Manual Preparadora de Polímeros Prominent

Operating Instructions Continuous Flow System Ultromat AF0, AT0 and ATF
Please completely read through operating instructions! Do not discard! The system operator shall be liable for any damages caused by installation or operating errors!
Part No. 986446
ProMinent Dosiertechnik GmbH 69123 Heidelberg Germany
BA UL 015 12/08 GB
ProMinent
Corporate information
Corporate information: Continuous Flow System Ultromat AF0, AT0 and ATF ProMinent Dosiertechnik GmbH, 2008
ProMinent Dosiertechnik GmbH Im Schuhmachergewann 5-11 69123 Heidelberg Germany Telephone: +49 6221 842-0 Fax: +49 6221 842-617 info@prominent.com www.prominent.com
Technical changes reserved.
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ProMinent
Contents
Contents
Identcode .................................................................................................................................... General Notes for the User ......................................................................................................... 6 9
1 About this Product ............................................................................................................ 10 2 Safety Chapter ................................................................................................................... 10 2.1 2.2 2.3 2.4 2.5 2.6 Identification of the notes on safety ........................................................................... 10 Proper Use ................................................................................................................. 11 Information for Emergency Cases ............................................................................. 12 Description and Test of the Safety Devices ............................................................... 12 Notes on Safety ......................................................................................................... 13 Sound Pressure Level ................................................................................................ 13
3 Transport and Storage of the System ............................................................................. 14 4 About this System ............................................................................................................. 14 4.1 4.2 Application ................................................................................................................. 14 Design ........................................................................................................................ 14 4.2.1 4.2.2 4.2.3 4.3 Ultromat AF0 (for the preparation of liquid polymers) ................................. 15 Ultromat AT0 (for the preparation of powdery polymers) ............................ 15 Ultromat ATF (for the preparation of powdery and liquid polymers) ............ 15
System Sizes ............................................................................................................. 16
5 Design and Function ......................................................................................................... 19 5.1 5.2 Layout of the System ................................................................................................. 19 Description of the Component Parts ......................................................................... 19 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 5.2.7 5.2.8 5.2.9 5.3 Three-Chamber Reservoir ............................................................................. 19 Water Fitting with Wetting Fitting .................................................................. 19 Powder feeder ............................................................................................... 21 Agitators ........................................................................................................ 21 Control Cabinet ............................................................................................. 21 Socket-Outlet for the Connection of a Small-Type Feeder (not AF0) ............ 21 Ultromat EA Assembly ................................................................................. 21 Remote Control ............................................................................................. 23 Concentrate Piping (not type AT0) ................................................................ 23
5.2.10 Crane Lifting Lugs ......................................................................................... 23 Operating Modes ....................................................................................................... 23 5.3.1 5.3.2 5.3.3 5.4 5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 Preparation Mode .......................................................................................... 23 Setting Mode ................................................................................................. 23 Remote Control Mode ................................................................................... 23 Agitator for the Chamber 3 (Agitator 3) ......................................................... 24 Overflow Valve for Chamber 3 ....................................................................... 24 Evaluation Water Shortage for the Redilution Unit ........................................ 24 Concentrate Pump (only types AF0 and ATF) ............................................... 24 Empty Signal for Concentrate Tank (only types AF0 and ATF) ...................... 24 Metering Monitor for Liquid Concentrate (only types AF0 and ATF) ............. 24
Ultromat Options ...................................................................................................... 24
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Contents
5.4.7 5.4.8 5.4.9 5.5 5.5.1 5.5.2 5.5.3
Add-On Hopper 50l, 75l, and 100l (only types AF0 and ATF) ....................... 24 Vibrator (only types AF0 and ATF) ................................................................. 25 Powder Feeder for Automatic Refilling (only types AF0 and ATF) ................. 25 Powder Feed Tank (only types AF0 and ATF) ................................................ 25 Powder Feed Tank with Bag Dumper (only types AF0 and ATF) ................... 25 Redilution Station .......................................................................................... 25
Ultromat Accessories ............................................................................................... 25
6 Assembly and Installation ................................................................................................ 25 6.1 6.2 6.3 Assembly ................................................................................................................... 25 Installation, Hydraulical .............................................................................................. 26 Installation, Electrical ................................................................................................. 26 6.3.1 6.3.2 Connection of the Mains Line ....................................................................... 26 Opening of the Control .................................................................................. 26
7 Control ............................................................................................................................... 27 7.1 Design and Function .................................................................................................. 27 7.1.1 7.1.2 7.1.3 7.1.4 7.2 7.3 7.4 7.2.1 Display Elements and Controls ..................................................................... 27 Display Elements (Status Indication) ............................................................. 27 Controls ......................................................................................................... 28 Operation of the System and Operating Status Indications .......................... 28 Layout of the Menu ....................................................................................... 29
Menu System ............................................................................................................. 29 Operation of the Control Selection of a Menu Option ............................................ 30 Display Mode ............................................................................................................. 30 7.4.1 7.4.2 7.4.3 Standard Operation ....................................................................................... 30 Interruption of Standard Operation ............................................................... 30 Display of the Identcode of the Control ........................................................ 31
8 Commissioning ................................................................................................................. 31 8.1 8.2 8.3 Assembly, Preparatory Work ...................................................................................... 31 Checking the Identcode of the Control ...................................................................... 31 Settings for Commissioning ....................................................................................... 31 8.3.1 8.3.2 8.3.3 8.3.4 8.3.5 8.3.6 8.4 8.5 Setting of the Minimum Flow (only with wetting fitting for AT0 and AFT) ..................................................... 32 Setting of the Heating of the Metering Pipe (only types AF0 and ATF) ......... 32 Setting of the Lead and Lag Times (only types AF0 and ATF) ...................... 32 Agitators 1 and 2 ........................................................................................... 33 Agitator 3 (option) .......................................................................................... 33 Access Code ................................................................................................. 33
Setting of Concentration ............................................................................................ 33 Settings of Calibration ............................................................................................... 34 8.5.1 8.5.2 8.5.3 8.5.4 8.5.5 Setting water feed ......................................................................................... 34 Calibration of the Powder Feeder (only types AF0 and ATF) ......................... 34 Calibration of the Concentrate Pump (only types AF0 and ATF) ................... 35 Setting of the Metering Monitor for Liquid Concentrate (only types AF0 and ATF with Spectra) ......................................................... 35 Setting of Capacitive Sensors (types AF0 and ATF) ...................................... 36 Setting of Flow .............................................................................................. 36 Testing Agitators and Powder Feeder ........................................................... 37 Running empty the Ultromat ...................................................................... 37
8.6
Service Menu ............................................................................................................. 36 8.6.1 8.6.2 8.6.3
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Contents
8.7
Setting of the Frequency Converter Altivar 11 ........................................................... 37 8.7.1 8.7.2 8.7.3 8.7.4 Function of the Controls ................................................................................ 37 Menu Overview .............................................................................................. 38 Setting of the Parameters .............................................................................. 38 Settings for Ultromat AF0 or ATF ................................................................. 40
8.8
Commissioning of the System ................................................................................... 40
9 Operation of the System ................................................................................................... 40 9.1 Standard Operation ................................................................................................... 40 9.1.1 9.1.2 9.1.3 9.2 9.3 9.4 Prerequisites for a Proper Operation ............................................................. 40 Feeding of the Storage Tank with Powdery Polymer (not type AF0) ............. 41 Refilling of the Concentrate Tank with Liquid Polymer (not type AT0) ........... 41
Switching on Mains and Behaviour during Mains Power Failure ............................... 41 Decommissioning ...................................................................................................... 41 Disposal ..................................................................................................................... 42
10 Maloperations of the System ........................................................................................... 42 11 Troubleshooting ................................................................................................................ 43 11.1 Warnings .................................................................................................................... 45 11.1.1 Error Message Water shortage ................................................................... 45 11.1.2 Error Message Feed too high ..................................................................... 45 11.2 Malfunctions .............................................................................................................. 46 11.2.1 Error Message Wetting cone ...................................................................... 46 11.2.2 Error Message Fault fill level ....................................................................... 46 11.2.3 Error Message Redilution ........................................................................... 46 11.2.4 Error Message Board n defective ............................................................ 47 11.2.5 Error Message Powder shortage ................................................................ 47 11.2.6 Error Message Agitator failure .................................................................... 47 11.2.7 Error Message Supply overfull ................................................................... 47 11.3 Replacement of the Line Fuse of the control ............................................................. 48 12 Maintenance ...................................................................................................................... 48 12.1 Inspection of Powder Feeder and Wetting Fitting ..................................................... 48 12.2 Cleaning of the Strainer in the Pressure Reducer ...................................................... 48 12.3 Inspection and Cleaning of the Solenoid Valve ......................................................... 48 12.4 Removal and Inspection of the Flow Meter (turboDOS) ............................................ 49 12.5 Disassembly of the Cover of an Inspection Hole ....................................................... 49 12.6 Cleaning of the Top of the Three-Chamber Reservoir ............................................... 49 13 Replacement Parts and Accessories .............................................................................. 50 13.1 Replacement parts ..................................................................................................... 50 13.2 Accessories ................................................................................................................ 50 13.3 EC Declaration of Conformity .................................................................................... 51 Annex ........................................................................................................................................ 51 13.4 Control Menu Ultromat AF0 ..................................................................................... 52 13.5 Control Menu Ultromat AT0 ...................................................................................... 53 13.6 Control Menu Ultromat ATF ...................................................................................... 54 13.7 Commissioning Report .............................................................................................. 55
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Identcode
Identcode ULTa AF0

U LTa Ultromat continuous flow systems
AF0 Type continuous flow system for liquid polymer 0400 1000 2000 4000 8000 Reservoir size / issue quantity 400 litres capacity / 400 l/h, 1,000 litres capacity / 1,000 l/h 2,000 litres capacity / 2,000 l/h 4,000 litres capacity / 4,000 l/h 8,000 litres capacity / 8,000 l/h 0 1 Design standard mirror-imaged 0 Wetting fitting with Y wetting A Electrical connection: 400 Vac, 50/60 Hz (3ph, N, PE) 0 Control ProMinent control 0 1 2 3 Options without options with overflow valve for Ultromat reservoir with evaluation water shortage redilution with 1 + 2 0 Powder feeder, add-on hopper none 0 Vibrator for powder feeder none 0 1 2 3 4 5 Agitator for 3rd chamber none agitator for reservoir 400, 0.18 kW, 50/60 Hz, 750/900 rpm agitator for reservoir 1000, 0.55 kW, 50/60 Hz, 750/900 rpm agitator for reservoir 2000, 0.75 kW, 50/60 Hz, 750/900 rpm agitator for reservoir 4000, 1.1 kW, 50/60 Hz, 750/900 rpm agitator for reservoir 8000, 2.2 kW, 50/60 Hz, 750/900 rpm 1 2 Liquid concentrate pump (installed at Ultromat) with Sigma conc. pump with Spectra conc. pump 0 1 2 3 Monitor for liquid concentrate pump none with float switch for concentrate tank with flow monitor (only Spectra) with float switch and flow monitor (only Spectra) DE EN FR CZ IT NL PL ES Language German English French Czech Italian Dutch Polish Spanish
Standard equipment: - lifting lugs - Pause/system status message
ULTa
AF0 0400
DE
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ProMinent
Identcode
Identcode ULTa AT0

