manual preparadora de polímeros Prominent

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

Operating InstructionsContinuous Flow SystemUltromat® AF0, AT0 and ATF

ProM

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Corporate information:Continuous Flow System Ultromat® AF0, AT0 and ATF© ProMinent Dosiertechnik GmbH, 2008

ProMinent Dosiertechnik GmbHIm Schuhmachergewann 5-1169123 HeidelbergGermanyTelephone: +49 6221 842-0Fax: +49 6221 [email protected]

Technical changes reserved.

Corporate information

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ProMinent®

Identcode .................................................................................................................................... 6

General Notes for the User ......................................................................................................... 9

1 About this Product ............................................................................................................ 10

2 Safety Chapter ................................................................................................................... 10

2.1 Identification of the notes on safety ........................................................................... 10

2.2 Proper Use ................................................................................................................. 11

2.3 Information for Emergency Cases ............................................................................. 12

2.4 Description and Test of the Safety Devices ............................................................... 12

2.5 Notes on Safety ......................................................................................................... 13

2.6 Sound Pressure Level ................................................................................................ 13

3 Transport and Storage of the System ............................................................................. 14

4 About this System ............................................................................................................. 14

4.1 Application ................................................................................................................. 14

4.2 Design ........................................................................................................................ 14

4.2.1 Ultromat® AF0 (for the preparation of liquid polymers) ................................. 15

4.2.2 Ultromat® AT0 (for the preparation of powdery polymers) ............................ 15

4.2.3 Ultromat® ATF (for the preparation of powdery and liquid polymers) ............ 15

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

5 Design and Function ......................................................................................................... 19

5.1 Layout of the System ................................................................................................. 19

5.2 Description of the Component Parts ......................................................................... 19

5.2.1 Three-Chamber Reservoir ............................................................................. 19

5.2.2 Water Fitting with Wetting Fitting .................................................................. 19

5.2.3 Powder feeder ............................................................................................... 21

5.2.4 Agitators ........................................................................................................ 21

5.2.5 Control Cabinet ............................................................................................. 21

5.2.6 Socket-Outlet for the Connection of a Small-Type Feeder (not AF0) ............ 21

5.2.7 Ultromat® EA Assembly ................................................................................. 21

5.2.8 Remote Control ............................................................................................. 23

5.2.9 Concentrate Piping (not type AT0) ................................................................ 23

5.2.10 Crane Lifting Lugs ......................................................................................... 23

5.3 Operating Modes ....................................................................................................... 23

5.3.1 Preparation Mode .......................................................................................... 23

5.3.2 Setting Mode ................................................................................................. 23

5.3.3 Remote Control Mode ................................................................................... 23

5.4 Ultromat® Options ...................................................................................................... 24

5.4.1 Agitator for the Chamber 3 (Agitator 3) ......................................................... 24

5.4.2 Overflow Valve for Chamber 3 ....................................................................... 24

5.4.3 Evaluation Water Shortage for the Redilution Unit ........................................ 24

5.4.4 Concentrate Pump (only types AF0 and ATF) ............................................... 24

5.4.5 Empty Signal for Concentrate Tank (only types AF0 and ATF) ...................... 24

5.4.6 Metering Monitor for Liquid Concentrate (only types AF0 and ATF) ............. 24

Contents

Contents

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Contents

5.4.7 Add-On Hopper 50l, 75l, and 100l (only types AF0 and ATF) ....................... 24

5.4.8 Vibrator (only types AF0 and ATF) ................................................................. 25

5.4.9 Powder Feeder for Automatic Refilling (only types AF0 and ATF) ................. 25

5.5 Ultromat® Accessories ............................................................................................... 25

5.5.1 Powder Feed Tank (only types AF0 and ATF) ................................................ 25

5.5.2 Powder Feed Tank with Bag Dumper (only types AF0 and ATF) ................... 25

5.5.3 Redilution Station .......................................................................................... 25

6 Assembly and Installation ................................................................................................ 25

6.1 Assembly ................................................................................................................... 25

6.2 Installation, Hydraulical .............................................................................................. 26

6.3 Installation, Electrical ................................................................................................. 26

6.3.1 Connection of the Mains Line ....................................................................... 26

6.3.2 Opening of the Control .................................................................................. 26

7 Control ............................................................................................................................... 27

7.1 Design and Function .................................................................................................. 27

7.1.1 Display Elements and Controls ..................................................................... 27

7.1.2 Display Elements (Status Indication) ............................................................. 27

7.1.3 Controls ......................................................................................................... 28

7.1.4 Operation of the System and Operating Status Indications .......................... 28

7.2 Menu System ............................................................................................................. 29

7.2.1 Layout of the Menu ....................................................................................... 29

7.3 Operation of the Control – Selection of a Menu Option ............................................ 30

7.4 Display Mode ............................................................................................................. 30

7.4.1 Standard Operation ....................................................................................... 30

7.4.2 Interruption of Standard Operation ............................................................... 30

7.4.3 Display of the Identcode of the Control ........................................................ 31

8 Commissioning ................................................................................................................. 31

8.1 Assembly, Preparatory Work ...................................................................................... 31

8.2 Checking the Identcode of the Control ...................................................................... 31

8.3 Settings for Commissioning ....................................................................................... 31

8.3.1 Setting of the Minimum Flow(only with wetting fitting for AT0 and AFT) ..................................................... 32

8.3.2 Setting of the Heating of the Metering Pipe (only types AF0 and ATF) ......... 32

8.3.3 Setting of the Lead and Lag Times (only types AF0 and ATF) ...................... 32

8.3.4 Agitators 1 and 2 ........................................................................................... 33

8.3.5 Agitator 3 (option) .......................................................................................... 33

8.3.6 Access Code ................................................................................................. 33

8.4 Setting of Concentration ............................................................................................ 33

8.5 Settings of Calibration ............................................................................................... 34

8.5.1 Setting water feed ......................................................................................... 34

8.5.2 Calibration of the Powder Feeder (only types AF0 and ATF) ......................... 34

8.5.3 Calibration of the Concentrate Pump (only types AF0 and ATF) ................... 35

8.5.4 Setting of the Metering Monitor for Liquid Concentrate(only types AF0 and ATF with Spectra) ......................................................... 35

8.5.5 Setting of Capacitive Sensors (types AF0 and ATF) ...................................... 36

8.6 Service Menu ............................................................................................................. 36

8.6.1 Setting of Flow .............................................................................................. 36

8.6.2 Testing Agitators and Powder Feeder ........................................................... 37

8.6.3 Running empty the Ultromat® ...................................................................... 37

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Contents

8.7 Setting of the Frequency Converter Altivar 11 ........................................................... 37

8.7.1 Function of the Controls ................................................................................ 37

8.7.2 Menu Overview .............................................................................................. 38

8.7.3 Setting of the Parameters .............................................................................. 38

8.7.4 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 Prerequisites for a Proper Operation ............................................................. 40

9.1.2 Feeding of the Storage Tank with Powdery Polymer (not type AF0) ............. 41

9.1.3 Refilling of the Concentrate Tank with Liquid Polymer (not type AT0) ........... 41

9.2 Switching on Mains and Behaviour during Mains Power Failure ............................... 41

9.3 Decommissioning ...................................................................................................... 41

