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Final Dossier for CP361/1 Doha South Sewage Treatment Works

PROJECT CODE : DA 07/08 C 40 G, CONTRACT NO: C2010/33

Volume Identification Details


Part
Volume
Section Name No. (if File No. Description
Number
any)
61 Section-4 N/A File-10 Final Dossier for Sludge Handling System

Details of Content
File No.10
10.1. Dewatering Centrifuge Package (Part 3 of 5)
10.1.1. Polymer Plant- Ultromat (Existing Installation)
CLIENT CONSULTANT
PUBLIC WORKS AUTHORITY
STATE OF QATAR
KE~ KEO INTERNATIONAL CONSULTANTS
DOHA, STATE OF QATAR

PROJECT: DOHA SOUTH SEWAGE TREATMENT WORKS PHASE II EXP. DOCUMENT TITLE: Sludge Handling System Final Dossier
PROJECT CODE: DA 07/08 C 40 G

File No. 10

Note

Polymer plant (Ultromat) is not under the scope of the contract CP- 361/1.

Content provided under File No. 10 should be taken as reference (indicative) purpose only.

provided under File-10.


Hence do not consider content
expansion.
And is not part of Phase-2
4 is already in place (Phase-1).
Plant) for Dewatering Centrifuge -
Ultromat (Polymer Preparation

CONTRACTOR:

LARSEN & TOUBRO CONSORTIUM LARSEN &TOUBRO •GALFAR Gltrar


ALMISNAD

~ SUB-CONTRACTOR:
xyLem Let's Sol v e W ater '
. ~; f\J t !~
,~
,CONTRACT NO: C2010/33
..;..
c

l .

c
CLIENT CONSULTANT

(Q! PUBLIC WORKS AUTHORITY


STATE OF QATAR

PROJECT: DOHA SOUTH SEWAGE TREATMENT WORKS PHASE II EXP.


KE~ KEO INTERNATIONAL CONSULTANTS
DOHA, STATE OF QATAR

DOCUMENT TITLE: Sludge Handling System Final Dossier


PROJECT CODE: DA 07/08 C 40 G

( File No.10

10.1. Dewatering Centrifuge Package (Part 3 of 5)

10.1.1. Polymer Plant- Ultromat

10.1.1.1. Safety Information

CONTRACTOR:

(9
( LARSEN & TOUBRO CONSORTIUM LARSEN &TOUBRO •GALFAR G4trar
ALMISNAD

SUB-CONTRACTOR:
xylem Let's Solve W ater
CONTRACT NO: C201O/33
Sicherheitshinweise fUr Ultromat®Anlagen
....
@

C
Safety Information for Ultromat®Systems
DItI EN ISO 9001
701 00 1.4 50'2
Q)

.-C
Hinweise zum Betrieb der Anlage
Die Bedienung der Ultromat® Anlagen darf nur durch unterwiesenes Perso-
:E
nal erfolgen.

Vor dem Start des Ansetzprozesses muss sich das Bedienpersonal ver-
gewissern, dass die Entleerungsventile fur die Ansetz- und Reifekammern
geschlossen sind und die Vorratskammer mit der Transferpumpe verrohrt
wurde.

Beim manuellen Befiillen des Trockengutdosierers ist auf einen sicheren


Stand des Bedienpersonals zu achten. Verschuttetes Polyelektrolytpulver
kann bei Feuchtigkeit zu erh6hter Rutschgefahr fiihren und ist sofort zu
entfernen.

Keinesfalls bei Normalbetrieb oder einer St6rung die Inspektionsdeckel ent-


( fernen und in die Behiilterkammern hinein greifen. Die Ruhrwerke k6nnen
unvermittelt anlaufen.

Zur Beseitigung von St6rungen, die Arbeiten am Ultromat® erforderlich


machen, ist die Anlage stets vom Netz zu trennen und gegen unbefugtes
Wiedereinschalten zu sichern.

FOr Wartungsarbeiten muss die Anlage stets vom Netz getrennt und gegen
unbefugtes Einschalten gesichert werden.

Vor dem Offnen der Steuerung muss sichergestellt sein, dass am Gerat
keine Spannung mehr anliegt.

Information on operation of the system


Only specially instructed personnel are permitted to operate the Ultromat®
systems.

Before starting the preparation process, the operating personnel must


ensure that the discharge valves for the batch and conditioning chambers
are closed and the pipe from the supply chamber is connected to the
transfer pump.

The operating personnel must ensure stable footing when manually filling
the dry material metering unit. Spilt polyelectrolyte powder can pose an
increased risk of slipping when moist and should be removed immediately.

