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 o...

Page 16: ...can be set The viscosity of the polymer solution produced must not however exceed 1500 mPas Please refer to the polymer suppliers application data sheets for information about the viscosity of the dif...

Page 17: ...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 rp...

Page 18: ...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 Ambient conditions Value Storage and...

Page 19: ...rs 3 n Flush fitting 4 n Powder feeder 5 n Control cabinet 6 n Three chamber storage tank 7 The flush fittings and water piping are available in either PVC or PP A0430 Fig 4 System construction The se...

Page 20: ...Lugs For easier handling of the system a suitable hoisting device can be attached to the four lifting lugs 5 2 3 Water fitting with flush fitting The water pipework supplies the system with the requi...

Page 21: ...eder is controlled to occur at a time delay after the solenoid valve activation Consequently at the start of the preparation process no powder deposits can occur in the flush fitting There is always a...

Page 22: ...mat treatment systems The dry feeder is activated by a frequency converter to ensure quantity proportional dosing of the powdered polymer into the preparation water A loosening wheel is fitted directl...

Page 23: ...for the redilution unit The redilution unit is used to redilute the prepared polymer solution To do this the feed pump transports the polymer solution out of the Ultromat storage tank into the redilut...

Page 24: ...13 Top hopper 50 l 75 l and 100 l Should an enlarged powder reservoir be required top hoppers with an additional volumetric capacity of 50 75 and 100 litres are available 5 2 14 Powder feeder device...

Page 25: ...system Selection of the installation site The system must be easily accessible at all times for opera tion maintenance and filling Permissible ambient temperature 5 C to 40 C Humidity None Rain and c...

Page 26: ...tallation electrical WARNING Live parts Possible consequence Fatal or very serious injuries Measure Always disconnect the system from the mains power supply at the electrical connections before car ry...

Page 27: ...ED on the sensor is off the setting is correct 2 The yellow LED on the sensor is on Reduce the sensitivity using the adjustment screw turn anti clockwise until the LED goes out 3 The yellow LED on the...

Page 28: ...onnected not contained in the scope of supply the parameters must be checked locally and adjusted to match the liquid concentrate pump A0822 Fig 8 Sinamics G110 frequency converter Function Remarks St...

Page 29: ...following parameters differ from the standard parameters of the frequency converter FC Settings for the dry feeder Parameter G110 Dry feeder values 0003 3 0305 1 22 A 0307 0 18 kW 0311 1360 RPM 0700...

Page 30: ...pump Parameter G110 Spectra values 0003 3 0305 1 9 A 0307 0 37 kW 0311 1380 RPM 0700 5 0731 4 1000 5 1082 83 Hz 1120 0 1 s 1121 0 1 s 1210 4 2000 83 Hz 2010 9 2011 2 2012 2 2013 4 2014 6000 Operation...

Page 31: ...ng is cor rect 2 The yellow LED on the sensor is illuminated Reduce the sensitivity on the adjustment screw turn anti clock wise until the LED goes out 1 The yellow LED on the sensor is not illuminate...

Page 32: ...the red LED display lights up and ANALG appears on the display then the pump is not receiving an analog signal 1 Keep the P key pressed until the display flashes Then release the P key 2 Keep the arr...

Page 33: ...ating screens A brief training session is sufficient to allow you to operate the Ultromat Please carefully read the operating instructions prior to use The operation of the system in manual mode must...

Page 34: ...e Elapsed time Enter weight Capacity Liquid Calibration time Elapsed time Enter weight Capacity Flow monitor Switching point START STOP Water Actual flow START STOP water calibration Concentration Con...

Page 35: ...t Service Water meter Mode measurement Auto Manual Manual value Pulse rate DFM Run empty Stop On Pressure sensor Sensor measured value Measured value Offset Factory setting Factory settings reset Iden...

Page 36: ...iquid concentrate white off black on flashing fault 14 Flow sensor liquid concentrate white NOK black OK flashing fault 15 Stirrer white off black on flashing fault 16 Date 17 Display of the current d...

Page 37: ...is selected in the service menu NOTICE This operating mode is only for service technicians To avoid damage to the system only service technicians may operate the system in MANUAL operating mode In MA...

Page 38: ...X X X Switchover dry product liquid concentrate X X X Change concentration X X X Change active Ingredient liquid concentrate X X Read parameter data X Change parameter data X X Carry out calibration...

Page 39: ...nction on the touch panel which requires higher user rights the login window appears automatically for entry of user and password If you activate the User field the screen keyboard appears and the use...