9.4 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 ULTa AF0

Identcode

ULTa Ul t romat ® con t inuous f low sys temsType

AF0 continuous flow system for liquid polymer

Reservoir size / issue quantity0400 400 litres capacity / 400 l/h,1000 1,000 litres capacity / 1,000 l/h2000 2,000 litres capacity / 2,000 l/h4000 4,000 litres capacity / 4,000 l/h8000 8,000 litres capacity / 8,000 l/h

Design0 standard1 mirror-imaged

Wetting fitting0 with Y wetting

Electrical connection:A 400 Vac, 50/60 Hz (3ph, N, PE)

Control0 ProMinent control

Options0 without options1 with overflow valve for Ultromat reservoir2 with evaluation water shortage redilution3 with 1 + 2

Powder feeder, add-on hopper0 none

Vibrator for powder feeder0 none

Agitator for 3rd chamber0 none1 agitator for reservoir 400, 0.18 kW, 50/60 Hz, 750/900 rpm2 agitator for reservoir 1000, 0.55 kW, 50/60 Hz, 750/900 rpm3 agitator for reservoir 2000, 0.75 kW, 50/60 Hz, 750/900 rpm4 agitator for reservoir 4000, 1.1 kW, 50/60 Hz, 750/900 rpm5 agitator for reservoir 8000, 2.2 kW, 50/60 Hz, 750/900 rpm

Liquid concentrate pump (installed at Ultromat)1 with Sigma conc. pump2 with Spectra conc. pump

Monitor for liquid concentrate pump0 none1 with float switch for concentrate tank2 with flow monitor (only Spectra)3 with float switch and flow monitor

(only Spectra)

LanguageDE GermanEN EnglishFR FrenchCZ CzechIT ItalianNL DutchPL PolishES Spanish

ULTa AF0 0400 0 0 A 0 0 0 0 0 0 0 DE

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

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Identcode

Identcode ULTa AT0

ULTa Ul t ro m a t ® con t inuous f low sys temsType

AT0 continuous flow system for powdery polymer



Wetting fitting0 with Y wetting1 with wetting cone, PVC piping, for 400 - 20002 with wetting cone, PVC piping, for 4000 - 80003 with wetting cone, PP piping, for 400 - 20004 with wetting cone, PP piping, for 4000 - 8000


Control0 ProMinent® control

Options0 without options1 with overflow valve for Ultromat® reservoir2 with evaluation water shortage redilution3 with 1 + 2

Powder feeder, add-on hopper0 none1 with add-on hopper 50 l2 with add-on hopper 75 l3 with add-on hopper 100 l4 with add-on hopper 50 l + powder feeder5 with add-on hopper 75 l + powder feeder6 with add-on hopper 100 l + powder feeder7 with adapter lid + powder feeder

Vibrator for powder feeder0 none1 with vibrator for powder feeder


Liquid concentrate pump (installed at Ultromat)0 none

Monitor for liquid concentrate pump0 none


ULTa AT0 0400 0 0 A 0 0 0 0 0 0 0 DE

Standard equipment:- lifting lugs- socket-outlet for small-type feeder- Pause/system status message

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Identcode ULTa ATF

Identcode

ULTa U l t romat con t inuous f low sys temsType

ATF continuous flow system for liquid and powdery polymer



Wetting fitting0 with Y wetting1 with wetting cone, PVC piping, for 400 - 20002 with wetting cone, PVC piping, for 4000 - 80003 with wetting cone, PP piping, for 400 - 20004 with wetting cone, PP piping, for 4000 - 8000


Control0 ProMinent control

Options0 without options1 with overflow valve for Ultromat® reservoir2 with evaluation water shortage redilution3 with 1 + 2

Powder feeder, add-on hopper0 none1 with add-on hopper 50 l2 with add-on hopper 75 l3 with add-on hopper 100 l4 with add-on hopper 50 l + powder feeder5 with add-on hopper 75 l + powder feeder6 with add-on hopper 100 l + powder feeder7 with adapter lid + powder feeder

Vibrator for powder feeder0 none1 with vibrator for powder feeder


Liquid concentrate pump (installed at Ultromat)0 none1 with Sigma conc. pump2 with Spectra conc. pump

Monitor for liquid concentrate pump1 with float switch for concentrate tank2 with flow monitor (only Spectra)3 with float switch and flow monitor

(only Spectra)


ULTa ATF 0400 0 0 A 0 0 0 0 0 0 0 DE

Standard equipment:- lifting lugs- socket-outlet for small-type feeder- Pause/system status message

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General Notes for the UserPlease read through the following user guidelines! Familiarity with these points ensures optimumuse 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 facilitateyour work.

Notes on safety identified by pictographs (see Chapter 2).

Notes to the system operator

Contain notes and quotations from German guidelines for the operator’s area of responsibility.They, however, do not release him from his responsibility as operator, they are only meant toremind the operator of certain problems and are meant to make the operator aware of theseproblems. They neither claim completeness nor validity for all countries nor any type ofapplication 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, pressthe Change key. Please state the Identcode as well as the version number in case of complaintsor when removing already installed Ultromat® systems.

General Notes for the User

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1 About this Product

The Ultromat® AF0, AT0, ATF system by ProMinent is an automatic preparation station forpolyelectrolyte.

It can be used in all applications where synthetic polymers are to be automatically prepared intopolymer solutions as flocculants. As such a dissolving station, the system is suitable fornumerous process-technical applications such as e.g. in water treatment, waste watertreatment, and paper production.

• The Ultromat® AF0 is meant to dissolve liquid polymers.

• The Ultromat® AT0 can be used in all applications where pourable, synthetic powderypolymers are to be prepared.

• With the Ultromat® ATF, powdery polymers and liquid polymers can be prepared.

2 Safety Chapter

2.1 Identification of the notes on safety

The following terms are used in the present operating instructions to indicate the variousseverity levels of the danger:

WARNING

Characterizes a possibly hazardous situation. Your life is in danger and there is a dangerof serious injury if these notes are disregarded!

CAUTION

Characterizes a possibly hazardous situation. There is a danger of slight or minor injury ordamage to property if these notes are disregarded!

The following warning signs are used in the present operating instructions to indicate differenttypes 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

About this Product / Safety Chapter

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2.2 Proper Use

• The Ultromat® is exclusively designed to generate a polymer solution as flocculant frompowdery polymer or liquid polymer with drinking water.

• All other uses or modifications require the prior written consent of ProMinent® DosiertechnikGmbH, Heidelberg.

• The system may not be operated beyond the scope of the conditions described in thisdocumentation!

• The system is not designed for use in explosive areas!

• If non-genuine parts or third-party accessories are used, the proper functioning of thesystem 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 lifephases of the system!

• Please observe the relevant local regulations in all life phases of the system!

Activity Training

Mounting / installation trained qualified employees

Commissioning technical experts

Operation instructed persons

Maintenance / repair customer service

Decommissioning / disposal technical experts

Troubleshooting instructed persons

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 recognisepossible dangers based on his/her technical training, and experience as well as the knowledge ofpertinent regulations.