AT0 Type continuous flow system for powdery polymer 0400 1000 2000 4000 8000 Reservoir size / issue quantity 400 litres capacity / 400 l/h, 1,000 litres capacity / 1,000 l/h 2,000 litres capacity / 2,000 l/h 4,000 litres capacity / 4,000 l/h 8,000 litres capacity / 8,000 l/h 0 1 Design standard mirror-imaged 0 1 2 3 4 Wetting fitting with Y wetting with wetting cone, PVC piping, for 400 - 2000 with wetting cone, PVC piping, for 4000 - 8000 with wetting cone, PP piping, for 400 - 2000 with wetting cone, PP piping, for 4000 - 8000 A Electrical connection: 400 Vac, 50/60 Hz (3ph, N, PE) 0 Control ProMinent control 0 1 2 3 Options without options with overflow valve for Ultromat reservoir with evaluation water shortage redilution with 1 + 2 0 1 2 3 4 5 6 7 Powder feeder, add-on hopper none with add-on hopper 50 l with add-on hopper 75 l with add-on hopper 100 l with add-on hopper 50 l + powder feeder with add-on hopper 75 l + powder feeder with add-on hopper 100 l + powder feeder with adapter lid + powder feeder 0 1 Vibrator for powder feeder none with vibrator for powder feeder 0 1 2 3 4 5 Agitator for 3rd chamber none agitator for reservoir 400, 0.18 kW, 50/60 Hz, 750/900 rpm agitator for reservoir 1000, 0.55 kW, 50/60 Hz, 750/900 rpm agitator for reservoir 2000, 0.75 kW, 50/60 Hz, 750/900 rpm agitator for reservoir 4000, 1.1 kW, 50/60 Hz, 750/900 rpm agitator for reservoir 8000, 2.2 kW, 50/60 Hz, 750/900 rpm 0 Liquid concentrate pump (installed at Ultromat) none 0 Monitor for liquid concentrate pump none DE EN FR CZ IT NL PL ES Language German English French Czech Italian Dutch Polish Spanish Standard equipment: - lifting lugs - socket-outlet for small-type feeder - Pause/system status message ULTa AT0 0400 0 0 A 0 0 0 0 0 0 0 DE
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Identcode
Identcode ULTa ATF

ATF Type continuous flow system for liquid and powdery polymer 0400 1000 2000 4000 8000 Reservoir size / issue quantity 400 litres capacity / 400 l/h, 1,000 litres capacity / 1,000 l/h 2,000 litres capacity / 2,000 l/h 4,000 litres capacity / 4,000 l/h 8,000 litres capacity / 8,000 l/h 0 1 Design standard mirror-imaged 0 1 2 3 4 Wetting fitting with Y wetting with wetting cone, PVC piping, for 400 - 2000 with wetting cone, PVC piping, for 4000 - 8000 with wetting cone, PP piping, for 400 - 2000 with wetting cone, PP piping, for 4000 - 8000 A Electrical connection: 400 Vac, 50/60 Hz (3ph, N, PE) 0 Control ProMinent control 0 1 2 3 Options without options with overflow valve for Ultromat reservoir with evaluation water shortage redilution with 1 + 2 0 1 2 3 4 5 6 7 Powder feeder, add-on hopper none with add-on hopper 50 l with add-on hopper 75 l with add-on hopper 100 l with add-on hopper 50 l + powder feeder with add-on hopper 75 l + powder feeder with add-on hopper 100 l + powder feeder with adapter lid + powder feeder 0 1 Vibrator for powder feeder none with vibrator for powder feeder 0 1 2 3 4 5 Agitator for 3rd chamber none agitator for reservoir 400, 0.18 kW, 50/60 Hz, 750/900 rpm agitator for reservoir 1000, 0.55 kW, 50/60 Hz, 750/900 rpm agitator for reservoir 2000, 0.75 kW, 50/60 Hz, 750/900 rpm agitator for reservoir 4000, 1.1 kW, 50/60 Hz, 750/900 rpm agitator for reservoir 8000, 2.2 kW, 50/60 Hz, 750/900 rpm 0 1 2 Liquid concentrate pump (installed at Ultromat) none with Sigma conc. pump with Spectra conc. pump 1 2 3 Monitor for liquid concentrate pump with float switch for concentrate tank with flow monitor (only Spectra) with float switch and flow monitor (only Spectra) DE EN FR CZ IT NL PL ES Language German English French Czech Italian Dutch Polish Spanish Standard equipment: - lifting lugs - socket-outlet for small-type feeder - Pause/system status message
ULTa
ATF 0400
DE
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ProMinent
General Notes for the User
General Notes for the User

Please read through the following user guidelines! Familiarity with these points ensures optimum use of the operating instructions. Key points in the text are indicated as follows: Enumerations Instructions
Working guidelines: NOTE A note provides important notes for the correct functioning of the unit or is to facilitate your work.
Notes on safety identified by pictographs (see Chapter 2). Notes to the system operator Contain notes and quotations from German guidelines for the operators area of responsibility. They, however, do not release him from his responsibility as operator, they are only meant to remind the operator of certain problems and are meant to make the operator aware of these problems. They neither claim completeness nor validity for all countries nor any type of application nor unconditional up-to-dateness. Version number of the software The version number of the software can be accessed as follows: In the permanent display, press the Change key. Please state the Identcode as well as the version number in case of complaints or when removing already installed Ultromat systems.
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About this Product / Safety Chapter
About this Product
The Ultromat AF0, AT0, ATF system by ProMinent is an automatic preparation station for polyelectrolyte. It can be used in all applications where synthetic polymers are to be automatically prepared into polymer solutions as flocculants. As such a dissolving station, the system is suitable for numerous process-technical applications such as e.g. in water treatment, waste water treatment, and paper production. The Ultromat AF0 is meant to dissolve liquid polymers. The Ultromat AT0 can be used in all applications where pourable, synthetic powdery polymers are to be prepared. With the Ultromat ATF, powdery polymers and liquid polymers can be prepared.
2
2.1
Safety Chapter
Identification of the notes on safety
The following terms are used in the present operating instructions to indicate the various severity levels of the danger: WARNING Characterizes a possibly hazardous situation. Your life is in danger and there is a danger of serious injury if these notes are disregarded! CAUTION Characterizes a possibly hazardous situation. There is a danger of slight or minor injury or damage to property if these notes are disregarded! The following warning signs are used in the present operating instructions to indicate different types of danger: Warning of danger area
Warning of hazardous electrical voltage
Warning of injury to hands
Warning of unexpected start
Warning of slipping risk
Warning of hot surfaces
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Safety Chapter
2.2

Proper Use
The Ultromat is exclusively designed to generate a polymer solution as flocculant from powdery polymer or liquid polymer with drinking water. All other uses or modifications require the prior written consent of ProMinent Dosiertechnik GmbH, Heidelberg. The system may not be operated beyond the scope of the conditions described in this documentation! The system is not designed for use in explosive areas! If non-genuine parts or third-party accessories are used, the proper functioning of the system is no longer guaranteed. The Ultromat may only be operated by sufficiently qualified personnel (see table below)! You are obliged to observe the information in the operating instructions on the various life phases of the system! Please observe the relevant local regulations in all life phases of the system! Training trained qualified employees technical experts instructed persons customer service technical experts instructed persons
Activity Mounting / installation Commissioning Operation Maintenance / repair Decommissioning / disposal Troubleshooting
Table 1: Qualification of the personnel for the operation of the system Explanations for the table: A technical expert is a person who is able to assess the tasks assigned to him/her and to recognise possible dangers based on his/her technical training, and experience as well as the knowledge of pertinent regulations. Note: A technical qualification is typically proven by the required completion of a training, e.g. as engineer, master or journeyman. The assessment of the technical training can also be based on an activity of several years in the relevant field of work. A qualified employee is a person who is able to assess the tasks assigned to him/her and to recognise possible dangers based on his/her technical training, knowledge and experience as well as the knowledge of pertinent regulations. Note: A technical training of equal qualification can also have been acquired by an activity of several years in the relevant field of work. An instructed person is a person having been informed about the tasks assigned to him/her and the possible hazards in case of improper behaviour and having been trained, if required, as well as having been informed about the required protective equipment and protective measures. The customer service means service technicians which have been provable trained and authorised by ProMinent for work at the system. Notes to the system operator The pertinent accident prevention regulations as well as all other generally acknowledged safety-technical regulations must be observed!
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Safety Chapter
2.3
Information for Emergency Cases
In an emergency case, the system must be disconnected from the mains using the red-yellow mains switch on the right in the control cabinet. The system and the connected units are then de-energised. WARNING In an emergency case, pressing the Start/Stop key may not be sufficient. Switch off the system using the red-yellow mains switch.
2.4
Description and Test of the Safety Devices
1 Emergency switch 2 Warning decal Warning of hazardous electrical voltage 3 Cover of the inspection holes with warning decal Warning of injury to hands 4 Warning decal Warning of hot surfaces
3 4 3 3 2 1
Fig. 1: Safety devices
Emergency switch The red-yellow mains switch on the right in the control cabinet de-energises the system and the connected units. Test: Set the mains switch to Off while all parts of the system are running all parts must stop all lights extinguish. Cover of the inspection holes The screwed on covers of the inspection holes prevent that persons might injure their hands at the running propellers of the agitators. Test: Check whether the covers are positioned on the inspection holes and secured with screws. Warning decals Warning of hazardous electrical voltage
Warning of injury to hands
Warning of hot surfaces
Test: Check whether the decals are still affixed and legible.
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Safety Chapter
2.5
WARNING
Notes on Safety
The operating instructions must be kept at the system!
CAUTION The plastic parts of the system are sensitive to improper mechanical stress!
WARNING Risk of electric shock! The control cabinet must always be closed during operation. The mains switch must be set to Off and secured against restart before starting any installation and maintenance work!
WARNING Risk of injury to arms and hands! Propellers are rotating in the chambers! First set the mains switch to Off and secure against restart, then remove the screwed cover of an inspection hole if a reservoir chamber must absolutely be accessed! Risk of injury to hands! Below the safety guard of the powder feeder, a screw conveyor and a bulker wheel are located! First set the mains switch to Off and secure against restart, if work has to be carried out below the safety guard!
WARNING Risk of sudden start! The agitators with propeller may start suddenly as long as they are connected to the power supply also in case of an error message or in hold mode (Start/Stop key). WARNING Risk of slipping! Liquid polymer or polymer solution is slippery! Immediately remove spilled powdery polymer, liquid polymer or leaked polymer solution! Only for types AT0 and ATF: WARNING Hot surface! An incorrectly adjusted heating of the metering pipe may become hot! Ensure that the heating of the metering pipe is adjusted correctly!
2.6
Sound Pressure Level
The sound pressure level is < 70 dB(A) for powdery polymer according to EN ISO 11202:1997 (Acoustics. Noise emitted by machinery and equipment.)
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Transport and Storage of the System / About this System
3
WARNING
Transport and Storage of the System
Fractures in plastic material may result in various hazards! 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 devices. When using forklift trucks, use long forks which extend across the entire depth of the three-chamber reservoir. If a crane is used mount the transport belts such that shear stress is absolutely prevented even if lifting lugs exist. If equipped with lifting lugs, Ultromat systems of the type 4000 or 8000 may only be lifted with a traverse. The length of the traverse must be 10 20cm longer at the minimum than the three-chamber reservoir. The support must be able to carry the weight of the system.
Environmental conditions for storage and transport: Permissible ambient temperature: Others: No dust, no direct sunlight
-5 C - +50 C
Humidity:none. Do not allow any rain and condensation!
4
4.1
About this System