Page 40: ...touch panel The virtual keyboard appears for value entry The MIN and MAX limits are displayed at the top left of the touch panel 2 Enter the desired value and press the Key The value set is transferr...

Page 41: ...isplay of the currently used dosing product 2 Display of the concentration 3 Display of the feed rate 4 Button Change Powder Liquid You can only change the dosing product with the system switched off...

Page 42: ...an external switch During operating mode PAUSE no new preparation can be started The content of chamber 3 can be extracted down to the level Min Min 9 8 Jump to the Archive F3 The function key F3 is u...

Page 43: ...indicator of the current level NOTICE Incorrect measurement due to contamination of the pressure sensor To avoid incorrect measurements the pressure sensor must be cleaned during system maintenance F...

Page 44: ...ent does not function the system can be operated with a preset value You can find the setting for this in the service menu 9 11 Redilution This function is used by the control to monitor a downstream...

Page 45: ...ch the individual drives on manually To do this you must touch the points corresponding to the drives on the touch panel If a drive is activated the drive point is lighted up in black If a drive is de...

Page 46: ...to Chapter 10 1 Parameters on page 46 Calibration refer to Chapter 10 2 Calibration on page 52 System refer to Chapter 10 3 System on page 56 Concentration refer to Chapter 10 4 Concentration on page...

Page 47: ...00 l h Ultromat Water supply Min water supply 400 600 400 1000 1500 1000 2000 3000 2000 4000 6000 4000 6000 9000 6000 8000 12000 8000 If the current water supply is lower than the set minimum water su...

Page 48: ...er the preparation operation the stirrers can continue running in Pulse Pause mode You can set the parameters for the switching on and off times as follows Parameters Factory setting Setting range Sti...

Page 49: ...g 25 Parameter Powder A metering pipe heating system also removes any moisture that has pene trated the unit and thus prevents any caking of the powder The vibrator prevents the forming of bridges in...

Page 50: ...he range from 0 to 86 Hz If a liquid concentrate pump is used without an external fan the winding of the pump motor must be protected against overheating at low speeds A minimum frequency is set accor...

Page 51: ...m is signalled Level Max If the Level Max is exceeded Ultromat preparation is stopped Level Min If the Level Min is undershot Ultromat preparation is started Level Min Min If the Level Min Min is unde...

Page 52: ...em to AUTO mode then the following message appears on the display Fault Dry feeder not calibrated of Fault Liquid concentrate pump not calibrated and the system switches to FAULT mode 10 2 1 Calibrati...

Page 53: ...ol The capacity is recalculated and displayed as the parameter CAPACITY in kg h 7 Refit the wetting cone once the dry feeder has been calibrated 10 2 2 Calibration liquid concentrate Mode Menu Archive...

Page 54: ...he control The capacity is recalculated and displayed as the parameter CAPACITY in kg h 8 Close the metering line so that it is again leak tight 10 2 3 Calibration Flow monitor Spectra only Before the...

Page 55: ...ty during standard operation in Text field 1 2 Start the liquid concentrate pump using the button START 2 3 If the liquid concentrate pump is running with the set frequency you can set the switching p...

Page 56: ...rupt the calibration at any time by pressing the STOP key 1 Start the calibration using the button START The water solenoid valve opens 2 Adjust the water supply so that the water supply value is disp...

Page 57: ...uch the button Start The selected language is active 10 3 2 Setting date and time Menu Archive Reset Mode A0802 Unit Stop System date time Language Time Touch Set date and time Fig 33 Setting date and...

Page 58: ...3 Touch Panel Menu Archive Reset Mode A0803 Unit Stop System touch panel Language Time Touch Activate Activate Contrast Clean screen Calibrate touch Fig 34 Display System You can set the touch panel...

Page 59: ...ly read data In Extern mode the setpoints for the concentration are specified by the process management system Addition ally in Extern mode the Ultromat can be switched to Pause and a fault acknowledg...

Page 60: ...active ingredient in the liquid polymer typically 40 is entered in the control 10 5 Information 10 5 1 Ultromat Identity code Menu Archive Reset Mode A0790 Unit Stop Identcode Identcode Version Type...

Page 61: ...e Version Mode Menu Archive Reset Software Version Ultromat Unit Stop Identcode Version Version Touchpanel Creation date Version S7 Project Creation date A0797 Project Fig 37 Software Version In this...

Page 62: ...r Pressure sensor Factory setting Run empty Mode measurement Flow meter A0805 Imp l Auto Auto Manual Manual value Fig 39 Manual flow entry In the event of failure of the automatic water flow measureme...

Page 63: ...refilled Therefore to run empty you must switch off automatic mode Mode Menu Archive Reset Service running empty Unit Stop Water meter Pressure sensor Factory setting Run empty Run empty A0806 Mode em...