Note:

A technical qualification is typically proven by the required completion of a training, e.g. asengineer, master or journeyman. The assessment of the technical training can also be based onan 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 torecognise possible dangers based on his/her technical training, knowledge and experience aswell as the knowledge of pertinent regulations.

Note:

A technical training of equal qualification can also have been acquired by an activity of severalyears in the relevant field of work.

An instructed person is a person having been informed about the tasks assigned to him/herand the possible hazards in case of improper behaviour and having been trained, if required, aswell as having been informed about the required protective equipment and protective measures.

The customer service means service technicians which have been provable trained andauthorised by ProMinent® for work at the system.

Notes to the system operator

The pertinent accident prevention regulations as well as all other generally acknowledgedsafety-technical regulations must be observed!

Safety Chapter

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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-yellowmains switch on the right in the control cabinet. The system and the connected units are thende-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”

Emergency switch The red-yellow mains switch on the right in the control cabinet de-energises the system and theconnected units.

Test: Set the mains switch to “Off” while all parts of the system are running – all parts muststop – all lights extinguish.

Cover of the inspection holes The screwed on covers of the inspection holes prevent that persons might injure their hands atthe 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.

Fig. 1: Safety devices

343 3 2

1

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Safety Chapter

2.5 Notes on Safety

WARNING

• 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 anyinstallation 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 thescrewed cover of an inspection hole if a reservoir chamber must absolutely beaccessed!

• Risk of injury to hands!Below the safety guard of the powder feeder, a screw conveyor and a bulker wheel arelocated!First set the mains switch to “Off” and secure against restart, if work has to be carriedout below the safety guard!

WARNING

Risk of sudden start!The agitators with propeller may start suddenly as long as they are connected to thepower 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 polymeraccording 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 Transport and Storage of the System

WARNING

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 thethree-chamber reservoir.

• If a crane is used mount the transport belts such that shear stress is absolutelyprevented even if lifting lugs exist.

• If equipped with lifting lugs, Ultromat® systems of the type 4000 or 8000 may only belifted with a traverse. The length of the traverse must be 10 – 20cm longer at theminimum than the three-chamber reservoir.

• The support must be able to carry the weight of the system.

Environmental conditionsfor storage and transport: Permissible ambient temperature: -5 °C - +50 °C

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

Others:No dust, no direct sunlight

4 About this System

4.1 Application

The Ultromat® AF0, AT0, ATF system by ProMinent is an automatic preparation station forpolyelectrolyte.

It can be used in all applications where synthetic polymers are to be automatically prepared intopolymer solutions as flocculants. As such a dissolving station, the system is suitable fornumerous process-technical applications such as e.g. in water treatment, waste watertreatment, and paper production.

• The Ultromat® AF0 is meant to dissolve liquid polymers.

• The Ultromat® AT0 can be used in all applications where pourable, synthetic powderypolymers 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 polymersolution may, however, not exceed 1,500mPas. For information on the viscosity of variouspolymer 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 isto be adapted correspondingly, if required. Concentrations above 0.5% can result in a reductionof the capacity of the preparation performance.

The maturing time available for the preparation of a polymer solution depends on the issuequantity and the capacity of the Ultromat® and is approx. 60 minutes for maximum nominalissue rate. The system capacities range between max. 400 l working solution per hour forAT0 400 to 8,000 l for AT0 8000.

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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 liquidconcentrate.

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 anoption, 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 isswitched to liquid operation (using the key switch in the control cabinet door), the powderfeeder is deactivated and the concentrate pump is activated.

About this System

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About this System

4.3 System Sizes

NOTE

For the exact dimensions of the individual Ultromat® system, please see the dimensionsheet!

Ultromat® AF0

Ultromat® ULTa AF0.. 400 1000 2000 4000 8000

Reservoir capacity (litres) 400 1,000 2,000 4,000 8,000

Chamber volume (l) 133 333 666 1.333 2.666

Issue quantity (l/h) 400 1,000 2,000 4,000 8,000

Ultromat® ULTa AF0..

Maturing time (min) 60 60 60 60 60

Solution concentration (%) 0.05 - 0.5 0.05 - 0.5 0.05 - 0.5 0.05 - 0,5 0.05 - 0.5

Dimensions HxWxD (mm) 1987x905x1250 2631x970x1600 3305x1155x1750 3293x1515x1924 4589x1922x1926

Net weight (kg) 150 360 410 560 1,160

Total weight (kg) 550 1,360 2,410 4,560 9,160

Overflow connection DN 40 DN 50 DN 50 DN 65 DN 80

Issue connection DN 25 DN 25 DN 32 DN 40 DN 50

Water feed for redilution 1� 1� 1� 1 1/2� 2�

Liquid concentrate piping DN 15 DN 15 DN 15 DN 20 DN 20

Max. water feed 1,500 l/h 1,500 l/h 3,000 l/h 6,000 l/h 12,000 l/h

Electrical power input * 1.5 kW 2.6 kW 3.2 kW 5.0 kW 9.5 kW

External protection 25 A 25 A 25 A 25 A 40 A

Agitator 1

Output 0.25 kW 0.55 kW 0.75 kW 1.1 kW 2.2 kW

Speed ((50Hz) 750 rpm 750 rpm 750 rpm 750 rpm 750 rpm

System of protection IP 55 IP 55 IP 55 IP 55 IP 55

Agitators 2 + 3 (option)




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

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About this System

Ultromat® AT0

Ultromat® ULTa AT0.. 400 1000 2000 4000 8000


Chamber volume (l) 133 333 666 1,333 2,666



Solution concentration (%) 0.05 - 0.5 0.05 - 0.5 0.05 - 0.5 0.05 - 0.5 0.05 - 0.5


Net weight (kg) 190 400 450 600 1,200

Total weight (kg) 590 1,400 2,450 4,600 9,200





Electrical power input* 1.5 kW 2.6 kW 3.2 kW 5.0 kW 9.5 kW


Agitator 1








Powder feeder

Type TGD 18.13 TGD 18.13 TGD 18.13 TGD 30.13 TGD 38.13

Maximum metering output 18 kg/h / 29 l/h 18 kg/h / 29 l/h 18 kg/h / 29 l/h 55 kg/h / 92 l/h 110 kg/h / 184 l/h


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Fig. 2: Ultromat® dimensions

L B

H

About this System

Ultromat® ATF

Ultromat® ULTa ATF.. 400 1000 2000 4000 8000


Chamber volume (l) 133 333 666 1,333 2,666



Solution concentration (%) 0.05 - 0.5 0.05 - 0.5 0.05 - 0.5 0.05 - 0.5 0.05 - 0.5


Net weight,without metering pump (kg) 190 400 450 600 1200

Total weight (kg) 590 1,400 2,450 4,600 9,200




Liquid concentrate piping(ATF) DN 15 DN 15 DN 15 DN 20 DN 20


Electrical power input* 1.5 kW 2.6 kW 3.2 kW 5.0 kW 9.5 kW


Agitator 1








Powder feeder

Type TGD 18.13 TGD 18.13 TGD 18.13 TGD 30.13 TGD 38.13

Maximum metering output 18 kg/h / 29 l/h 18 kg/h / 29 l/h 18 kg/h / 29 l/h 55 kg/h / 92 l/h 110 kg/h / 184 l/h


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ProMinent®

Design and Function

5 Design and Function

5.1 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 closedthree-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 PVCor PP, supplemented by brass fittings.