Application
The Ultromat AF0, AT0, ATF system by ProMinent is an automatic preparation station for polyelectrolyte. It can be used in all applications where synthetic polymers are to be automatically prepared into polymer solutions as flocculants. As such a dissolving station, the system is suitable for numerous process-technical applications such as e.g. in water treatment, waste water treatment, and paper production. The Ultromat AF0 is meant to dissolve liquid polymers. The Ultromat AT0 can be used in all applications where pourable, synthetic powdery polymers are to be prepared. With the Ultromat ATF, powdery polymers and liquid polymers can be prepared.
4.2
Design
The system was designed for the fully automatic preparation of polymer solutions. Almost all commercially available polymers can be used. With the control of the Ultromat systems, concentrations of 0.05 to 1.0% can be set. The viscosity of the prepared polymer solution may, however, not exceed 1,500mPas. For information on the viscosity of various polymer solutions, please see the application data sheets of the polymer suppliers. To be able to make full use of the preparation chamber, the flow rate of the preparation water is to be adapted correspondingly, if required. Concentrations above 0.5% can result in a reduction of the capacity of the preparation performance. The maturing time available for the preparation of a polymer solution depends on the issue quantity and the capacity of the Ultromat and is approx. 60 minutes for maximum nominal issue rate. The system capacities range between max. 400 l working solution per hour for AT0 400 to 8,000 l for AT0 8000.
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ProMinent
About this System
4.2.1
Ultromat AF0 (for the preparation of liquid polymers)
The Ultromat AF0 is equipped with a built-in metering pipe for metering of the liquid concentrate. 4.2.2 Ultromat AT0 (for the preparation of powdery polymers)
The Ultromat AT0 is equipped with a powder feeder for metering of the powdery polymer. As an option, it is available with an Y wetting or a wetting cone. 4.2.3 Ultromat ATF (for the preparation of powdery and liquid polymers)
The Ultromat ATF can process both powdery and liquid polymers. If the Ultromat ATF is switched to liquid operation (using the key switch in the control cabinet door), the powder feeder is deactivated and the concentrate pump is activated.
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About this System
4.3
NOTE
System Sizes
For the exact dimensions of the individual Ultromat system, please see the dimension sheet! Ultromat AF0 Ultromat ULTa AF0.. Reservoir capacity (litres) Chamber volume (l) Issue quantity (l/h) Ultromat ULTa AF0.. Maturing time (min) Solution concentration (%) Dimensions HxWxD (mm) Net weight (kg) Total weight (kg) Overflow connection Issue connection Water feed for redilution Liquid concentrate piping Max. water feed Electrical power input * External protection Agitator 1 Output Speed ((50Hz) System of protection Agitators 2 + 3 (option) Output Speed ((50Hz) System of protection 0.18 kW 750 rpm IP 55 0.55 kW 750 rpm IP 55 0.75 kW 750 rpm IP 55 1.1 kW 750 rpm IP 55 2.2 kW 750 rpm IP 55 0.25 kW 750 rpm IP 55 0.55 kW 750 rpm IP 55 0.75 kW 750 rpm IP 55 1.1 kW 750 rpm IP 55 2.2 kW 750 rpm IP 55 60 0.05 - 0.5 1987x905x1250 150 550 DN 40 DN 25 1 DN 15 1,500 l/h 1.5 kW 25 A 60 0.05 - 0.5 360 1,360 DN 50 DN 25 1 DN 15 1,500 l/h 2.6 kW 25 A 60 0.05 - 0.5 410 2,410 DN 50 DN 32 1 DN 15 3,000 l/h 3.2 kW 25 A 60 0.05 - 0,5 3293x1515x1924 560 4,560 DN 65 DN 40 1 1/2 DN 20 6,000 l/h 5.0 kW 25 A 60 0.05 - 0.5 4589x1922x1926 1,160 9,160 DN 80 DN 50 2 DN 20 12,000 l/h 9.5 kW 40 A
400 400 133 400
1000 1,000 333 1,000
2000 2,000 666 2,000
4000 4,000 1.333 4,000
8000 8,000 2.666 8,000
2631x970x1600 3305x1155x1750
* The electrical power input is for systems with 3 agitators.
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ProMinent
About this System
Ultromat AT0 Ultromat ULTa AT0.. Reservoir capacity (litres) Chamber volume (l) Issue quantity (l/h) Maturing time (min) Solution concentration (%) Dimensions HxWxD (mm) Net weight (kg) Total weight (kg) Overflow connection Issue connection Water feed for redilution Max. water feed Electrical power input* External protection Agitator 1 Output Speed ((50Hz) System of protection Agitators 2 + 3 (option) Output Speed ((50Hz) System of protection Powder feeder Type Maximum metering output TGD 18.13 18 kg/h / 29 l/h TGD 18.13 18 kg/h / 29 l/h TGD 18.13 18 kg/h / 29 l/h TGD 30.13 55 kg/h / 92 l/h TGD 38.13 110 kg/h / 184 l/h 0.18 kW 750 rpm IP 55 0.55 kW 750 rpm IP 55 0.75 kW 750 rpm IP 55 1.1 kW 750 rpm IP 55 2.2 kW 750 rpm IP 55 0.25 kW 750 rpm IP 55 0.55 kW 750 rpm IP 55 0.75 kW 750 rpm IP 55 1.1 kW 750 rpm IP 55 2.2 kW 750 rpm IP 55 400 400 133 400 60 0.05 - 0.5 1777x905x1250 190 590 DN 40 DN 25 1 1,500 l/h 1.5 kW 25 A 1000 1,000 333 1,000 60 0.05 - 0.5 2421x970x1600 400 1,400 DN 50 DN 25 1 1,500 l/h 2.6 kW 25 A 2000 2,000 666 2,000 60 0.05 - 0.5 3095x1155x1750 450 2,450 DN 50 DN 32 1 3,000 l/h 3.2 kW 25 A 4000 4,000 1,333 4,000 60 0.05 - 0.5 3081x1515x2182 600 4,600 DN 65 DN 40 1 1/2 6,000 l/h 5.0 kW 25 A 8000 8,000 2,666 8,000 60 0.05 - 0.5 4377x1922x2290 1,200 9,200 DN 80 DN 50 2 12,000 l/h 9.5 kW 40 A
ProMinent
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About this System
Ultromat ATF Ultromat ULTa ATF.. Reservoir capacity (litres) Chamber volume (l) Issue quantity (l/h) Maturing time (min) Solution concentration (%) Dimensions HxWxD (mm) Net weight, without metering pump (kg) Total weight (kg) Overflow connection Issue connection Water feed for redilution Liquid concentrate piping (ATF) Max. water feed Electrical power input* External protection Agitator 1 Output Speed ((50Hz) System of protection Agitators 2 + 3 (option) Output Speed ((50Hz) System of protection Powder feeder Type Maximum metering output TGD 18.13 18 kg/h / 29 l/h TGD 18.13 18 kg/h / 29 l/h TGD 18.13 18 kg/h / 29 l/h TGD 30.13 55 kg/h / 92 l/h TGD 38.13 110 kg/h / 184 l/h 0.18 kW 750 rpm IP 55 0.55 kW 750 rpm IP 55 0.75 kW 750 rpm IP 55 1.1 kW 750 rpm IP 55 2.2 kW 750 rpm IP 55 0.25 kW 750 rpm IP 55 0.55 kW 750 rpm IP 55 0.75 kW 750 rpm IP 55 1.1 kW 750 rpm IP 55 2.2 kW 750 rpm IP 55 400 400 133 400 60 0.05 - 0.5 1987x905x1250 190 590 DN 40 DN 25 1 DN 15 1,500 l/h 1.5 kW 25 A 1000 1,000 333 1,000 60 0.05 - 0.5 2000 2,000 666 2,000 60 0.05 - 0.5 4000 4,000 1,333 4,000 60 0.05 - 0.5 3293x1515x2182 600 4,600 DN 65 DN 40 1 1/2 DN 20 6,000 l/h 5.0 kW 25 A 8000 8,000 2,666 8,000 60 0.05 - 0.5 4589x1922x2290 1200 9,200 DN 80 DN 50 2 DN 20 12,000 l/h 9.5 kW 40 A
2631x970x1600 3305x1155x1750 400 1,400 DN 50 DN 25 1 DN 15 1,500 l/h 2.6 kW 25 A 450 2,450 DN 50 DN 32 1 DN 15 3,000 l/h 3.2 kW 25 A
L Fig. 2: Ultromat dimensions
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ProMinent
Design and Function
5
5.1
Design and Function

Layout of the System
All system parts are integrated in a compact unit for powder storage, powder metering, wetting, dissolving and maturing of the powdery polymers. An Ultromat ATF system consists of a closed three-chamber reservoir (7), the concentrate pump (2), the water fitting (1) with wetting fitting (4), the powder feeder (5), the agitators (3), and the control cabinet (6). The three-chamber reservoir, the wetting fitting and the powder feeder are made of PP. The water piping can be made of PVC or PP, supplemented by brass fittings.
3 4 5 6
1 Fig. 3: Ultromat ATF
1 Water fitting 2 Concentrate pump (only AF0 and ATF) 3 Agitators 4 Wetting fitting (only AT0 and ATF) 5 Powder feeder (only AT0 and ATF) 6 Control cabinet 7 Three-Chamber Reservoir
The gaskets are made of EPDM as standard. The agitator shafts and the blades of the agitators as well as the delivery unit of the powder feeder are completely made of corrosion-resistant stainless steel.
5.2
5.2.1
Description of the Component Parts

