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Operating Instructions
®
Ultromat
AT/96 and ATF/96 Series V 4.0
Three-compartment Plant for the Preparation of Polyelectrolyte
Please read the operating instructions through completely before commissioning this equipment.
Do not discard! Any part which has been subject to misuse is excluded from the warranty!
Part. No. 987965
ProMinent Dosiertechnik GmbH
69123 Heidelberg
Germany
BA UL 007 06/02 GB
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Summary of Contents for ProMinent Ultromat AT/96 Series
- Page 1 Please read the operating instructions through completely before commissioning this equipment. Do not discard! Any part which has been subject to misuse is excluded from the warranty! Part. No. 987965 ProMinent Dosiertechnik GmbH 69123 Heidelberg Germany BA UL 007 06/02 GB •...
- Page 2 Printing Printing: Operating Instructions for Ultromat ® AT/96 und ATF/96 Serie V 4.0 Three-compartment Plant for the Preparation of Polyelectrolyte © ProMinent Dosiertechnik GmbH, 2002 Address: ProMinent Dosiertechnik GmbH Im Schuhmachergewann 5-11 69123 Heidelberg P.O. Box 101760 69007 Heidelberg Germany Tel.: +49 (6221) 842-0...
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Page 3: Table Of Contents
................................. 4 General Safety Guidelines ..............................5 Assembly and Installation ..............................Installation of the Plant .............................. Electrical Installation ..............................5.2.1 Connecting Mains Supply Cable ..................... 5.2.2 Opening the Controller (see diagram 4) ..................Fitting Options ................................... ProMinent ® page 3... - Page 4 8 Operating the Plant .................................. Normal Operation ................................8.1.1 Preconditions for Correct Operation .................... 8.1.2 Supplying Dry Feeder with Powder ....................Switching On Mains Power and Mains Power Failure Procedure .......... Emergency Measures ..............................Plant Idle ....................................page 4 ProMinent ®...
- Page 5 12.9 Assembly Drawing ATF 2000 ..........................12.10 Assembly Drawing ATF 4000 ..........................12.11 Assembly Drawing ATF 8000 ..........................12.12 Programming Menu Ultromat ® AT/96 ......................® 12.13 Programming Menu Ultromat ATF/96 ......................12.14 Commissioning Protocol ............................ProMinent ® page 5...
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Page 6: General User Guidelines
Describes a potentially dangerous situation. Could result in loss of life or serious injury if preventative measures are not taken. NOTICE Describes a potentially threatening situation. Could result in damage to property if preventative measures are not taken. page 6 ProMinent ®... -
Page 7: Ultromat ® At/96 (For Powdered Polymer Batching)
(volume) of the Ultromat and lasts approx. 60 minutes for a maximum extraction rate. The plant capacities range from a maximum 400 L of prepared solution per hour for the AT 400, to 8000 l for the AT 8000. ProMinent ® page 7... -
Page 8: Atf/96 (For Powder And Liquid Polymer Batching)
H1= 1516 L = 4434 R 2” 1200/ DN 80/ 9.5 kW 2.2 kW 12 - 264 L/h 8000 B = 1910 10000 kg DN 50 750 rpm TD 38.20 H = 2350 IP 55 H1= 1518 page 8 ProMinent ®... -
Page 9: Ultromat Atf/96 Dimensions
DN 20 8000 = 1910 9200 kg DN 50 750 rmp H = 2350 IP 55 H1 = 1518 N.B. Ultromat ® power supply is used for device incorporating three agitators. Diagram 1: Ultromat ® Dimensions ProMinent ® page 9... -
Page 10: Description Of Functions
The pressure control valve, which incorporates a strainer, limits and maintains the correct operating pressure. A solenoid valve automatically opens and closes the water inlet. The turbine counter (ProMinent ® turboDOS) continuously relays the flow volume at any time to the controller. -
Page 11: Powder Feeder
The agitators will continue to run for the pre-set time span even if the plant has been turned on/off using the start/stop key. Even if a malfunction has occurred, with exception of malfunctions of the agitators themselves the agitators will continue to run intermittently. ProMinent ® page 11... -
Page 12: Control Cabinet
A breaker wheel ensures continuous extraction of the dosing powder which is located above the feeder screw. In addition, a feeder screw pipe heater removes any moisture from the pipe, and so prevents dosing powder from blocking the pipe. page 12 ProMinent ®... -
Page 13: Operating Methods
No malfunctions contact open: • Plant was stopped on site or by remote • Malfunction 3.5.3 Overflow Safety Cut-out ® The overflow safety cut-out signals an overflow in the Ultromat storage compartment and triggers an alarm. ProMinent ® page 13... -
Page 14: Evaluation Of After Dilution Unit
If the dry feeder is not equipped with automatic feed operation, a mobile step ladder is recommended in order to facilitate manual filling of the dry feeder. Access is gained from the front of the feeder. page 14 ProMinent ®... -