The gaskets are made of EPDM as standard. The agitator shafts and the blades of the agitatorsas well as the delivery unit of the powder feeder are completely made of corrosion-resistantstainless steel.

5.2 Description of the Component Parts

5.2.1 Three-Chamber Reservoir

The closed-type PP reservoir with agitator traverse, consoles for powder feeder and controlcabinet as well as overflow, discharge and issue connections is divided into three separatechamber such that a sufficient maturing time of the polymer solution is guaranteed. The divisionof the reservoir also largely prevents a mixing of the matured and the freshly prepared solutionsand facilitates a continuous issue.

The fill level of the chamber 3 is monitored by a fill level sensor. The system is equipped with amin. and max. contact to start or stop the automatic preparation process as well as with anadditional empty contact as protection against dry running and a further sensor as overflowprotection. All inspection openings of the reservoir are secured by screwable covers which canbe firmly tightened.

5.2.2 Water Fitting with Wetting Fitting

The water piping supplies the system with the required preparation water. The pressure reducerwith strainer ensures that the operating pressure is limited and that the correct operatingpressure is maintained. The solenoid valve automatically opens and closes the water inlet. Theused flow meter constantly reports the current flow rate to the control. The two control valvesare used to define the flow rate during commissioning. The wetting fitting guarantees an inten-sive wetting of the powdery polymer with preparation water. A manual shut-off valve facilitatesin 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 flowof the preparation water. The metering medium then does not clot.

Fig. 3: Ultromat® ATF

1

2

3

3

7

4 5 6

1 Water fitting2 Concentrate pump

(only AF0 and ATF)3 Agitators4 Wetting fitting

(only AT0 and ATF)5 Powder feeder

(only AT0 and ATF)6 Control cabinet7 Three-Chamber

Reservoir

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ProMinent®

Fig. 5: Water fitting with wetting cone

7

5

23

41

6

With the help of a mixing unit, the main flow of the preparation water generates a slight vacuumat the outlet of the cone. The wetted powder is thus suctioned off and then goes to chamber 1together with the preparation water.

To ensure that neither at the start of the preparation process, no powder deposits in the wettingfitting, switching on of the powder feeder is controlled time-delayed with regard to the solenoidvalve, i.e. water always flows for several seconds before the powder feeder starts. At the end ofthe preparation process, this is repeated vice versa. If the upper level is reached, the powderfeeder is deactivated immediately, but water still continues to flow for several seconds.

Design and Function

Fig. 4: Water fitting with Y wetting

1 Shut-off device2 Pressure reducer3 Solenoid valve4 Flow meter5 Control valves6 Y pipe

5

2 34

1

6

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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 separateoperating instructions “Dry feeders”. The heating of the metering pipe as well as the min. filllevel sensor for the dry material hopper are standard for Ultromat® preparation systems. For avolume-proportional metering of the powdery polymer into the preparation water, the powderfeeder is controlled via a frequency converter.

For the continuous discharge of the powdery polymer a bulking wheel is installed which islocated directly above the feeder screw. In addition, a metering pipe heating removespenetrated 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 thechamber 3 is available as an option. The agitators ensure a gentle agitation of the solution in thereservoir 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 andcommand units required to operate the system, in particular the Ultromat® control and thefrequency converter to control the powder feeder. The control cabinet of the Ultromat® ATF is inaddition 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 acircuit breaker.

5.2.7 Ultromat® EA Assembly

K1

N L X10

1 4 X11 X12

X13

X219 12

X215 8

X211 4

X2013 16

X209 12

X205 8

X201 4

X14

1 12

X18

16

1

H 5

H12H13

H9 H10 H11

H26 H27 H28 H29 H30 H31 H32

H1 H3

H6 H7 H8

H19

H2 H4

F1

F2 P1 P2

P3 P4

2A3LSALL H15LSLLSH

LSAHH

LSALLLSLLSH

LSAHH H14

H16H17H18

K2 K3K4 K5 K6

1 12

X19

16

1

X17

16

1X15

1 12X16

1 12

K7 K8 K9 K10 K11 K12

H 20 H 21 H 22 H 23 H 24 H 25

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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ProMinent®

Design and Function

Output relay:

The switching states of each relay are indicated by a LED. The LED is illuminated if the relay haspicked up.

Relay LED Function

K1 H6 Alarm

K2 H7 Horn acknowledged

K3 H8 not assigned

K4 H9 Agitators 1 and 2

K5 H10 Agitator 3

K6 H11 Switching powder/liquid

K7 H20 Heating

K8 H21 not assigned

K9 H22 Solenoid valve water

K10 H23 Issue (dry running)

K11 H24 operation

K12 H25 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 theconductivity 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 thelevels 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 Level undershot Level exceeded

H 5 (LSAHH, overflow) LED on LED off

H 12 (LSH, maximum) LED off LED on

H 13 (LSL, minimum) LED off LED on

H 15 (LSALL, dry running) LED off LED on

LED to indicate the signal states:

The LEDs indicate the internal signal states of the Ultromat EA assembly. The meaning is listedin the following table:

LED Identification LED on:

H1 FLK ok Concentrate pump ok

H2 RW ok Agitator ok

H 5 Level < LSAHH no overflow

H 12 Level > LSH Level exceeded

H 13 Level > LSL Level exceeded

H 15 Level > LSALL Level exceeded

H 19 Frequency converter Frequency converter ok

H 26 Powder > min. Powder stock exists

H 28 Flow ok Flow liquid polymer ok

H 29 Redilution on Redilution activated

H 30 Redilution ok Water flow redilution unit ok

H 31 FLK > min Liquid polymer stock exists

H 32 Remote control on External switch closed

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ProMinent®

5.2.8 Remote Control

This function facilitates the remote-controlled activation and deactivation of the system, ifneeded. 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:

• The system is stopped locally or remotely (pause from control desk).

• A fault exists.

5.2.9 Concentrate Piping (not type AT0)

For the metering of the liquid concentrate into chamber 1, the Ultromat® AF0 and ATF areequipped with the following piping:

Type Ultromat® Piping size Hose grommet

400 DN 15 DN 15

1000 DN 15 DN 15

2000 DN 15 DN 15

4000 DN 20 DN 20

8000 DN 20 DN 20

5.2.10 Crane Lifting Lugs

A suitable hoisting device can be mounted at the four lugs for an easier handling of the system.

5.3 Operating Modes

5.3.1 Preparation Mode

When the min. level in chamber 3 is reached, the Ultromat® starts the preparation process. Thesolenoid valve opens and the powder feeder starts to meter the powdery polymer upon expiry ofthe delay time. When the maximum level is reached, the control first stops the powder feederand 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 suppressesin this operating mode the execution of individual functions which may interfere with thesettings. When calibrating the powder feeder, the solenoid valve for the water inlet remainsclosed and the powder feeder is released and controlled independent of the water inlet. Whensetting 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 operatingand 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 operatingparameters are still set and indicated at site.