Three-Chamber Reservoir
The closed-type PP reservoir with agitator traverse, consoles for powder feeder and control cabinet as well as overflow, discharge and issue connections is divided into three separate chamber such that a sufficient maturing time of the polymer solution is guaranteed. The division of the reservoir also largely prevents a mixing of the matured and the freshly prepared solutions and facilitates a continuous issue. The fill level of the chamber 3 is monitored by a fill level sensor. The system is equipped with a min. and max. contact to start or stop the automatic preparation process as well as with an additional empty contact as protection against dry running and a further sensor as overflow protection. All inspection openings of the reservoir are secured by screwable covers which can be firmly tightened. 5.2.2 Water Fitting with Wetting Fitting
The water piping supplies the system with the required preparation water. The pressure reducer with strainer ensures that the operating pressure is limited and that the correct operating pressure is maintained. The solenoid valve automatically opens and closes the water inlet. The used flow meter constantly reports the current flow rate to the control. The two control valves are used to define the flow rate during commissioning. The wetting fitting guarantees an intensive wetting of the powdery polymer with preparation water. A manual shut-off valve facilitates in addition a disconnection of the water inlet for maintenance work. There are two types of wetting fittings: a) Y wetting b) wetting cone In case of the wetting cone, the wetting process is more complicated than described above: The powdery polymer drops into the wetting cone where it is uniformly wetted with a partial flow of the preparation water. The metering medium then does not clot.
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Design and Function
With the help of a mixing unit, the main flow of the preparation water generates a slight vacuum at the outlet of the cone. The wetted powder is thus suctioned off and then goes to chamber 1 together with the preparation water. To ensure that neither at the start of the preparation process, no powder deposits in the wetting fitting, switching on of the powder feeder is controlled time-delayed with regard to the solenoid valve, i.e. water always flows for several seconds before the powder feeder starts. At the end of the preparation process, this is repeated vice versa. If the upper level is reached, the powder feeder is deactivated immediately, but water still continues to flow for several seconds.
2
1 Shut-off device 2 Pressure reducer 3 Solenoid valve 4 Flow meter 5 Control valves 6 Y pipe
3 4
Fig. 4: Water fitting with Y wetting
5 2 1 3 4
Fig. 5: Water fitting with wetting cone
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ProMinent
Design and Function
5.2.3
Powder feeder
For detailed information on the layout and the function of the unit, please see the separate operating instructions Dry feeders. The heating of the metering pipe as well as the min. fill level sensor for the dry material hopper are standard for Ultromat preparation systems. For a volume-proportional metering of the powdery polymer into the preparation water, the powder feeder is controlled via a frequency converter. For the continuous discharge of the powdery polymer a bulking wheel is installed which is located directly above the feeder screw. In addition, a metering pipe heating removes penetrated moisture and thus prevents a caking of the powdery polymer. 5.2.4 Agitators
The Ultromat is equipped with two electrical agitators as standard. A third agitator for the chamber 3 is available as an option. The agitators ensure a gentle agitation of the solution in the reservoir chambers. The agitators may suddenly start as long as they are supplied with system voltage! 5.2.5 Control Cabinet
The control cabinet houses the power supply unit and the fuses for all electrical control and command units required to operate the system, in particular the Ultromat control and the frequency converter to control the powder feeder. The control cabinet of the Ultromat ATF is in addition equipped with a key switch to switch to powder or liquid operation. 5.2.6 Socket-Outlet for the Connection of a Small-Type Feeder (not AF0)
The Ultromat is equipped with a socket-outlet for the connection of a small-type feeder. The socket-oulet is attached at the side of the control cabinet and secured electrically through a circuit breaker. 5.2.7
N L X10
Ultromat EA Assembly
1 4 X11 1 X12 H2 H4 X19 H1 H3 LSAHH H9 H10 H11 F2 P1 P2 LSH LSL LSALL H5 H12 H13 H15 H6 H7 H8 H14 H16 H17 H18 16 1 LSAHH LSH P3 P4 LSL LSALL 12 16
F1
K4 K5 K6
K1 K2 K3
2A3
H19
X18
1 H 20 X13 K7 K8 H 21 K9 H 22 H 23 K10 H 24 H 25
X14
12
16
K11
K12
H26 H27 H28 H29 H30 H31 H32 X15 X16
X17
X20 X20 1 4 5 8
X20 X20 X21 X21 X21 9 12 13 16 1 4 5 8 9 12
12
12
The Ultromat EA Assembly is a compact function unit, installed on a board. The following functions were implemented: Power supply unit 24 V DC, 500mA Relay for coupling of the output signals (250V AC, 3A) Optocoupler to separate the input signals Level relay to evaluate the conductive level electrodes
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Design and Function
Output relay: The switching states of each relay are indicated by a LED. The LED is illuminated if the relay has picked up. Relay K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 LED H6 H7 H8 H9 H10 H11 H20 H21 H22 H23 H24 H25 Function Alarm Horn acknowledged not assigned Agitators 1 and 2 Agitator 3 Switching powder/liquid Heating not assigned Solenoid valve water Issue (dry running) operation alarm (parallel K1)
Setting the sensitivity of the level relay: The sensitivity of the level relay can be set using the potentiometers P1 and P2. If the conductivity of the preparation water drops, the sensitivity of the level relay must be increased. To achieve this, turn the potentiometers P1 and P2 clockwise using a screwdriver. The potentiometer P1 is responsible for the overflow level (LSAHH), the potentiometer P2 for the levels dry running (LSALL), minimum (LSL), and maximum (LSH). The control range of the potentiometers has 15 steps. The switching states of the levels are indicated by LEDs. LED/level H 5 (LSAHH, overflow) H 12 (LSH, maximum) H 13 (LSL, minimum) H 15 (LSALL, dry running) LED to indicate the signal states: The LEDs indicate the internal signal states of the Ultromat EA assembly. The meaning is listed in the following table: LED H1 H2 H5 H 12 H 13 H 15 H 19 H 26 H 28 H 29 H 30 H 31 H 32 Identification FLK ok RW ok Level < LSAHH Level > LSH Level > LSL Level > LSALL Frequency converter Powder > min. Flow ok Redilution on Redilution ok FLK > min Remote control on LED on: Concentrate pump ok Agitator ok no overflow Level exceeded Level exceeded Level exceeded Frequency converter ok Powder stock exists Flow liquid polymer ok Redilution activated Water flow redilution unit ok Liquid polymer stock exists External switch closed Level undershot LED on LED off LED off LED off Level exceeded LED off LED on LED on LED on
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ProMinent
Design and Function
5.2.8
Remote Control
This function facilitates the remote-controlled activation and deactivation of the system, if needed. The Ultromat can be switched to the operating or hold state via an external switch. A potential-free contact is available for system status messages. The signals have the following meanings: Contact closed: The system is ready for operation. No fault exists.
Contact open: 5.2.9 The system is stopped locally or remotely (pause from control desk). A fault exists. Concentrate Piping (not type AT0)
For the metering of the liquid concentrate into chamber 1, the Ultromat AF0 and ATF are equipped with the following piping: Type Ultromat 400 1000 2000 4000 8000 5.2.10 Crane Lifting Lugs Piping size DN 15 DN 15 DN 15 DN 20 DN 20 Hose grommet DN 15 DN 15 DN 15 DN 20 DN 20
A suitable hoisting device can be mounted at the four lugs for an easier handling of the system.
5.3
5.3.1
Operating Modes
Preparation Mode
When the min. level in chamber 3 is reached, the Ultromat starts the preparation process. The solenoid valve opens and the powder feeder starts to meter the powdery polymer upon expiry of the delay time. When the maximum level is reached, the control first stops the powder feeder and then closes the solenoid valve after expiry of the lag time. The Ultromat goes to the operating mode Issue supply. 5.3.2 Setting Mode
In the setting mode, all required settings can be made. For this purpose, the control suppresses in this operating mode the execution of individual functions which may interfere with the settings. When calibrating the powder feeder, the solenoid valve for the water inlet remains closed and the powder feeder is released and controlled independent of the water inlet. When setting the water inlet, the powder feeder remains switched off. 5.3.3 Remote Control Mode
When selecting the option Remote control, the system can be switched between operating and hold state from a control desk. In this case, the preparation process is also fully automatic, if the system was switched to the operating state via the remote control contact. The operating parameters are still set and indicated at site.
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Design and Function
5.4
Ultromat Options
The following options are available for the Ultromat: 5.4.1 Agitator for the Chamber 3 (Agitator 3)
The Ultromat is equipped with two electrical agitators as standard. A third agitator for the chamber 3 is available as an option. 5.4.2 Overflow Valve for Chamber 3
The overflow valve signals an overflow of the chamber 3 of the Ultromat and triggers a combined alarm. 5.4.3 Evaluation Water Shortage for the Redilution Unit
The redilution unit is used for a further dilution of the prepared polymer solution. A delivery pump transports the polymer solution from the storage tank of the Ultromat to the redilution unit. The diluent water is fed to the redilution unit via a solenoid valve. A downstream float flow meter with min. contact monitors the diluent water. The min. contact of the rotameter is monitored with the option Evaluation redilution unit. If the min. contact indicates a water shortage, the Ultromat goes to fault and the release for the delivery pump (polymer solution) is withdrawn. The Ultromat makes available a potential-free contact for the control of the delivery pump (release delivery pump). This contact is closed when the dry running level in chamber 3 has been exceeded, and opens when the dry running level has been undershot. The delivery pump is typically controlled via an external circuit (motor starter combination). Because the delivery pump can be switch on and off externally, an additional input for the evaluation of the motor starter (potential-free auxiliary contact) is available at the Ultromat control. The min. contact at the flow meter is only evaluated if the delivery pump is running and thus the potential-free auxiliary contact at the motor starter was closed. If the delivery pump is not running, the potential-free contact is not closed and the min. contact at the flow meter is not evaluated. 5.4.4 Concentrate Pump (only types AF0 and ATF)
For the metering of liquid polymer into the chamber 1. Diaphragm metering pumps and eccentric screw pumps are available. 5.4.5 Empty Signal for Concentrate Tank (only types AF0 and ATF)
The option Empty signal concentrate tank includes a float switch which is installed in the delivery container from the top. 5.4.6 Metering Monitor for Liquid Concentrate (only types AF0 and ATF)
The Ultromat AF0 and AFT can be operated with liquid polymers. The concentrate pump meters the concentrate into chamber 1. The metering monitor can only be used if eccentric screw pumps are used. The metering monitor consists of a flow adapter and a thermal flow sensor. The setting menu Setting metering monitor supports the setting of the flow sensor. 5.4.7 Add-On Hopper 50 l, 75 l, and 100 l (only types AF0 and ATF)
For an increased stock of powder add-on hoppers with an additional capacity of 50, 75, and 100l, respectively, are available.
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ProMinent
Design and Function / Assembly and Installation
5.4.8
Vibrator (only types AF0 and ATF)
The vibrator helps to prevent bridging in the powdery polymer of the add-on hopper such that the powdery polymer has a better flowability. 5.4.9 Powder Feeder for Automatic Refilling (only types AF0 and ATF)
For an automatic filling of the dry material hopper with powdery polymer, a powder delivery unit is available. The powder delivery unit can be installed directly onto the powder feeder using an adapter plate. To bridge short maintenance work at the powder delivery unit or in case of high powder consumption, it is recommended to interconnect a 50l add-on hopper with connection adapter.
5.5
Ultromat Accessories
The following accessories are available for the Ultromat: 5.5.1 Powder Feed Tank (only types AF0 and ATF)
The powder feed tank serves the intermediate storage of powdery polymers which were supplied in big bag containers. The big bag is suspended in a frame above the feed tank and emptied into the powder feed tank. 5.5.2 Powder Feed Tank with Bag Dumper (only types AF0 and ATF)
The powder feed tanks with bag cumper serves the intermediate storage of powdery polymers which are supplied in containers of 25 kg. 5.5.3 Redilution Station
Since the Ultromat systems can be operated with high concentrations, the preparation of a higher concentrated polymer solution with subsequent redilution is a good option in many cases. Polymer solutions with higher concentrations have a longer life and the downstream dilution increases the issue output of the entire system. But the viscosity of the polymer solution may not exceed 1.500 mPas. The redilution stations, which are pre-mounted on a panel, were matched to the relevant system size and are typically designed for a dilution in the volume ratio 1 : 5.
Assembly and Installation
The system is completely pre-assembled ex works. The wiring between the control cabinet and the electrical units is also complete.
6.1
WARNING
Assembly
The system may be damaged or may break! The installation of the system requires a weight-bearing capable, level and horizontal support adequate for the dimensions and the high operating weight of the system! Damages may be caused by and in the system. The system must be easily accessible any time for operation, maintenance, and filling.
CAUTION Insufficient mixing performance is possible! Reduced motor output because of insufficient cooling! Ensure an unobstructed supply for the cooling air! Ensure the specified nominal rating of the electric motor by max. 40 C ambient temperature and installation heights below 1,000m above sea level. If required, use an electric motor with higher nominal rating.
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Assembly and Installation
Ambient conditions Permissible ambient temperature: 5 C - 40 C The system may not be exposed to condensation or rain. The system may not be exposed to direct sunlight.
6.2