Page 64: ...g height So that the correct filling height can be displayed you must add the dead zone in the lower part of the storage tank approx 60 mm to the Sensor Value To determine the dead zone of the storage...

Page 65: ...de A0808 Reset Change Fig 42 Service Reset You reset the parameters of the Ultromat to the factory settings via the Reset button NOTICE Incorrect functions can arise if the incorrect identcode iden ti...

Page 66: ...e The cause of a fault should be eliminated before the cor responding fault message is acknowledged However you can silence the horn by pressing the key Horn off Requirements n A reasonable operating...

Page 67: ...mains power is reconnected preparation mode is not continued Following a mains power failure or in the event of a longer loss of mains power which results in the controller being restarted the control...

Page 68: ...e chamber storage tank through the provided indi vidual chamber connectors 6 Carefully rinse the three chamber tank with water 7 Also rinse the rinsing apparatus hopper and mixing device once more wit...

Page 69: ...er values for the frequency converter must not be changed They are factory set on the powder feeder n When setting the concentration the maximum viscosity limit of 1500 mPas must not be exceeded n If...

Page 70: ...rior to the start of the preparation process ensure that the drainage cocks are closed for all three chambers Monitor in particular the correct switching operation of the level sensors when they first...

Page 71: ...s instructions for the pressure reducer 14 3 Checking and cleaning the solenoid valve WARNING Danger of electric shock Possible consequence Fatal or very serious injuries The control cabinet must alw...

Page 72: ...he flow meter with the correct alignment in the water supply line flow arrow 14 5 Removing the cover of an inspection opening CAUTION Propellers are rotating in the storage tanks Slight or minor injur...

Page 73: ...sually by the red warning light on the control cabinet The controller also displays a fault message The warning tone can be switched off by pressing Reset F4 The activation of the downstream feed pump...

Page 74: ...larm display as does the fault message In parallel to the optical signalling of the alarm the fault switches the system output COLLECTIVE ALARM If a fault occurs the output COLLECTIVE ALARM is activat...

Page 75: ...ncentration parameter too high Reduce concentration parameter Liquid concentrate pump min capacity reached Concentration parameter too low Increase concentration parameter NO NO Water supply too low I...

Page 76: ...protection switch set incorrectly Check motor protection switch setting Digital input defective Check digital input Water low in the redilution unit Water supply to redilution unit failed Check water...

Page 77: ...supply avail able 0 Transfer pump off water supply avail able DI A 6 Redilution flow monitor 1 Flow present 0 Flow not present DI B 0 Lack of powder dry feeder 1 Powder present 0 Powder not present D...

Page 78: ...3 is full DQ A 2 Collective alarm 0 No collective alarm 1 Collective alarm active DQ A 3 Horn 0 Horn off 1 Horn on DQ A 4 Solenoid valve 0 Solenoid valve closed 1 Solenoid valve open DQ A 5 Stirrer 1...

Page 79: ...time Elapsed time Enter weight Capacity Liquid Calibration time Elapsed time Enter weight Capacity Flow monitor Switching point START STOP Water Actual flow START STOP water calibration Concentration...

Page 80: ...ject Service Water meter Mode measurement Auto Manual Manual value Pulse rate DFM Run empty Stop On Pressure sensor Sensor measured value Measured value Offset Factory setting Factory settings reset I...

Page 81: ...000 6 000 l h Min water supply flowrate Ultromat 8000 8 000 l h Heating switch on time 5 s Heating switch off time 45 s Vibrator on 1 s Vibrator off 60 s Supply lead in time 7 s Supply run on time 5 s...

Page 82: ...h 2 years ISO VG 220 250 ml Dry material feeder SK1 SD Maintenance free 16 5 Control sequence Level min Level min Level max Full Empty On Off On On On Off Off Off A0438 Fig 46 Control sequence I Liqui...

Page 83: ...the event of a modification to the product not agreed with us Extract from the EC Declaration of Conformity Designation of the product Automatic polyelectrolyte treatment system Ultromat S7 1200 Seri...

Page 84: ...water pressure 26 Inspection openings 13 M Main switch 13 N non discriminatory approach 2 P Profibus 59 Pump 32 R Relevant EC directives 83 S Safety Equipment 13 Safety information 9 Sensor 31 Serial...

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Page 88: ...985956 3 en_GB 2013 ProMinent GmbH Im Schuhmachergewann 5 11 69123 Heidelberg Telephone 49 6221 842 0 Fax 49 6221 842 419 email info prominent com Internet www prominent com...

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