Design and Function

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ProMinent®

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 thechamber 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 acombined 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 deliverypump transports the polymer solution from the storage tank of the Ultromat® to the redilutionunit.

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 themin. contact indicates a water shortage, the Ultromat® goes to fault and the release for thedelivery 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 hasbeen exceeded, and opens when the dry running level has been undershot. The delivery pumpis typically controlled via an external circuit (motor starter combination).

Because the delivery pump can be switch on and off externally, an additional input for theevaluation 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 andthus 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. contactat 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 andeccentric 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 thedelivery 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 pumpmeters the concentrate into chamber 1.

The metering monitor can only be used if eccentric screw pumps are used. The meteringmonitor consists of a flow adapter and a thermal flow sensor. The setting menu “Settingmetering 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, and100l, 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 thatthe 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 unitis available. The powder delivery unit can be installed directly onto the powder feeder using anadapter plate.

To bridge short maintenance work at the powder delivery unit or in case of high powderconsumption, 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 weresupplied in big bag containers. The big bag is suspended in a frame above the feed tank andemptied 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 polymerswhich 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 ahigher 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 dilutionincreases the issue output of the entire system. But the viscosity of the polymer solution may notexceed 1.500 mPas. The redilution stations, which are pre-mounted on a panel, were matchedto the relevant system size and are typically designed for a dilution in the volume ratio 1 : 5.

6 Assembly and Installation

The system is completely pre-assembled ex works. The wiring between the control cabinet andthe electrical units is also complete.

6.1 Assembly

WARNING

• The system may be damaged or may break!The installation of the system requires a weight-bearing capable, level and horizontalsupport 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 ambienttemperature and installation heights below 1,000m above sea level.

• If required, use an electric motor with higher nominal rating.

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ProMinent®

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

Prerequisites:

• The preparation water must be of drinking water quality. It must be free from solids andsuspended 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.

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 forthe polymer and the legal regulations for disposal!

NOTE

• Overflow and discharge lines must be routed with downward slope and operationwithout backpressure must be possible!

• When decommissioning the system, it is recommended to install a T-piece with astop-cock as discharge option between the shut-off valve of the chamber 3 and thedelivery 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 Installation, Electrical

WARNING

• The electrical installation may only be performed by a qualified electrician!

• Always disconnect the system from the power supply and secure against re-startbefore carrying out any installation work in the electrical connections.

6.3.1 Connection of the Mains Line

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 themotors are rotating in the right direction!

Connect the electrical line according to the connection diagram (see pocket in the controlcabinet).

Route the mains cable into the control cabinet of the system through a suitable opening andconnect 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. Theupper 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 theindex finger and simultaneously pulling it forward a bit. The complete upper part can thenbe 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 shortribbon cable!

The upper part with the two guiding rails can now be inserted into the slot approx. 80mmabove. In this “parking position”, all connecting terminals and fuses are freely accessible.

7 Control

7.1 Design and Function

The Ultromat® control is accommodated in a plastic housing (for control panel installation onlytype of protection IP 54). It includes the actual microprocessor control as well as the pertinentterminal board with the required connection terminals, the power supply unit, the fuse as well asall 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 Display Elements and Controls

7.1.2 Display Elements (Status Indication)

Fig. 6: Display elements Ultromat® control

L3 L4 L5 L6 L7 L8 L9 L10

L11 L2

L1

1+2 3

Display element Signal Meaning

L1 green LED indicator Device in operating modeLED indicator off Device in hold mode

L2 red LED indicator Fault (flashing light)Warning (permanent light)

L3 green LED indicator Control metering pipe heating

L4 green LED indicator Control metering (powder feeder for type AT0 orconcentrate pump for ATF)

L5 green LED indicator Control water feed red LED indicatorFlow smaller than specified min. flow

L6 green LED indicator Control delivery pump (polymer solution)

L7 green LED indicator Control agitator chamber 1 +2

L8 green LED indicator Control agitator supply 3 (option)

L9 red LED indicator Powder shortage in powder feeder (types AF0 and ATF)

L10 and L11 green LED indicator Function only in calibration mode and test mode

LCD display 2 lines, max. 16 characters

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ProMinent®

Control

7.1.3 Controls

Fig. 7: Controls of the Ultromat® control

T5

T2

T1

1+2 3

T3

T4

T6

T8

T7

Display element Signal Meaning

T1 Start / stop key Switches the Ultromat® system to operating or hold mode

T2 Ack key Acknowledges a received alarm

T3 Enter key Saves a value, goes to the next menu option

T4 Change key Change in the menu

T5 T key Start/stop key for the calibration of the powder feeder,the concentrate pump, the setting of the water feed, andmetering monitor, test devices

T6 Down key Modification of numerical values

T7 Return key Return within the menu

T8 Up key Modification of numerical values

separate key in thecontrol cabinet door:

Horn off key To mute the horn signal in case of a combined alarm(does not acknowledge the alarm!)

7.1.4 Operation of the System and Operating Status Indications

Mains switch

The Ultromat® is switched on and off using the mains switch located at the side of the controlcabinet.

START / STOP key

The operating processes are stopped and started by pressing the START/STOP key. Theswitched 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 theoperating processes are stopped via remote control.

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T key

The T key is required during calibration in order to start or stop an action. The LED (L11) flasheswhenever the T key must or can be pressed during the calibration. If an action was triggeredwith 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 beenacknowledged. After acknowledging, the LED and the error text extinguish. If several faults aregiven, the texts are indicated alternatively.

Centralised fault

The horn signal of the centralised fault can be deactivated for the present alarm with the sepa-rate 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 keyswitch in the control cabinet door.

Before changing the operating mode, the Ultromat® must be disconnected from the powersupply 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 Menu System

7.2.1 Layout of the Menu

The menu is divided into the display level and the setting level. In the display level, the operatingstatus of the system and the alarms are indicated. In the setting level, the parameters forcontrolling the system can be changed and the calibration can be performed (see also “Controlmenu” in the annex). After selection of the setting level, the control automatically returns to thedisplay level after 10 minutes.

Control

Calibration ConcentrationCommissioning

Concentration

Service

Flow

Agitator

Agitator 3

Powderfeeder

Access code

Display menu

Water feedmin. flow

HeatingSwitch-on / off time

Water feedlead/lag time

Agitator 1+2Switch-on / off time

Agitator 3Switch-on / off time

Concentrate pumpminimum frequency

Setting oflanguage

Changeaccess code

CalibrationPowder feeder

CalibrationConcentrate pump

SettingWater feed

SettingMetering monitor

Run empty

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ProMinent®

Preparation modefeed = xxxl/h

Conc. = x.x%feed = xxxl/h

Supply fullIssue supply

Conc. = x.x%Issue supply

Remote controlPAUSE

STOPFeed = 0l/h

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 theprevious menu level.