Installation, Hydraulical
The preparation water must be of drinking water quality. It must be free from solids and suspended particles. The inlet water pressure must range between 3 bar and 5 bar. The process water, overflow and discharge lines must have the correct dimensions.
Prerequisites:
CAUTION Damages to the environment because of polymer solutions are possible! When draining the discharge lines and the overflow line, observe the safety data sheet for the polymer and the legal regulations for disposal! NOTE Overflow and discharge lines must be routed with downward slope and operation without backpressure must be possible! When decommissioning the system, it is recommended to install a T-piece with a stop-cock as discharge option between the shut-off valve of the chamber 3 and the delivery pump. Connect the line for the preparation water to the water fitting. Not type AT0: Connect the line for the liquid polymer to the concentrate pump. Connect the delivery pump to the issue line. Tube the discharge lines and route into a suitable drain. Connect the overflow line to the overflow union and route into a suitable drain.
6.3
WARNING
Installation, Electrical
The electrical installation may only be performed by a qualified electrician! Always disconnect the system from the power supply and secure against re-start before carrying out any installation work in the electrical connections. Connection of the Mains Line
6.3.1 WARNING
When connecting the units, always ensure a correct terminal assignment. CAUTION Risk of malfunctions! When connecting agitators, powder feeder, motor pumps always ensure that the motors are rotating in the right direction! Connect the electrical line according to the connection diagram (see pocket in the control cabinet). Route the mains cable into the control cabinet of the system through a suitable opening and connect it to the designated terminal block. 6.3.2 Opening of the Control
To open the plastic housing, loosen the four countersunk screws in the cover corners. The upper part is also connected to the bottom part with additional snap-on hooks. The snap-on hooks can be released by pressing on the upper edge of the cover with the index finger and simultaneously pulling it forward a bit. The complete upper part can then be removed to the front.
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ProMinent
Assembly and Installation / Control
Separate the upper part gently from the bottom part because they are connected by a short ribbon cable! The upper part with the two guiding rails can now be inserted into the slot approx. 80mm above. In this parking position, all connecting terminals and fuses are freely accessible.
7
7.1
Control
Design and Function
The Ultromat control is accommodated in a plastic housing (for control panel installation only type of protection IP 54). It includes the actual microprocessor control as well as the pertinent terminal board with the required connection terminals, the power supply unit, the fuse as well as all plug-in cards for inputs and outputs. All information on the operation of the system such as error messages, warning notices, measured values as well as the entire menu system are shown on a LCD screen. All parameters and configuration data are saved in a fail-safe memory. 7.1.1 7.1.2 Display Elements and Controls Display Elements (Status Indication)
L3 L4
L5 L6
L7 L8
L9 L10
1+2
L11
L2
L1
Fig. 6: Display elements Ultromat control
Display element L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 and L11 LCD display
Signal green LED indicator LED indicator off red LED indicator green LED indicator green LED indicator green LED indicator green LED indicator green LED indicator green LED indicator red LED indicator green LED indicator 2 lines, max. 16 characters
Meaning Device in operating mode Device in hold mode Fault (flashing light) Warning (permanent light) Control metering pipe heating Control metering (powder feeder for type AT0 or concentrate pump for ATF) Control water feed red LED indicator Flow smaller than specified min. flow Control delivery pump (polymer solution) Control agitator chamber 1 +2 Control agitator supply 3 (option) Powder shortage in powder feeder (types AF0 and ATF) Function only in calibration mode and test mode
ProMinent
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Control
7.1.3
Controls
1+2
3 T3
T4 T5
T2
T1
T6 T7 T8
Fig. 7: Controls of the Ultromat control
Display element T1 T2 T3 T4 T5
Signal Start / stop key Ack key Enter key Change key T key
Meaning Switches the Ultromat system to operating or hold mode Acknowledges a received alarm Saves a value, goes to the next menu option Change in the menu Start/stop key for the calibration of the powder feeder, the concentrate pump, the setting of the water feed, and metering monitor, test devices Modification of numerical values Return within the menu Modification of numerical values
T6 T7 T8 separate key in the control cabinet door:
Down key Return key Up key
Horn off key
To mute the horn signal in case of a combined alarm (does not acknowledge the alarm!) Operation of the System and Operating Status Indications
7.1.4
Mains switch The Ultromat is switched on and off using the mains switch located at the side of the control cabinet. START / STOP key The operating processes are stopped and started by pressing the START/STOP key. The switched on system can be in the operating mode (L1: green LED on) or in hold mode (L1: LED off). Function Remote control The Ultromat can also be switched to hold mode via a potential-free remote control contact (only for option: Remote control). In this case, Remote control PAUSE is indicated if the operating processes are stopped via remote control.
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ProMinent
Control
T key The T key is required during calibration in order to start or stop an action. The LED (L11) flashes whenever the T key must or can be pressed during the calibration. If an action was triggered with the T key, the LED (L11) is permanently lit green. Alarm The red Alarm indicator (L2) is located next to the Ack key. In standard operation it is not lit. In case of a fault, it flashes until the fault is remedied and the error message has been acknowledged. After acknowledging, the LED and the error text extinguish. If several faults are given, the texts are indicated alternatively. Centralised fault The horn signal of the centralised fault can be deactivated for the present alarm with the separate key Horn off in the front door of the control cabinet. Key switch Powder or Liquid For the Ultromat ATF, the operating mode Powder or Liquid can be selected via a key switch in the control cabinet door. Before changing the operating mode, the Ultromat must be disconnected from the power supply for approx. 10 seconds using the mains switch. After reconnection to the power supply, the control accepts the switch position and continues in the selected operating mode. The parameters for powder and liquid mode are saved separately.
7.2
7.2.1
Menu System
Layout of the Menu
The menu is divided into the display level and the setting level. In the display level, the operating status of the system and the alarms are indicated. In the setting level, the parameters for controlling the system can be changed and the calibration can be performed (see also Control menu in the annex). After selection of the setting level, the control automatically returns to the display level after 10 minutes.
Display menu Access code
Commissioning Setting of language Water feed min. flow Heating Switch-on / off time Water feed lead/lag time Agitator 1+2 Switch-on / off time Agitator 3 Switch-on / off time Concentrate pump minimum frequency Change access code
Calibration Setting Water feed Calibration Powder feeder Calibration Concentrate pump Setting Metering monitor
Concentration Concentration
Service
Flow
Agitator
Agitator 3
Powder feeder
Run empty
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Control
7.3
Operation of the Control Selection of a Menu Option

Enter key to confirm, or save a displayed value or a setting. Change key to change the display within a menu level Return key for the gradual level return within the operating menu. The return is made to the previous menu level.
Pressing the Enter key, the display goes from the display menu to the setting menu. After pressing the Enter key again and entering the access code (default: 1000), pressing the Change key switches between the submenus Settings commissioning, Settings calibration, Settings concentration and Settings service. All other subsequent menus are accessed by pressing the Enter key again. Values are entered with the help of the arrow keys UP and DOWN. In general, the value last entered is shown. When permanently pressing one of the arrow keys, the value starts to change more rapidly. The previous level can be reached by pressing the Return key.
7.4
7.4.1
Display Mode
Standard Operation
The following messages are shown on the control display during the preparation process: Preparation mode feed = xxxl/h Conc. = x.x% feed = xxxl/h
When the maximum fill level in chamber 3 is reached, the control display shows the following messages: Supply full Issue supply Conc. = x.x% Issue supply
7.4.2
Interruption of Standard Operation
By pressing the Start/Stop key, the standard operation is interrupted or started. In hold mode, the control display shows the message: STOP Feed = 0l/h
If the standard operation is interrupted via the remote control input, the following message is shown: Remote control PAUSE
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ProMinent
Control / Commissioning
7.4.3
Display of the Identcode of the Control
By pressing the Change key in the permanent display, the Identcode ULSaTxxxxxxxxx is shown as well as in the second line the software version(e.g.: 02/4.1) of the control and the operating mode L (Liquid) or D (Dry material = powder polymer). Please provide these data to ProMinent Dosiertechnik GmbH in case of complaints and customer service requests in the event of malfunctions.
8
8.1
Commissioning
Assembly, Preparatory Work
WARNING Before first commissioning, the mechanical and electrical connections must be checked for correct connection (e.g. direction of rotation of motors, supply voltage etc.). Make sure that the voltage, frequency and current type applied in the control cabinet match the data on the rating plate (on the right side of the control cabinet). For assembly, the handling and installation described in Chapters 3 and 6 must be observed. For Ultromat AF0 and ATF connect in addition the supply with liquid concentrate. Preparation water, issue and overflow lines must be assembled and checked for leakages and subjected to function tests. Provide a sufficient quantity of substances in the prescribed quality. After having switched on the mains switch, the following is displayed on the LCD screen: Stop, feed = 0 l/h. If a different message is displayed, press the start/stop key until the message Stop is displayed. For the option Remote control, the message Remote control PAUSE may be displayed. The system must then be activated through the control desk.
8.2
Checking the Identcode of the Control

Press the Change key in the permanent display to go the Identcode screen. Press the Change key again to return to the permanent display.
8.3
Settings for Commissioning
In the delivery status, the parameters of the menu Settings commissioning are set to the following defaults: Parameter Language Water feed min. flow Ultromat 400 Ultromat 1000 Ultromat 2000 Ultromat 4000 Ultromat 8000 Heating switch-on time Heating switch-off time Feed lead time Feed lag time

Defaults D 500 l/h 1,200 l/h 2,400 l/h 5,000 l/h 10,000 l/h 5s 35 s 7s 5 min
Range D, E, F, P, C, N, H
0 - 12,000 l/h
1 10 s 30 100 s 0 30 s 0 - 30 min
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Commissioning
Parameter Agitator 1+2 Agitator 1+2 Agitator 3 Agitator 3 Change access code
Defaults switch-on time 15 min Switch-off time 15 min switch-on time 5 min Switch-off time 10 min 1000
Range 5 - 50 min 5 - 50 min 0 - 20 min 5 - 50 min 1000 - 9999
During commissioning, the parameters can be adapted to the process.
8.3.1
Setting of the Minimum Flow (only with wetting fitting for AT0 and AFT)
If the water feed is reduced because of a pressure drop in the water supply, the water level in the wetting cone drops. For a water feed of less than 80 % of the specified water quantity, the wetting cone is no longer sufficiently wetted with water. This may result in a clogging of the wetting cone and thus to malfunctions. Press the Enter key to go to the display min. flow. Press the Enter key again and change the value using the arrow keys. 8.3.2 Setting of the Heating of the Metering Pipe (only types AF0 and ATF)
WARNING Hot surface! An incorrectly adjusted heating of the metering pipe may result in burns! Select the switching-on and -off times such that the temperature of the heating of the metering pipe does not exceed 40 C! CAUTION The feeder screw might be damaged! Temperatures above 40 C (lukewarm) may result in a clogging of the bulk good and destroy the feeder screw! Select the switching-on and -off times such that the temperature of the heating of the metering pipe does not exceed 40 C! Press the Enter key to go to the display Heating switch-on time? By pressing the Enter key again, the current switch-on time is shown. The switch-on time can be reduced or increased using the arrow keys. Press the ENTER key to confirm the entry. The switch-off time is changed or set as described for the switch-on time. 8.3.3 Setting of the Lead and Lag Times (only types AF0 and ATF)
In order to prevent clogging of the bulk good in the wetting cone, lead and lag times can be specified for the preparation water such that in both cases a sufficient wetting is guaranteed. After opening of the solenoid valves, several seconds pass until the wetting cone is sufficiently wetted with water. Upon expiry of the lead time, a stable state should have been reached and the internal walls of the cone should be completely covered with water. When the max. level in chamber 3 is reached, the powder feeder is deactivated. The solenoid valve is only closed upon expiry of the lag time. Set the lag time such that the wetting cone is sufficiently wetted with water.
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Commissioning
Fig. 8: Processes in the chambers, diagram
8.3.4
Agitators 1 and 2
The agitators are automatically restarted with each preparation process. Upon completion of the preparation process, both agitators continue in the pulse/pause mode. The value can be changed with the arrow keys by selecting the submenu Agitator 1 + 2 switch-on time as well as Agitator 1 + 2 switch-off time and pressing of the Enter key. Press the Enter key again and the new value is accepted by the control. 8.3.5 Agitator 3 (option)
The agitator 3 starts automatically with each preparation process und continues to run in the pulse/pause mode. Based on the adapted switch-on and switch-off times, a sufficient mixing can be obtained without destroying the matured macromolecules. 8.3.6 Access Code
In the last step of the commissioning menu, the pre-set access code has to be changed. Otherwise, the effect of protection is compromised. The new access code should be recorded and deposited at a safe place.
8.4
Setting of Concentration
The Ultromat systems can be operated with solution concentrations between 0.05 % and 1.0 %, provided the viscosity of the polymer solution of 1,500 mPas is not exceeded. To specify concentrations smaller than 0.1 % and larger than 0.5 %, the desired concentration can only be obtained by a corresponding adjustment of the flow rate of the preparation water. This may result in a reduction of the system capacity. Select the submenu Setting concentration and press the Enter key Concentration is displayed. Enter the desired concentration using the arrow keys.
ProMinent
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Commissioning
8.5
Settings of Calibration
The calibration menu is only shown if the Ultromat system was switched to the hold mode by pressing the Start/Stop key. The following settings can be made: 1. Setting water feed 2. Calibration powder feeder 3. Calibration concentrate pump 4. Setting metering monitor 8.5.1 Setting water feed
For water feed, the following values should be specified: Type Ultromat
Water feed 400 1,500 l/h 1,500 l/h 3,000 l/h 6,000 l/h 12,000 l/h
Ultromat 1000 Ultromat 2000 Ultromat 4000 Ultromat 8000
In the menu Setting water feed, press the Enter key to go to the display Water feed the LED next to the T key on the control panel flashes. After pressing the T key in the corresponding menu option, the solenoid valve opens and the current flow is shown. With Y wetting: Remove the cover from the control valve. Adjust the required water quantity at the right control valve using a screwdriver with a large blade width (min. 10mm). The current flow rate can be read from the LCD screen of the control. After stabilisation of the operating status, the water flow to the wetting cone may be readjusted to achieve the needed cone wetting. Complete the setting by pressing the T key. With wetting cone: Remove the covers from both control valves. Adjust the water flow at the left adjusting T-piece (smaller nominal width) with a screwdriver with large blade width (min. 10 mm) such that the water level in the wetting cone stabilised at approx. 15 to 20 mm below the overflow pipe. As soon as the water level in the cone has stabilised, the required water quantity has to be adjusted at the right control valve (large nominal width). The current flow rate can be read from the LCD screen of the control. After stabilisation of the operating status, the water flow to the wetting cone may be readjusted to achieve the needed cone wetting. Complete the setting by pressing the T key. 8.5.2 Calibration of the Powder Feeder (only types AF0 and ATF)
Required material: Balance PE bag (capacity min. 500 g) Loosen the screw couplings and disassemble the wetting cone. Press the Enter key in the menu Calibration powder feeder to go to the menu Powder feeder. The LED next to the T key flashes.
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Commissioning
Hold the PE bag (capacity min. 500 g) under the metering pipe and press the T key. The powder feeder runs at full capacity. If a sufficient amount is poured into the bag, stop the powder feeder by pressing the T key again. Weigh the discharged powder amount and enter the weight in grams into the control using the arrow keys. After pressing of the Enter key, the control calculates the metering output in grams/minute and saves this value. Remount the wetting cone after completion of the calibration of the powder feeder. 8.5.3 Calibration of the Concentrate Pump (only types AF0 and ATF)
Required material: Balance Collection container (capacity min. 1 l) Determine the own weight of the collection container. Open the metering line at a suitable point. In the menu Calibration concentrate pump, press the Enter key to go to the display Concentrate pump the LED next to the T key flashes. By pressing the T key, the concentrate pump starts the concentrate is discharged into the collection container. Press the T key again to stop the concentrate pump. Weigh the collected amount of liquid concentrate and enter the weight into the control using the arrow keys. After pressing of the Enter key, the control calculates the metering output in grams/minute and saves this value. Tightly close the metering line again.
8.5.4
Setting of the Metering Monitor for Liquid Concentrate (only types AF0 and ATF with Spectra)
The metering monitor is only available if the Ultromat AF0 or ATF has been ordered with Spectra as concentrate pump. For the Sigma as concentrate pump, the option Metering monitor is not available. 1. Release key lock: If the keys are locked, press both keys of the metering monitor in the operating mode at the same time for 10 s the key lock is released as soon as the indicator extinguishes. 2. High flow calibration: The liquid concentrate must pump at normal speed. Press and hold the right key. The right LED (No. 9) is illuminated and starts to flash after approx. 5 s. Release the key. 3. Low flow calibration: The low flow calibration may only be performed after the high flow calibration! Pump the liquid concentrate at minimum speed or stop the flow. Press and hold the left key. The left LED (No. 0) is illuminated and starts to flash after approx. 5 s. Release the key. The system accepts the new value and goes to operating mode.
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Commissioning
4. Changing of the switching point (optional) Pump the liquid concentrate to set the switching point. Press the key briefly - the flashing LED indicates where the switching point is currently. Move the switching point in the desired direction with the keys or . Set the switching point as high as possible (green illuminated LED with the highest number). If no key is pressed for 2s, the system accepts the new value and goes to operating mode. 5. Locking the keys: Press both keys at the same time in operating mode for 10s the keys are locked as soon as the indicator extinguishes. 8.5.5 Setting of Capacitive Sensors (types AF0 and ATF)
The capacitive sensors to report powder shortage in the powder feeder or overflow in the wetting cone must be checked and set individually The sensor has a yellow LED at its cable-side end to indicate the switching state and next to it a sunken adjusting screw to set the sensitivity. Required material: 1 small screwdriver The sensor is checked and adjusted in 2 steps: 1. For empty powder feeder (or standard water flow in the wetting cone): a) The yellow LED at the sensor is not illuminated - the setting is correct. b) The yellow LED at the sensor is illuminated: Reduce the sensitivity at the adjusting screw (turn anti-clockwise) until the LED extinguishes. 2. For filled powder feeder (or overflowing water of the wetting cone): a) The yellow LED at the sensor is illuminated - the setting is correct. b) The yellow LED at the sensor is not illuminated: Increase the sensitivity at the adjusting screw (turn clockwise) until the LED is illuminated.
8.6
8.6.1
Service Menu
Setting of Flow
The menu Setting flow is required in case the turboDOS or contact water meter fails. Set a fixed value in the menu manual flow entry if the flow meter no longer emits any signal. During a preparation process, the control no longer obtains the flow values from the flow meter, but uses the set fixed value. The fixed value must, of course, be chosen such that it corresponds to the former feed. CAUTION Changes in the concentration of the polymer solution are possible! The operating mode with manual flow entry may only be used as briefly as possible and with caution! After restoration of the flow meter, automatic flow measurement must be activated again.
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Commissioning
8.6.2
Testing Agitators and Powder Feeder
Agitators and powder feeder can be switched on and off manually. Select the pertinent menu and press the T key. The following menus are available: Test agitator 1 + 2 Test agitator 3 (option) Test powder feeder (only AT0 and ATF) Test concentrate pump (only AT0 and ATF) Running empty the Ultromat
8.6.3
The menu Run empty prevents a new preparation in the Ultromat and maintains the release for the downstream delivery pump (transfer pump) until the dry running level has been undershot. For running empty, go to the menu Run empty and press the T key.
Fig. 10: Extract operating menu Run empty
8.7
8.7.1
Setting of the Frequency Converter Altivar 11