Page 15: After Dilution Unit
Equally, the effective running of the plant when using non-original parts and accessories cannot be guaranteed. The relevant accident prevention regulations and other generally recognised technical safety regulations must be observed. ProMinent ® page 15... -
Page 16: Assembly And Installation
Some options require reconfiguration of the controller and can therefore only be fitted by our service personnel. Refitting procedures must be done correctly and should be carried out by our experts, in order to ensure that effective plant operation is maintained. page 16 ProMinent ®... -
Page 17: Controller
All stored parameter and configuration data is protected from breaks in the power supply. 6.1.1 Display and Operation Module L3 L4 Ultromat AT Conc. = 0.11 % Feed = 1277 L/h TEST-KEY CHANGE- ENTER- CONFIRM key STOP START DOWN- BACK- ® Diagram 4: Control Panel, Ultromat Controller ProMinent ® page 17... -
Page 18: Display Supplement (Displays State)
If not, a warning “switch off first” will appear once the selected operational mode is activated. The power supply must then be switched off for approx. 10 sec. After reconnection the controller returns the Ultromat ® to the selected operating mode. page 18 ProMinent ®... -
Page 19: Menu System
By pressing one of the arrow keys continuously, it will change at an ever increasing rate. By continually entering and confirming, you can travel through the menus. With the help of the Back key you can revert any time to the previous menu level. ProMinent ® page 19... -
Page 20: Display Mode
(e.g. :02/4.1) and the operating mode, e.g. “Fluid” (F) or “Powder” (P). In case of claims and customer service requirements for operational malfunctions these codes must be given to ProMinent Dosiertechnik GmbH. Commissioning Assembly, Initial Tasks During assembly it is absolutely essential that the handling and positioning instructions given in sections 1 and 5 are followed correctly. -
Page 21: Checking Identcode
E = English Flow monitoring (water in-flow): F = French P = Polish 0 = turbine 67 imp./L C = Czech 10 pulses/Litre N = Dutch pulse/Litre H = Hungarian 3 = 0.25 pulse/Litre Diagramm 6: Identcode ProMinent ® page 21... -
Page 22: Start Up Settings
IMPORTANT On/off times should be selected so that the feeder screw pipe temperature does not exceed hand-heat of 40 °C. Higher temperatures can lead to caking of powder which can cause irreparable damage to feeder screw. page 22 ProMinent ®... -
Page 23: Setting Prerinsing Time And Rinsing Delay Time
Level Ultromat empty Solenoid valve, waterin-flow prerinsing rinsing delay (0-30 sec.) (0-30 sec.) Powder feeder on-time (5-50 min.) Agitators 1+2 f-time on-time (5-50 min.) (0-20 min.) Agitator 3 f-time (5-50 min. ) ProMinent ® page 23... -
Page 24: Concentration Settings
Hold a light PE container (fill-volume minimum 500 g) beneath the feeder screw pipe, press the test key. The dry feeder will commence operating at full speed. When there is sufficient powder in the container, stop the dry feeder by pressing the test key once more. page 24 ProMinent ®... -
Page 25: Calibration Of Dosing Pump For Liquid Concentrate
This procedure should be used as briefly as possible. Since the water intake is not precisely determined, discrepancies can occur in the polymer solution concentration. After flow meter function has been restored the system must be switched back to “automatic flow measurement”. ProMinent ® page 25... -
Page 26: Testing Agitator And Powder Feeder
↑↓ 1 l/h flow value start / stop agitator 1+2 start / stop agitator 3 start / stop powder feeder Warning: running dry running protection empty out of service page 26 ProMinent ®... -
Page 27: Speed Controller Settings
The “HSP = high speed at 20 mA” parameter must not be changed in liquid mode, as the speed controller is controlled by 4-12 mA current signal. Maximum frequency is 50 Hz. ProMinent ® page 27... -
Page 28: Level Sensor Settings
In such cases the operating personnel must bear the responsibility for removing the cause of the malfunction as quickly as possible so that a more serious malfunction does not develop. A plant in warning mode must nevertheless be closely monitored in the meantime. page 28 ProMinent ®... -
Page 29: Supplying Dry Feeder With Powder
Emptying takes place using the pipe-connectors which are fitted on each compartment for this purpose. Rinse the tank thoroughly with water. IMPORTANT If not in use for more than 2 days, the powder feeder must be completely empried. ProMinent ® page 29... -
Page 30: Operational Errors
This possibility should be taken into consideration whenever an error analysis is undertaken. If sensors prove themselves to be too insensitive, it will be necessary to reset those sensors. page 30 ProMinent ®... -
Page 31: Fault Identification/Malfunctions/Breakdown Advice