Pressing the Enter key, the display goes from the display menu to the setting menu. Afterpressing the Enter key again and entering the access code (default: 1000), pressing the Changekey switches between the submenus “Settings commissioning”, “Settings calibration”, “Settingsconcentration” and “Settings service”. All other subsequent menus are accessed by pressingthe Enter key again.

Values are entered with the help of the arrow keys “UP” and “DOWN”. In general, the value lastentered is shown. When permanently pressing one of the arrow keys, the value starts to changemore rapidly.

The previous level can be reached by pressing the Return key.

7.4 Display Mode

7.4.1 Standard Operation

The following messages are shown on the control display during the preparation process:

When the maximum fill level in chamber 3 is reached, the control display shows the followingmessages:

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:

If the standard operation is interrupted via the remote control input, the following message isshown:

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Control / Commissioning

7.4.3 Display of the Identcode of the Control

By pressing the Change key in the permanent display, the Identcode “ULSaTxxxxxxxxx” isshown as well as in the second line the software version(e.g.: 02/4.1) of the control and theoperating mode “L” (“Liquid”) or “D” (Dry material” = powder polymer).

Please provide these data to ProMinent® Dosiertechnik GmbH in case of complaints andcustomer service requests in the event of malfunctions.

8 Commissioning

8.1 Assembly, Preparatory Work

WARNING

• Before first commissioning, the mechanical and electrical connections must bechecked for correct connection (e.g. direction of rotation of motors, supply voltageetc.).

• Make sure that the voltage, frequency and current type applied in the control cabinetmatch 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 beobserved.

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 leakagesand 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 bedisplayed. 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 thefollowing defaults:

Parameter Defaults Range

Language D D, E, F, P, C, N, H

Water feed min. flow

Ultromat® 400 500 l/h

Ultromat® 1000 1,200 l/h

Ultromat® 2000 2,400 l/h 0 - 12,000 l/h



Heating switch-on time 5 s 1 – 10 s

Heating switch-off time 35 s 30 – 100 s

Feed lead time 7 s 0 – 30 s

Feed lag time 5 min 0 - 30 min

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Parameter Defaults Range

Commissioning

Agitator 1+2 switch-on time 15 min 5 - 50 min

Agitator 1+2 Switch-off time 15 min 5 - 50 min

Agitator 3 switch-on time 5 min 0 - 20 min

Agitator 3 Switch-off time 10 min 5 - 50 min

Change access code 1000 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 inthe wetting cone drops. For a water feed of less than 80 % of the specified water quantity, thewetting 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 themetering 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 anddestroy the feeder screw!Select the switching-on and -off times such that the temperature of the heating of themetering 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 bespecified 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 sufficientlywetted with water. Upon expiry of the lead time, a stable state should have been reached andthe 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 solenoidvalve is only closed upon expiry of the lag time. Set the lag time such that the wetting cone issufficiently wetted with water.

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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 thepreparation process, both agitators continue in the pulse/pause mode. The value can bechanged with the arrow keys by selecting the submenu “Agitator 1 + 2 switch-on time” as wellas “Agitator 1 + 2 switch-off time” and pressing of the Enter key. Press the Enter key again andthe 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 thepulse/pause mode. Based on the adapted switch-on and switch-off times, a sufficient mixingcan 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 % and1.0 %, 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 concentrationcan 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” isdisplayed.

Enter the desired concentration using the arrow keys.

Commissioning

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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 bypressing 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 Water feed






In the menu “Setting water feed”, press the Enter key to go to the display “Water feed” – theLED next to the T key on the control panel flashes.

After pressing the T key in the corresponding menu option, the solenoid valve opens andthe 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 largeblade width (min. 10mm). The current flow rate can be read from the LCD screen of thecontrol.

After stabilisation of the operating status, the water flow to the wetting cone may bereadjusted 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 screwdriverwith large blade width (min. 10 mm) such that the water level in the wetting cone stabilisedat approx. 15 to 20 mm below the overflow pipe. As soon as the water level in the cone hasstabilised, the required water quantity has to be adjusted at the right control valve (largenominal 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 bereadjusted 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 “Powderfeeder”. The LED next to the T key flashes.

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Hold the PE bag (capacity min. 500 g) under the metering pipe and press the T key. Thepowder feeder runs at full capacity. If a sufficient amount is poured into the bag, stop thepowder feeder by pressing the T key again.

Weigh the discharged powder amount and enter the weight in grams into the control usingthe arrow keys.

After pressing of the Enter key, the control calculates the metering output in grams/minuteand 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 thecollection 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 usingthe arrow keys.

After pressing of the Enter key, the control calculates the metering output in grams/minuteand 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 withSpectra as concentrate pump. For the Sigma as concentrate pump, the option “Meteringmonitor” is not available.

1. Release key lock:

If the keys are locked, press both keys of the metering monitor in the operating mode at thesame 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 afterapprox. 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 afterapprox. 5 s.

Release the key. The system accepts the new value and goes to operating mode.

Commissioning

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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 switchingpoint 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 soonas 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 thewetting 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 asunken 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 LEDextinguishes.

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 Service Menu

8.6.1 Setting of Flow

The menu “Setting flow” is required in case the turboDOS or contact water meter fails. Set afixed value in the menu “manual flow entry” if the flow meter no longer emits any signal. Duringa preparation process, the control no longer obtains the flow values from the flow meter, butuses the set fixed value. The fixed value must, of course, be chosen such that it corresponds tothe 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 andwith caution!After restoration of the flow meter, “automatic flow measurement” must be activatedagain.

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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)

8.6.3 Running empty the Ultromat®

The menu “Run empty” prevents a new preparation in the Ultromat® and maintains the releasefor the downstream delivery pump (transfer pump) until the dry running level has beenundershot.

For “running empty”, go to the menu “Run empty” and press the T key.

Fig. 10: Extract operating menu “Run empty”

8.7 Setting of the Frequency Converter Altivar 11

8.7.1 Function of the Controls

Fig. 11: Controls Altivar 11

Commissioning

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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

8.7.2 Menu Overview

8.7.3 Setting of the Parameters

The frequency converter is factory-set to the following defaults:

Setting parameters level 1

Parameter Value Description Range

bFr 50 Motor frequency (Hz) 50 / 60This parameter is only displayed at first switching on.It can, however, be changed any time in themenu “FUn”.