Function of the Controls
Fig. 11: Controls Altivar 11
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Commissioning
Exit the menu or parameter or return from the indicated value to the last saved value Go to the previous menu or parameter or increase the indicated value Three 7 segment indications Access of a menu or parameter or saving of the parameter or the indicated value Go to the next menu or parameter or decrease the indicated value Menu Overview
8.7.2
8.7.3
Setting of the Parameters
The frequency converter is factory-set to the following defaults: Setting parameters level 1 Parameter bFr Value 50 Description Motor frequency (Hz) This parameter is only displayed at first switching on. It can, however, be changed any time in the menu FUn. Ramp-up time (s) Run-down time (s) low speed at 4mA (Hz) high speed at 20mA (Hz) Thermal motor protection (A) 2. preselection frequency (Hz) 3. preselection frequency (Hz) 4. preselection frequency (Hz) Configuration analogue input (4-20mA) 0 - 3,1 0 - 200 0 - 200 0 - 200 Range 50 / 60
ACC dEC LSP HSP ItH SP2 SP3 SP4 AIt / ACT Menu drC Parameter UnS FrS StA FLG UFr 5 nCr
0,1* 0,1* 0 100* 1,5* 10 25 50 4A*
0.1 99.9s 0.1 99.9s
Value 230 50 20 20 0 1,5*
Description Nominal motor voltage (rating plate) (V): Nominal motor frequency (rating plate) (Hz): Stability of the frequency controller (%) Gain of the frequency controller (%) Ri compensation (%) nominal current of the motor read from the rating plate
Range 100 - 500 40 - 200 0 100 0 100 0 200 0.5 3.1
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Commissioning
Parameter CLI nSL SLP COS Men FUn Parameter tCC
Value 1,5* 0* 0* 0,78*
Description Motor limiting current Nominal motor slip (Hz) Slip compensation (%) Cos Phi of the motor (rating plate)
Range 1.0 3.1 0 - 10 0 150 0.50 1.00
Submenu ACt tCt
Value 2C LEL* no*
Description Type of control 2-wire control Type of 2-wire control Anti-clockwise rotation Preselection frequencies Assignment of the input LIA Assignment of the input Llb
rrS PS2 LiA LIb tLS PI rSF rP2 LI LC2 LI1 nSt StP brA AdC ACt tdC SdC SFt ACt SFr FLr d0 ACt Atr bFr SCS FCS no rEC InI
no no 0,0 no no no
Re-start at failures Second ramp Assignment of the input to control the second ramp 2. Current limitation
no no no no* yes 0,5 1,4 LF 4 no no* yes* 50 yes Controlled run-down in case of power failure Adjustment of run-down ramp Automatic feeding of direct current Operating mode Feed time Input current Timing frequency Frequency range Timing frequency (kHz) Aligning in operation Analogue output Assignment Automatic re-start Motor frequency (Hz) Saving of the configuration Call up of the configuration Function inactive Call up saved configuration The factory-set defaults become the current configuration
Note: (*) These settings deviate from the values which are entered as defaults after returning to the factory-set values via the parameter >FCS= InI<.
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Commissioning / Operation of the System
8.7.4
Settings for Ultromat AF0 or ATF
(Control type Switching frequency converter) Only type ATF: Go to the operating mode Liquid. Adapt the parameter Thermal motor protection = ltH to the concentrate pump. NOTE The parameter HSP = high speed at 20 mA must not be changed in the operating mode Liquid because the frequency converter is controlled with a current signal of 4-12 mA. Because of this a frequency of a maximum of 50 Hz is obtained.
8.8
CAUTION
Commissioning of the System
Water damages are possible! Large amounts of water or polymer solution may leak! Before starting the preparation process it is to be ensured that the drain valves for all three chambers are closed. Monitor the operation in this starting phase! Specifically ensure the correct switching function of the level sensors when the relevant switching points are first reached!
NOTE The error message Supply empty cannot be avoided because at the present time all chambers are still empty. Acknowledge this fault. Prerequisites: proper assembly and installation of the system was checked the drain valves for the three chambers are closed not type AF0: The storage tank is filled with the specified powder polymer not type AT0: The concentrate tank is filled with the specified liquid polymer Set all operating parameters. Calibrate all required devices. Start the system by pressing the Start/Stop key the system starts to run and starts the automatic preparation process.
9
9.1
9.1.1
Operation of the System

Standard Operation
Prerequisites for a Proper Operation
Prerequisites: A meaningful setting of the operating parameters A thorough calibration (specifically level sensors!) No arbitrary changes of the parameters at the frequency converter
WARNING The system may be only operated by instructed persons! The system can in principle be stopped or restarted in any operating phase by pressing the Start/Stop key. In general, any cause of malfunction should be remedied before acknowledging the relevant error message. The horn can also be stopped by pressing the key Horn off.
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Operation of the System
9.1.2
Feeding of the Storage Tank with Powdery Polymer (not type AF0)
WARNING Risk of slipping! Mixtures of polymer and water are slippery! When filling the dry feeder ensure a safe foothold! Immediately remove spilled powdery polymer or leaked polymer solution!
If the storage tank is not automatically filled by the small-type feeder, the supply of powdery polymer must also be continuously checked and refilled in time. Filling may be performed during operation. Remove the cover from the storage tank and carefully refill the powdery polymer. 9.1.3 Refilling of the Concentrate Tank with Liquid Polymer (not type AT0)
WARNING Risk of slipping! Liquid polymer and mixtures of polymer and water are slippery! When filling the concentrate tank ensure a safe foothold! Immediately remove spilled liquid polymer or leaked polymer solution!
If the concentrate tank is not automatically refilled, the supply of liquid polymer must also be continuously checked and refilled in time. Filling may be performed during operation. Remove the cover from the concentrate tank and carefully refill the liquid polymer.
9.2
Switching on Mains and Behaviour during Mains Power Failure
a) Switching on mains At each switching on of the mains, the agitators start to run independent of the measured system states. But the system only starts with simultaneous preparation process if the min. switching point in chamber 3 is reached. If the mains power fails during the preparation process even only briefly the preparation process is not continued at restart. b) Behaviour during mains power failure After a power failure or a longer power interruption which results in a restart of the control, the control continues the operation of the system unrestrictedly based on the detected states. If the level of the storage tank is in the normal range, no preparation process is started, even if a preparation process was running before the interruption.
9.3
Decommissioning
Press the Start/Stop key.
For a short time
For a longer period of time Set the mains switch to Off. Lock the mains switch to prevent an unauthorised restart of the system.
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Operation of the System / Maloperations of the System
For more than 2 days Set the mains switch to Off. Lock the mains switch to prevent an unauthorised restart of the system. Disconnect the mains plug. Completely empty the powder feeder Empty the three-chamber reservoir through the pertinent connections of the individual chambers. Thoroughly flush the three-chamber reservoir with water. In addition, flush again the wetting fitting (cone and mixing unit). Thoroughly flush the line between the shut-off valve of chamber 3 and the delivery pump. (If a flushing port was installed, the flushing is made easier.) CAUTION The delivery unit and the lines may clog! During the re-commissioning, the liquid polymer may not get into contact with the flushing water! Remove the flushing water from the delivery unit and the lines! Flush the delivery unit of the concentrate pump including suction line and pressure line. Disassemble and dry the delivery unit of the concentrate pump. Run pigs through the suction line and the pressure line. WARNING If the system is to be moved or stored, read Chap. 3 carefully!
9.4
CAUTION
Disposal
Please observe the relevant local regulations (specifically with regard to electronic waste)! Please also read the operating instructions for the other devices (powder feeder, pumps )! For Germany: The cleaned used parts can be disposed of at the municipal collection points of the cities and municipalities.
10