Identify cause supply off shut down Warnings do not require acknowledgment. The alarm light remains on continuously, the alarm is not triggered. When the cause of the fault has been removed, plant will automatically recommence normal operation. ProMinent ® page 31... -
Page 32: Malfunctions In The Water Inlet Pipe
(hopper and mixer) and clean carefully so that the water can flow freely again. • There is too much water flowing through the wetting cone. Solution: Reset the water flow. In particular reduce the partial flow through the wetting cone. page 32 ProMinent ®... -
Page 33: Malfunctions In The Storage Compartment
“Tank empty” appears and an alarm is sounded. Once alarm is confirmd, batching recommences and alarm stops. The “Tank empty” message remains until minimum liquid level is reached. Once minimum liquid level is reached, discharge pump connected downstream is activated. ProMinent ® page 33... -
Page 34: Hardware Fault Analysis
Plant Malfunctions/Error Messages - Breakdown Advice 10.9 Hardware Fault Analysis If the controller registers an internal hardware fault, please contact the ProMinent customer service department. 10.10 Dilution Faults The dilution unit is fitted with a flow meter which detects the water flow. A limit contact monitors the minimum water flow. -
Page 35: Dismantling And Examining The Flow Meter (Turbodos)
The plant should be stopped and disconnected from mains power for safety reasons. Only then can the inspection covers be removed, so that the inside of the tank can be cleaned. In addition the entire wetting cone should be rinsed again. ProMinent ® page 35... -
Page 36: Appendix
Appendix 12.1 Declaration of Conformity page 36 ProMinent ®... -
Page 37: Assembly Drawing At 400
Appendix 12.2 Assembly Drawing AT 400 Typenschild nameplate Ultromat AT Plaque signalétique Ultromat AT 1000/96 Baujahr ProMinent Heidelberg Hauptschalter main switch Sectionneur DN40 R1" Kammer 2 Kammer 3 Kammer 1 Kammer 3 Kammer 2 Kammer 1 chamber 2 chamber 1... -
Page 38: Assembly Drawing At 1000
Lieferumfang der Standardausführung L'agitateur de la chambre 3 ne fait pas standard equipment not includes gehört das Rührwerk in Kammer 3 partie de la version standard electric stirrer in chamber 3 page 38 ProMinent ®... -
Page 39: Assembly Drawing At 2000
Appendix 12.4 Assembly Drawing AT 2000 Typenschild nameplate Plaque signalétique Ultromat AT Ultromat AT 1000/96 Baujahr ProMinent Heidelberg Hauptschalter main switch Sectionneur DN50 Kammer 3 Kammer 1 Kammer 2 Kammer 3 Kammer 1 Kammer 2 chamber 3 chamber 2 chamber 1... -
Page 40: Assembly Drawing At 4000
Coffret de commande nicht zum Lieferumfang der Standardausführung standard equipment not includes L'agitateur de la chambre 3 ne fait pas gehört das Rührwerk in Kammer 3 electric stirrer in chamber 3 partie de la version standard. page 40 ProMinent ®... -
Page 41: Assembly Drawing At 8000
Coffret de commande nicht zum Lieferumfang der Standardausführung standard equipment not includes L'agitateur de la chambre 3 ne fait pas gehört das Rührwerk in Kammer 3 electric stirrer in chamber 3 partie de la version standard. ProMinent ® page 41... -
Page 42: Assembly Drawing Atf 4000
Lieferumfang der Standardausführung L'agitateur de la chambre 3 ne fait pas standard equipment not includes gehört das Rührwerk in Kammer 3 partie de la version standard electric stirrer in chamber 3 page 42 ProMinent ®... -
Page 43: Assembly Drawing Atf 1000
Coffret de commande nicht zum Lieferumfang der Standardausführung standard equipment not includes L'agitateur de la chambre 3 ne fait pas gehört das Rührwerk in Kammer 3 electric stirrer in chamber 3 partie de la version standard. ProMinent ® page 43... -
Page 44: Assembly Drawing Atf 2000
Coffret de commande nicht zum Lieferumfang der Standardausführung standard equipment not includes L'agitateur de la chambre 3 ne fait pas gehört das Rührwerk in Kammer 3 electric stirrer in chamber 3 partie de la version standard. page 44 ProMinent ®... -
Page 45: Assembly Drawing Atf 4000
Coffret de commande nicht zum Lieferumfang der Standardausführung standard equipment not includes L'agitateur de la chambre 3 ne fait pas gehört das Rührwerk in Kammer 3 electric stirrer in chamber 3 partie de la version standard. ProMinent ® page 45... -
Page 46: Assembly Drawing Atf 8000
Coffret de commande nicht zum Lieferumfang der Standardausführung standard equipment not includes L'agitateur de la chambre 3 ne fait pas gehört das Rührwerk in Kammer 3 electric stirrer in chamber 3 partie de la version standard. page 46 ProMinent ®... -
Page 47: Programming Menu Ultromat
Appendix ® 12.12 Programming Menu Ultromat AT/96 ProMinent ® page 47... -
Page 48: Programming Menu Ultromat Atf/96
Appendix ® 12.13 Programming Menu Ultromat ATF/96 page 48 ProMinent ®... -
Page 49: Commissioning Protocol
15 min Agitator 3 on time 5 min Agitator 3 off time 10 min Concentrate pump min. 25 Hz frequency Access code 1000 Powder product Trade name: Supplier: Liquid product Trade name: Supplier: Date: Client: Location: ProMinent ® page 49...
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