ACC 0,1* Ramp-up time (s) 0.1 – 99.9s

dEC 0,1* Run-down time (s) 0.1 – 99.9s

LSP 0 low speed at 4mA (Hz)

HSP 100* high speed at 20mA (Hz)

ItH 1,5* Thermal motor protection (A) 0 - 3,1

SP2 10 2. preselection frequency (Hz) 0 - 200



AIt / ACT 4A* Configuration analogue input (4-20mA)

Menu „drC”

Parameter Value Description Range

UnS 230 Nominal motor voltage (rating plate) (V): 100 - 500

FrS 50 Nominal motor frequency (rating plate) (Hz): 40 - 200

StA 20 Stability of the frequency controller (%) 0 – 100

FLG 20 Gain of the frequency controller (%) 0 – 100

UFr 5 0 Ri compensation (%) 0 – 200

nCr 1,5* nominal current of the motor read from therating plate 0.5 – 3.1

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Commissioning

Parameter Value Description RangeCLI 1,5* Motor limiting current 1.0 – 3.1

nSL 0* Nominal motor slip (Hz) 0 - 10

SLP 0* Slip compensation (%) 0 – 150

COS 0,78* Cos Phi of the motor (rating plate) 0.50 – 1.00

Menü „FUn“

Parameter Submenu Value Description

tCC Type of control

ACt 2C 2-wire control

tCt LEL* Type of 2-wire control

rrS no* Anti-clockwise rotation

PS2 Preselection frequencies

LiA no Assignment of the input LIA

LIb no Assignment of the input Llb

tLS 0,0

PI no

rSF no Re-start at failures

rP2 Second ramp

LI no Assignment of the input to control the secondramp

LC2 2. Current limitation

LI1 no

nSt no

StP no Controlled run-down in case of power failure

brA no* Adjustment of run-down ramp

AdC Automatic feeding of direct current

ACt yes Operating mode

tdC 0,5 Feed time

SdC 1,4 Input current

SFt Timing frequency

ACt LF Frequency range

SFr 4 Timing frequency (kHz)

FLr no Aligning in operation

d0 Analogue output

ACt no* Assignment

Atr yes* Automatic re-start

bFr 50 Motor frequency (Hz)

SCS yes Saving of the configuration

FCS Call up of the configuration

no Function inactive

rEC Call up saved configuration

InI The factory-set defaults become the currentconfiguration

Note: (*) These settings deviate from the values which are entered as defaults after returning tothe factory-set values via the parameter >FCS= InI<.

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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 Commissioning of the System

CAUTION

• 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 allthree chambers are closed.

• Monitor the operation in this starting phase!Specifically ensure the correct switching function of the level sensors when therelevant switching points are first reached!

NOTE

The error message “Supply empty” cannot be avoided because at the present time allchambers 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 theautomatic preparation process.

9 Operation of the System

9.1 Standard Operation

9.1.1 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 relevanterror message. The horn can also be stopped by pressing the key “Horn off”.

Commissioning / Operation of the System

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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 powderypolymer must also be continuously checked and refilled in time. Filling may be performed duringoperation. 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 becontinuously checked and refilled in time. Filling may be performed during operation. Removethe 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 measuredsystem states.

But the system only starts with simultaneous preparation process if the min. switching point inchamber 3 is reached. If the mains power fails during the preparation process – even onlybriefly – 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, thecontrol continues the operation of the system unrestrictedly based on the detected states. If thelevel of the storage tank is in the normal range, no preparation process is started, even if apreparation process was running before the interruption.

9.3 Decommissioning

For a short time

Press the “Start/Stop” key.

For a longer period of time

Set the mains switch to “Off”.

Lock the mains switch to prevent an unauthorised restart of the system.

Operation of the System

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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 individualchambers.

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. (Ifa 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 theflushing 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 Disposal

CAUTION

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 ofthe 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 arefactory-set to the powder feeder.

• When setting the concentration, the maximum viscosity of 1,500mPas may not beexceeded.

• 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, afaulty system behaviour may result.

• If the system is started without having remedied the original fault, additional and severefaults may result (see Chap. 11).

Operation of the System / Maloperations of the System

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Troubleshooting

11 Troubleshooting

WARNING


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 redalarm LED at the control cabinet. In addition, the control indicates an error message. The alertcan be deactivated by pressing the separate push-button “HORN OFF” at the front of thecontrol cabinet.The release of the downstream delivery pump (polymer solution) is not affected by the combinedalarm.

Acknowledgement For the system to restart again after a fault, the error message must be acknowledged with theAck 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 remediedwith 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 screwedcover of an inspection hole if a reservoir chamber must absolutely be accessed!

WARNING


Sensors For each fault analysis it should first be considered that a capacitive proximity senor or aconcentrate flow sensor erroneously signals a fault (because its sensitivity is set to high andsuddenly responds to changed ambient conditions).

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Troubleshooting

Fault table

Warnings *

Error message Fault Effect Delay LED red Alarm relay Action

First switch off Powder / liquid Hold state 1s on off Switch off/ontoggle pressed mains switch

Minimum frequency! Concentrate pump - 5s on off Increase feed liquidundercontrolled polymer

Meteringstop,

Water shortage Feed monitoring Feed active 3s on off Increase water feed;Chap. 11.1.1

Feed too high Feed monitoring - 3s off off Decreasewater feed;Chap. 11.1.2

* Remarks on warnings:

• 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.

Malfunctions

Error message Fault Effect Delay LED red Alarm relay Action

Metering monitor Metering monitor Hold state 20s flashes on Refill liquidpolymer

Wetting cone Overflow wetting cone Hold state 3s flashes on Remedy cause,Chap. 11.1.2

Fault fill level Level switch Hold state 5s flashes on Check level switch,chamber 3 defective Chap. 11.2.2

Fault converter Fault frequency converter Hold state 5s flashes on Check frequencyconverter

Concentrate Concentrate tank empty Hold state 10s flashes on Refill liquidshortage polymer

Redilution Monitoring redilution Hold state 3s flashes on Remedy cause,Chap. 11.2.3

Board “n” defective Fault in control Hold state 1s flashes on Call customer service,Chap. 11.2.4

Powder shortage Powder fill level Hold state 3s flashes on Refill powderyin powder feeder polymer,

Chap. 11.2.5

Pump failure Fault concentrate pump Hold state 2s flashes on Checkmotor starterconcentrate pump

Agitator failure Agitator failure Hold state 1s flashes on Remedy cause,Chap. 11.2.6

Supply overfull Overflow chamber 3 Hold state 1s flashes on Check level switchLSHH, Chap. 11.2.7

Water shortage Water feed Hold state 20s flashes on Check water feed,below min. value Chap. 11.1.1

Water shortage Supply voltage off System - off on Remedy causeswitched off

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Troubleshooting

11.1 Warnings

11.1.1 Error Message “Water shortage”

The error message “Water shortage” is indicated if the feed volume undershoots the set lowerlimit value for more than 3s. The powder feeder is switched off. After a total of 20 s ofinsufficient 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 restartsthe 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 Remedy

The operating pressure is too low. If the strainer in the pressure reducer is dirty,clean the strainer.If the strainer is not dirty, completely open the shut-offvalve in the water feed line. Check the water level in thewetting cone.If there is no improvement, reduce the restriction at thepressure 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.


Cause Remedy

The connection at the solenoid Set the mains switch to “Off”.valve came loose. Check the cable connector and fix, if required.

The throttle bore or the pilot Set the mains switch to “Off”.drilling in the valve outlet is Open the solenoid valve and thoroughly clean the interiorclogged. of the body.

The diaphragm inside the Set the mains switch to “Off”.solenoid valve is defective. Replace the solenoid valve.

C. Malfunction of the flow meter

The blade in the flow meter no longer rotates freely.


Cause Remedy

Blade in the flow meter no Close the shut-off valve.longer rotates freely Remove and clean the flow meter.