Maloperations of the System

An incorrect position of the drain valves results in malfunctions. An incorrect position of the shut-off valves in the water feed line results in malfunctions. Unauthorised persons must be prevented from entering or changing operating parameters. Use access codes. The default parameter values for the frequency converter may not be changed. They are factory-set to the powder feeder. When setting the concentration, the maximum viscosity of 1,500mPas may not be exceeded. If the polymer supply is not refilled, the system stops. If the cause of a fault on the system side is not remedied and if the Enter key is pressed, a faulty system behaviour may result. If the system is started without having remedied the original fault, additional and severe faults may result (see Chap. 11).
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Troubleshooting
11
WARNING
Troubleshooting
Risk of sudden start! The agitators with propeller may start suddenly as long as they are connected to the power supply also in case of an error message or in hold mode (Start/Stop key). NOTE Also read the operating instructions of the purchased parts to remedy malfunctions!
Combined alarm A system fault (combined alarm) will be indicated acoustically via an alert and visually via the red alarm LED at the control cabinet. In addition, the control indicates an error message. The alert can be deactivated by pressing the separate push-button HORN OFF at the front of the control cabinet. The release of the downstream delivery pump (polymer solution) is not affected by the combined alarm. Acknowledgement For the system to restart again after a fault, the error message must be acknowledged with the Ack key after having remedied the cause of the fault. Unspecified faults Should a problem occur which is not included in this list or can a listed fault not be remedied with the recommended troubleshooting, please immediately contact the ProMinent ProMaqua customer service. WARNING Risk of injury to arms and hands! Propellers are rotating in the chambers! First set the mains switch to Off and secure against restart, then remove the screwed cover of an inspection hole if a reservoir chamber must absolutely be accessed! WARNING Risk of sudden start! The agitators with propeller may start suddenly as long as they are connected to the power supply also in case of an error message or in hold mode (Start/Stop key). Sensors For each fault analysis it should first be considered that a capacitive proximity senor or a concentrate flow sensor erroneously signals a fault (because its sensitivity is set to high and suddenly responds to changed ambient conditions).
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Troubleshooting
Fault table Warnings * Error message First switch off Fault Powder / liquid toggle pressed Effect Hold state Metering stop, Feed active Delay 1s 5s LED red Alarm relay on on off off Action Switch off/on mains switch Increase feed liquid polymer
Minimum frequency! Concentrate pump undercontrolled
Water shortage Feed too high
Feed monitoring Feed monitoring
3s 3s
on off
off off
Increase water feed; Chap. 11.1.1 Decrease water feed; Chap. 11.1.2
* Remarks on warnings: Malfunctions Error message Metering monitor Wetting cone Fault fill level Fault converter Concentrate shortage Redilution Board n defective Powder shortage Fault Metering monitor Overflow wetting cone Level switch chamber 3 defective Fault frequency converter Concentrate tank empty Monitoring redilution Fault in control Powder fill level in powder feeder Fault concentrate pump Effect Hold state Hold state Hold state Hold state Hold state Hold state Hold state Hold state Delay 20s 3s 5s 5s 10s 3s 1s 3s LED red Alarm relay flashes flashes flashes flashes flashes flashes flashes flashes on on on on on on on on Action Refill liquid polymer Remedy cause, Chap. 11.1.2 Check level switch, Chap. 11.2.2 Check frequency converter Refill liquid polymer Remedy cause, Chap. 11.2.3 Call customer service, Chap. 11.2.4 Refill powdery polymer, Chap. 11.2.5 Check motor starter concentrate pump Remedy cause, Chap. 11.2.6 Check level switch LSHH, Chap. 11.2.7 Check water feed, Chap. 11.1.1 Remedy cause The alarm LED is lit continuously; no combined alarm is triggered. Warnings must not be acknowledged. As soon as the cause of the fault disappears, the operation is automatically restored.
Pump failure
Hold state
2s
flashes
on
Agitator failure Supply overfull Water shortage Water shortage
Agitator failure Overflow chamber 3 Water feed below min. value Supply voltage off
Hold state Hold state Hold state
1s 1s 20s
flashes flashes flashes off
on on on on
System switched off
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ProMinent
Troubleshooting
11.1
11.1.1
Warnings
Error Message Water shortage
The error message Water shortage is indicated if the feed volume undershoots the set lower limit value for more than 3s. The powder feeder is switched off. After a total of 20 s of insufficient feed volume, the control triggers a fault and closes the water feed valve. If the feed volume undershoots the lower limit value again within these 20 s, the control restarts the powder feeder again after expiry of the lead time. In the following, three causes and remedies are described: A. Malfunction in the water feed A fault in the water feed can be the cause. Possible causes and remedies: Cause The operating pressure is too low. Remedy If the strainer in the pressure reducer is dirty, clean the strainer. If the strainer is not dirty, completely open the shut-off valve in the water feed line. Check the water level in the wetting cone. If there is no improvement, reduce the restriction at the pressure reducer. Check the water level in the wetting cone.
B. Malfunction of the solenoid valve The solenoid valve malfunctions and does not open or close correctly. Possible causes and remedies: Cause The connection at the solenoid valve came loose. The throttle bore or the pilot drilling in the valve outlet is clogged. The diaphragm inside the solenoid valve is defective. C. Malfunction of the flow meter The blade in the flow meter no longer rotates freely. Possible causes and remedies: Cause Blade in the flow meter no longer rotates freely 11.1.2 Remedy Close the shut-off valve. Remove and clean the flow meter. Remedy Set the mains switch to Off. Check the cable connector and fix, if required. Set the mains switch to Off. Open the solenoid valve and thoroughly clean the interior of the body. Set the mains switch to Off. Replace the solenoid valve.
Error Message Feed too high
The error message Feed too high is indicated if the water flow is too high such that the powder feeder cannot meter sufficient powder to achieve the preset concentration. The control does not trigger any alarm but indicates the actual concentration. Possible causes and remedies: Cause Water flow is too high. Remedy Reduce the water flow.
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Troubleshooting
11.2
11.2.1
Malfunctions
Error Message Wetting cone
The error message Wetting cone is indicated if the alarm sensor for the overflow monitor in the wetting cone responds. At the same time, the control automatically stops the preparation process. It also stops the powder feeder and the solenoid valve closes delayed. Possible causes and remedies: Cause The wetting cone is clogged with powder. Excessive water throughput through the wetting fitting. 11.2.2 Remedy Remove and thoroughly clean wetting fitting (cone and spiral mixer). Readjust the water throughput, specifically reduce the partial flow through the wetting cone.
Error Message Fault fill level
The error message Fault fill level is indicated if the probes of the fill level sensor in chamber 3 report two different levels at the same time. WARNING Risk of injury to arms and hands! Propellers are rotating in the chambers! First set the mains switch to Off and secure against restart, then remove the screwed cover of an inspection hole if a reservoir chamber must absolutely be accessed! WARNING Risk of sudden start! The agitators with propeller may start suddenly as long as they are connected to the power supply also in case of an error message or in hold mode (Start/Stop key). Possible causes and remedies: Cause The fill level sensor reports contradictory messages. Remedy Switch off the system using the mains switch to permanently stop the agitators. Remove and clean the fill level sensor. Check the pertinent switching relays. Check the function of the fill level sensor.
11.2.3
Error Message Redilution
The error message Redilution is indicated if the water flow of the redilution unit drops below the preset limit value. The redilution unit is equipped with a float flow meter to indicate the flow of the water for redilution. A limit contact monitors the minimum water flow. Possible causes and remedies: Cause Water flow in the redilution unit too low. Remedy Remedy the cause of the low water flow in the redilution unit.
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Troubleshooting
11.2.4
Error Message Board n defective
The error Message Board n defective is indicated if the control determines an internal hardware error. Possible causes and remedies: Cause Internal hardware error. 11.2.5 Remedy Call the ProMinent-ProMaqua customer service.
Error Message Powder shortage
The error message Powder shortage is indicated if the level sensors in the storage tank signals powder shortage, the control stops the system. For information on possible malfunctions of the powder delivery unit, please see its separate operating instructions in Chapter 7 Measures to remedy malfunctions. Possible causes and remedies: Cause Remedy (see separate operating instructions of the powder delivery unit in Chapter 7 Measures to remedy malfunctions) 11.2.6 Error Message Agitator failure
The error message Agitator failure is indicated in case of a defect of an agitator and a combined alarm is triggered. The agitators are monitored by the motor circuit-breakers. Possible causes and remedies:
Cause
Defect in the motor of an agitator.
Remedy
Determine based on the motor circuit-breaker which agitator is affected. Check the corresponding motor for damages and replace, if necessary.
11.2.7
Error Message Supply overfull
The error message Supply overfull is indicated if the control during the preparation process does not receive a signal from the fill level sensor that the max. level is reached and the overflow sensor (option) instead detects the excessive level. The control now stops the preparation process. WARNING Risk of injury to arms and hands! Propellers are rotating in the chambers! First set the mains switch to Off and secure against restart, then remove the screwed cover of an inspection hole if a reservoir chamber must absolutely be accessed! WARNING Risk of sudden start! The agitators with propeller may start suddenly as long as they are connected to the power supply also in case of an error message or in hold mode (Start/Stop key). Possible causes and remedies: Cause The fill level sensor is dirty. Remedy Switch off the system using the mains switch to permanently stop the agitators. Remove and clean the fill level sensor. Check the function of the fill level sensor.
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Troubleshooting / Maintenance
11.3
Replacement of the Line Fuse of the control
The line fuses are located in a fuse holder in the control. WARNING Risk of electric shock! The mains switch must be set to Off and secured against restart before replacing the fuse! Open the blue housing of the control. Loosen the bayonet lock of the fuse holder and remove the defective fuse. Insert a new fuse in the fuse holder and lock the bayonet lock again. Close the housing
12
12.1

Maintenance
Inspection of Powder Feeder and Wetting Fitting
Powder feeder Inspect the powder feeder regularly for proper functioning during operation. Check whether the powdery polymer is correctly metered.
Wetting fitting Specifically check whether the conical wetting area of the wetting cone is completely wetted by water and that no powder deposits form.
12.2
Cleaning of the Strainer in the Pressure Reducer
The strainer must be cleaned at the latest if 2/3 of the throughput area of the strainer are dirty. To remove the strainer, press the start/stop key to set the system to hold. Manually close the shut-off valve upstream of the pressure reducer. For further steps, please see the manufacturers instructions in the annex.
12.3
WARNING
Inspection and Cleaning of the Solenoid Valve
Risk of electric shock! The mains switch must be set to Off and secured against restart before opening the solenoid valve! CAUTION Risk of malfunction of the system! Always take care of the cable when handling the solenoid valve. Make sure that the parts are correctly positioned and arranged when assembling.
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Maintenance
NOTE For detailed information and the relevant drawing, see the operating instructions of the solenoid valve in the annex of this documentation. Fully close the upstream shut-off valve. Loosen the four cylinder screws at the housing and remove the valve cap including the coil insert. Take care of the cable! Remove the insert. Check the diaphragm for damages. Clean the inside of the body, specifically the throttle bore and the small pilot drilling in the valve outlet.
12.4
CAUTION
Removal and Inspection of the Flow Meter (turboDOS)
Risk of malfunction of the system! Always take care of the cable when handling the flow meter. When reinstalling the flow meter, observe the flow arrow on the housing. Stop the system by pressing the Start/Stop key Close the shut-off valve in the water feed line. Loosen the relevant screws in the water piping to remove the flow meter. Check the blade inside the flow meter for free rotation and clean, if necessary. Install the flow meter in the water piping in the correct direction (flow arrow).
12.5
WARNING
Disassembly of the Cover of an Inspection Hole
Propellers are rotating in the chambers! First set the mains switch to Off and secure against restart, then remove the screwed cover of an inspection hole if a reservoir chamber must absolutely be accessed! The system may in principle only operated with tightly screw inspection holes. The covers may only be removed temporarily. to check the fill level to check the level sensors for correct switching function
After the inspection work, all covers must be reinstalled and fixed!
12.6
Cleaning of the Top of the Three-Chamber Reservoir
Clean the three-chamber reservoir from time to time because a slippery film may form in the course of time.
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Replacement Parts and Accessories
13
13.1
Replacement Parts and Accessories