11.1.2 Error Message “Feed too high”

The error message “Feed too high” is indicated if the water flow is too high such that thepowder feeder cannot meter sufficient powder to achieve the preset concentration.

The control does not trigger any alarm but indicates the actual concentration.


Cause Remedy

Water flow is too high. Reduce the water flow.

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Troubleshooting

11.2 Malfunctions

11.2.1 Error Message “Wetting cone”

The error message “Wetting cone” is indicated if the alarm sensor for the overflow monitor in thewetting 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.


Cause Remedy

The wetting cone is clogged Remove and thoroughly clean wetting fittingwith powder. (cone and spiral mixer).

Excessive water throughput Readjust the water throughput, specifically reducethrough the wetting fitting. the partial flow through the wetting cone.

11.2.2 Error Message “Fault fill level”

The error message “Fault fill level” is indicated if the probes of the fill level sensor in chamber 3report two different levels at the same time.

WARNING


WARNING



Cause Remedy

The fill level sensor reports Switch off the system using the mains switch tocontradictory messages. 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 belowthe preset limit value.

The redilution unit is equipped with a float flow meter to indicate the flow of the water forredilution. A limit contact monitors the minimum water flow.


Cause Remedy

Water flow in the redilution unit Remedy the cause of the low water flow in thetoo low. 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 internalhardware error.


Cause Remedy

Internal hardware error. Call the ProMinent®-ProMaqua® customer service.

11.2.5 Error Message “Powder shortage”

The error message “Powder shortage” is indicated if the level sensors in the storage tanksignals powder shortage, the control stops the system.

For information on possible malfunctions of the powder delivery unit, please see its separateoperating instructions in Chapter 7 “Measures to remedy malfunctions”.


Cause Remedy

(see separate operating instructions of the powder delivery unit in Chapter 7 “Measures toremedy malfunctions”)

11.2.6 Error Message “Agitator failure”

The error message “Agitator failure” is indicated in case of a defect of an agitator and acombined alarm is triggered.

The agitators are monitored by the motor circuit-breakers.


Cause Remedy

Defect in the motor of an agitator. Determine based on the motor circuit-breaker whichagitator is affected.Check the corresponding motor for damages andreplace, if necessary.

11.2.7 Error Message “Supply overfull”

The error message “Supply overfull” is indicated if the control during the preparation processdoes not receive a signal from the fill level sensor that the max. level is reached and the overflowsensor (option) instead detects the excessive level.

The control now stops the preparation process.

WARNING


WARNING



Cause Remedy

The fill level sensor is dirty. Switch off the system using the mains switch topermanently stop the agitators.Remove and clean the fill level sensor.Check the function of the fill level sensor.

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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 thefuse!

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 Maintenance

12.1 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 completelywetted 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 manufacturer’s instructions in the annex.

12.3 Inspection and Cleaning of the Solenoid Valve

WARNING

Risk of electric shock!The mains switch must be set to “Off” and secured against restart before opening the so-lenoid 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.

Troubleshooting / Maintenance

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NOTE

For detailed information and the relevant drawing, see the operating instructions ofthe 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 coilinsert. 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 thevalve outlet.

12.4 Removal and Inspection of the Flow Meter (turboDOS)

CAUTION

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 Disassembly of the Cover of an Inspection Hole

WARNING

Propellers are rotating in the chambers!First set the mains switch to “Off” and secure against restart, then remove the screwedcover 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 thecourse of time.

Maintenance

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Replacement Parts and Accessories

13 Replacement Parts and Accessories

13.1 Replacement parts

Control ULSa:

Designation Component Part Order no.:

F2 Fuse, 0.63 A, T, 5x20 712030

K1-K12 Relay, 250 V AC, 3A 711340

2A3 Ultromat EA assembly(assembly EA, ULSa signal separation) 731049

13.2 Accessories

Powder Feed Tank (only types AF0 and ATF)

The powder feed tank serves the intermediate storage of powdery polymers which weresupplied in big bag containers. The big bag is suspended in a frame above the feed tank andemptied 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 polymerswhich 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 Water fitting for the diluent water with manual shut-off valve, pressure reducer, solenoidvalve (230 V, option: 24 V DC) and float flow meter including minimum contact

2 Piping for the polymer solution to be diluted including non-return valve

3 Static mixer for mixing the stock solution with the diluent water

Type Working Solution Order no.

VS 1000 1,000 l/h 1005566

VS 2000 2,000 l/h 1005567

VS 5000 5,000 l/h 1005568

VS 10000 10,000 l/h 1005569

VS 20000 20,000 l/h 1005570

VS 30000 30,000 l/h 1005571

VS 50000 50,000 l/h 1005572

Ultromat® redilution unit VS-IP with flow meter

As Ultromat® redilution unit but with additional inductive flow meter

Type Working Solution Order no.

VS 1000 IP 1,000 l/h 1005584

VS 2000 IP 2,000 l/h 1005585

VS 5000 IP 5,000 l/h 1005586

VS 10000 IP 10,000 l/h 1005587

VS 20000 IP 20,000 l/h 1005588

VS 30000 IP 30,000 l/h 1005589

VS 50000 IP 50,000 l/h 1005590

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Annex

13.3 EC Declaration of Conformity

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Annex

13.4 Control Menu Ultromat® AF0

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Annex

13.5 Control Menu Ultromat® AT0

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13.6 Control Menu Ultromat® ATF

Annex

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Annex

example

Commissioning Report Ultromat® AT0, AF0 or ATF

Ultromat® type:

AT0 � 400 � 1 000 � 2 000 � 4 000 � 8 000

AF0 � 400 � 1 000 � 2 000 � 4 000 � 8 000

ATF � 400 � 1 000 � 2 000 � 4 000 � 8 000

Ident-Code:

ULSA 0 / 02/4.1 T

Software version: Project number:

13.7 Commissioning Report

Settings calibration:

Parameter: Powder Liquid

Concentration: %

Calibrated metering output: g/min

Water feed: l/h

Switching threshold flow monitor: g/min

Supplier:

Supplier:

Powdery polymer trade name:

Liquid polymer trade name:

Date:

Settings for Commissioning

Parameter Default setting Setting

Feed water min. flow Ultromat® 400 500 l/h

Feed water min. flow Ultromat® 1000 1,200 l/h




Heating switch-on time 5s

Heating switch-off time 35s

Feed lead time 7s

Feed lag time 5s

Agitator 1 + 2 switch-on time 15 min

Agitator 1 + 2 switch-off time 15 min

Agitator 3 switch-on time 5 min

Agitator 3 switch-off time 10 min

Concentrate pump minimum frequency 25 Hz

Access code 1000

Customer:

Installation location:

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Anschriftennachweise erhalten Sie durch: / Addresses of distributors are available from: ProMinent Dosiertechnik GmbH, Germany

Die ProMinent Firmengruppe / The ProMinent Group

12/08

Stammhaus / Head officeProMinent Dosiertechnik GmbH · Im Schuhmachergewann 5-11 · 69123 Heidelberg · [email protected] · www.prominent.com · Tel.: +49 6221 842-0 · Fax: +49 6221 842-617

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manual preparadora de polímeros Prominent

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