Replacement parts
Control ULSa: Designation F2 K1-K12 2A3 Component Part Fuse, 0.63 A, T, 5x20 Relay, 250 V AC, 3A Ultromat EA assembly (assembly EA, ULSa signal separation) Order no.: 712030 711340 731049
13.2
Accessories
Powder Feed Tank (only types AF0 and ATF) The powder feed tank serves the intermediate storage of powdery polymers which were supplied in big bag containers. The big bag is suspended in a frame above the feed tank and emptied into the powder feed tank. Powder feed tank (280 l), order no. 1005573
Powder Feed Tank with Bag Dumper (only types AF0 and ATF) The powder feed tanks with bag cumper serves the intermediate storage of powdery polymers which are supplied in containers of 25 kg. Powder feed tank with bag dumper (280 l), order no. 1025137 Ultromat redilution unit VS The Ultromat redilution units are pre-assembled units for the redilution of polymer solutions, mainly consisting of: 1 2 3 Water fitting for the diluent water with manual shut-off valve, pressure reducer, solenoid valve (230 V, option: 24 V DC) and float flow meter including minimum contact Piping for the polymer solution to be diluted including non-return valve Static mixer for mixing the stock solution with the diluent water Working Solution 1,000 l/h 2,000 l/h 5,000 l/h 10,000 l/h 20,000 l/h 30,000 l/h 50,000 l/h Order no. 1005566 1005567 1005568 1005569 1005570 1005571 1005572
Type VS 1000 VS 2000 VS 5000 VS 10000 VS 20000 VS 30000 VS 50000
Ultromat redilution unit VS-IP with flow meter As Ultromat redilution unit but with additional inductive flow meter Type VS 1000 IP VS 2000 IP VS 5000 IP VS 10000 IP VS 20000 IP VS 30000 IP VS 50000 IP Working Solution 1,000 l/h 2,000 l/h 5,000 l/h 10,000 l/h 20,000 l/h 30,000 l/h 50,000 l/h Order no. 1005584 1005585 1005586 1005587 1005588 1005589 1005590
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Annex
13.3
EC Declaration of Conformity
ProMinent
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Annex
13.4
Control Menu Ultromat AF0
Page 52
ProMinent
Annex
13.5
Control Menu Ultromat AT0
ProMinent
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Annex
13.6
Control Menu Ultromat ATF
Page 54
ProMinent
Annex
13.7
Commissioning Report
Commissioning Report Ultromat AT0, AF0 or ATF

Ultromat type: AT0 AF0 ATF 400 400 400 1 000 1 000 1 000 2 000 2 000 2 000 4 000 4 000 4 000 8 000 8 000 8 000
Ident-Code: ULSA 0
Software version:
Project number:
/
example 02/4.1 T
Settings calibration: Parameter: Concentration: Calibrated metering output: Water feed: Switching threshold flow monitor: Powder Liquid % g/min l/h g/min
Settings for Commissioning Parameter Feed water min. flow Ultromat 400 Feed water min. flow Ultromat 1000 Feed water min. flow Ultromat 2000 Feed water min. flow Ultromat 4000 Feed water min. flow Ultromat 8000 Heating switch-on time Heating switch-off time Feed lead time Feed lag time Agitator 1 + 2 switch-on time Agitator 1 + 2 switch-off time Agitator 3 switch-on time Agitator 3 switch-off time Concentrate pump minimum frequency Access code Powdery polymer trade name: Liquid polymer trade name: Customer: Installation location:

Default setting 500 l/h 1,200 l/h 2,400 l/h 5,000 l/h 10,000 l/h 5s 35s 7s 5s 15 min 15 min 5 min 10 min 25 Hz 1000 Supplier: Supplier: Date:
Setting
ProMinent
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Die ProMinent Firmengruppe / The ProMinent Group

Stammhaus / Head office
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ProMinent Algeria (Algeria) Tel.: +213 21 54 84 74 prominent_algerie@yahoo.fr ProMinent Argentina S.A. (Argentina) Tel.: +54 11 4742 4009 ProMinent Fluid Controls Pty. Ltd. (Australia) Tel.: +61 2 9450 0995 sales@prominentfluid.com.au www.prominentfluid.com ProMinent Dosiertechnik Ges. mbH (Austria) Tel.: +43 7448 30400 office@prominent.at www.prominent.at ProMinent Fluid Ctrls. (BD) Ltd. (Bangladesh) Tel.: +8802 8319047 info@prominent-bd.com www.prominent-bd.com ProMinent Belgium S.A., N.V. (Belgium) Tel.: +32 2 3914280 info@prominent.be www.prominent.be ProMinent Brasil Ltda. (Brazil) Tel.: +55 11 43610722 prominent@prominent.com.br www.prominent.com.br ProMinent Fluid Controls BG (Bulgaria) Tel.: +359 2 9631921 office@prominent.bg ProMinent Fluid Controls Ltd. (Canada) Tel.: +1 519 8365692 info@prominent.ca www.prominent.ca ProMinent Bermat S.A. (Chile) Tel.: +56 2 3354799 slagos@prominentbermat.cl www.prominentbermat.cl ProMinent Fluid Controls China Co. Ltd. (P.R. of China) Tel.: +86 411 87315738 dr.r.hou@prominent.com.cn www.@prominent.com.cn ProMinent Dosiertechnik CS s.r.o. (Czech Republ.) Tel.: +420 585 757011 info@prominent.cz www.prominent.cz ProMinent Systems spol. s.r.o. (Czech. Republ.) Tel.: +420 378 227 100 heidukova@prominentsystems.cz ProMinent Finland OY (Finland) Tel.: +35 89 4777890 prominent@prominent.fi www.prominent.fi Flow Center Oy (Finland) Tel.: +358 9 2513 7700 sales@flowcenter.fi www.flowcenter.fi ProMinent France S.A. (France) Tel.: +33 3 88101510 contact@prominent.fr www.prominent.fr Syclope Electronique (France) Tel.: +33 05 59 33 70 36 sycope@syclope.fr www.syclope.fr ProMinent ProMaqua GmbH (Germany) Tel.: +49 6221 6489-0 info@promaqua.com www.promaqua.com ProMinent Fluid Controls (UK) Ltd. (Great Britain) Tel.: +44 1530 560555 sales@prominent.co.uk www.prominent.co.uk ProMinent Hellas Ltd. (Greece) Tel.: +30 210 5134621 info@prominent.gr ProMinent Magyarorszg Kft. (Hungary) Tel.: +36 96 511400 prominent@prominent.hu www.prominent.hu Heidelberg ProMinent Fluid Controls (India) Tel.: +91 80 23578872 prominent@hpfcindia.com www.prominentindia.com ProMinent Fluid Controls Ltd. (Ireland) Tel.: +353 71 9151222 info@prominent.ie ProMinent Italiana S.R.L. (Italy) Tel.: +39 0471 920000 info@prominent.it www.prominent.it ProAcqua (Italy) Tel.: +39 0464 425222 info@proacqua.it Idrosid s.r.l. (Italy) Tel.: +39 0461 534623 info@idrosid.it www.idrosid.it ITECO s.r.l. (Italy) Tel.: +39 0461 242220 iteco@itecoitalia.com www.itecoitalia.com ProMinent Co. Ltd. Japan (Japan) Tel.: +81 3 5812-7831 hosotani@prominent.co.jp www.prominent.co.jp ProMinent Korea Co. Ltd. (Republic of Korea) Tel.: +82 31 7018353 info@prominent.co.kr www.prominent.co.kr ProMinent Office Kazakhstan (Kazakhstan) Tel.: +7 3272 504130 prominent@ducatmail.kz ProMinent Office Kaunas (Lithuania) Tel.: +370 37 325115 prominent1@takas.lt ProMinent Fluid Controls (M) Sdn. Bhd. 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(South Africa) Tel.: +27 11 866039341 jock.bartolo@prominentfluid.co.za ProMinent Gugal S.A. (Spain) Tel.: +34 972 287011/12 prominent@prominentspain.com www.@prominent.es ProMinent Doserteknik AB (Sweden) Tel.: +46 31 656600 info@prominent.se www.prominent.se Tomal AB (Sweden) Tel.: +46 0 346-713100 info@tomal.se www.tomal.se ProMinent Dosiertechnik AG (Switzerland) Tel.: +41 44 8706111 info@prominent.ch www.prominent.ch Voney AG (Switzerland) Tel.: +41 031 992 21 67 www.voney-ag.ch ProMinent Fluid Controls (Taiwan) Ltd. (Taiwan) Tel.: +886 7 8135122 richard@prominent.com.tw www.prominent.com.tw ProMinent Fluid Controls (Thailand) Co. Ltd. (Thailand) Tel.: +66 2 3760008 pfc@prominent.co.th www.prominent.co.th ProMinent Tunesia (Tunisia) Tel.: +216 79 391 999 prominent_tunisie@yahoo.fr ProMinent Office Kiev (Ukraine) Tel.: +380 44 5296933 prominent@i.com.ua ProMinent Juffali FZC (United Arabian Emirates) Tel.: +97 1655 72626 a.sadaqa@prominentfzc.ae www.prominentfzc.ae ProMinent Fluid Controls, Inc. (USA) Tel.: +1 412 7872484 sales@prominent.us www.prominent.us Aquatrac Instruments, Inc. (USA) Tel.: +1 800 909 9283
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12/08

Manual Preparadora de Polímeros Prominent

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Operating Instructions Continuous Flow System Ultromat AF0, AT0 and ATF

Part No. 986446

ProMinent Dosiertechnik GmbH 69123 Heidelberg Germany

Technical changes reserved.

System Sizes ............................................................................................................. 16

Ultromat Options ...................................................................................................... 24

5.4.7 5.4.8 5.4.9 5.5 5.5.1 5.5.2 5.5.3

Ultromat Accessories ............................................................................................... 25

Service Menu ............................................................................................................. 36 8.6.1 8.6.2 8.6.3

Commissioning of the System ................................................................................... 40

Identcode ULTa AF0

Standard equipment: - lifting lugs - Pause/system status message

Identcode ULTa AT0

Identcode ULTa ATF

General Notes for the User

General Notes for the User

About this Product / Safety Chapter

About this Product

Warning of hazardous electrical voltage

Warning of injury to hands

Warning of unexpected start

Warning of slipping risk

Warning of hot surfaces

Information for Emergency Cases

Description and Test of the Safety Devices

Fig. 1: Safety devices

Warning of injury to hands

Warning of hot surfaces

The operating instructions must be kept at the system!

Sound Pressure Level

Transport and Storage of the System / About this System

Transport and Storage of the System

Humidity:none. Do not allow any rain and condensation!

About this System

About this System

Ultromat AF0 (for the preparation of liquid polymers)

About this System

400 400 133 400

1000 1,000 333 1,000

2000 2,000 666 2,000

4000 4,000 1.333 4,000

8000 8,000 2.666 8,000

* The electrical power input is for systems with 3 agitators.

About this System

* The electrical power input is for systems with 3 agitators.

About this System

* The electrical power input is for systems with 3 agitators.

L Fig. 2: Ultromat dimensions

Design and Function

Design and Function

1 Fig. 3: Ultromat ATF

Description of the Component Parts

Design and Function

Fig. 4: Water fitting with Y wetting

Fig. 5: Water fitting with wetting cone

Design and Function

H26 H27 H28 H29 H30 H31 H32 X15 X16

X20 X20 X21 X21 X21 9 12 13 16 1 4 5 8 9 12

Design and Function

Design and Function

Design and Function

Design and Function / Assembly and Installation