(] On no account remove the inspection cover and reach into the tank
chambers during normal operation or in the event of a fault. The stirrers can
start up unexpectedly.

Before repairing faults that render it necessary to carry out work on the
Ultromat®, the system must always be disconnected from the mains power
supply and secured to prevent it being switched on again unintentionally or
by unauthorized persons.

Before carrying out maintenance work, the system must always be


disconnected from the mains power supply and secured to prevent it being
switched on again unintentionally or by unauthorized persons.

A check must be carried out to ensure that voltage is no longer applied in


the system before opening the control.

Teile Nr.lPart No. 987543 ProMinent Oosiertechnik GmbH· 0-69123 Heidelberg· Germany AL UL 001 0 2/00 G/G S/ F/ E

\
CLIENT CONSULTANT

( ~ KE~
PUBLIC WORKS AUTHORITY KEO INTERNATIONAL CONSULTANTS
STATE OF QATAR DOHA, STATE OF QATAR

PROJECT: DOHA SOUTH SEWAGE TREATMENT WORKS PHASE II EXP. DOCUMENT TITLE: Sludge Handling System Final Dossier
PROJECT CODE: DA 07/08 C 40 G

, ( File No.l0

10.1. Dewatering Centrifuge Package {Part 3 of S}

10.1.1. Polymer Plant- Ultromat

10.1.1.2. Assembly and Operating Instructions

CONTRACTOR:

r..ARSEN & TOUBRO CONSORTIUM LARSEN &TOUBRO •GALFAR Gltrar


ALMISNAD

SUB-CONTRACTOR:
xylem Le t's Solve W ate r
CONTRACT NO: C2010/33
..
@

C
~
.-
C
:E

Operating Instructions
Ultromat@ AT/96 and ATF/96 Series V 5.0
Three-compartment Plant for the Prepa~ation 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. 986834 ProMinent Dosiertechnik GmbH. 69123 Heidelberg. Germany SA UL 012 04/05 GS
Printing

Printing:
Operating Instructions for Ultromat®AT/96 und ATF/96 Serie V 5 .0
Three-compartment Plant for the Preparation of Polyelectrolyte
© ProMinent Dosiertechnik GmbH, 2002

Address:
ProMinent Dosiertechnik GmbH
1m Schuhmachergewann 5-11
69123 Heidelberg
Germany
Tel.: +49 (6221) 842-0
Fax: +49 (6221) 842-419
info@prominent.com
www.prominent.com

Subject to technical alteration.

page 2 ProMinent®
Table of Contents

Table of Contents

General User Guidelines


Transport and Storage of the Plant .......................................................................................................................... 7

2 Plant Information ....................................................................................................................................................................... 7


2.1 Applications ......................................................................................................................................................................... 7
2.2 Capacity ................................................................................................................................................................................. 7
2.2.1 Ultromat®AT/96 (for powdered polymer batching) .......................................................... 7
2.2.2 Ultromat®ATF/96 (for powder and liquid polymer batching) .................................... 8
2.3 Ultromat®AT/96 Dimensions ................................................................................................................................. 8
2.4 Ultromat®ATF/96 Dimensions .............................................................................................................................. 9

3 Description of Functions .................................................................................................................................................... 10


3.1 Plant Construction ......................................................................................................................................................... 10
3.2 Description of Individual Units ............................................................................................................................. 10
3.2.1 Three-compartment Tank ...................................................................................................................... 10
3.2.2 Inlet water system and wetting equipmentk .......................................................................... 11
3.2.3 Powder Feeder .............................................................................................................................................. 11
3.2.4 Agitators .............................................................................................................................................................. 11
3.2.5 Control Cabinet ............................................................................................................................................. 11
3.2.6 Ultromat EA assembly ............................................................................................................................. 12
3.2.7 Concentrate Pipework (ATF/96 only) ........................................................................................... 13
3.3 Plant Function ................................................................................................................................................................... 14
3.4 Operating Methods ....................................................................................................................................................... 14
3.4.1 Preparation Operation ............................................................................................................................. 14
3.4.2 Settings Configuration Option ........................................................................................................... 14
3.4.3 Remote Control Option ........................................................................................................................... 14
3.5 Ultromat® Options .......................................................................................................................................................... 14
3.5.1 Storage Compartment Agitator (Agitator 3) ........................................................................... 14
3.5.2 Remote Control ............................................................................................................................................. 15
3.5.3 Overflow Safety Cut-out ........................................................................................................................ 15
3.5.4 Evaluation of After Dilution Unit ....................................................................................................... 15
( 3.5.5 Power Socket for Automatic Hopper Loader ....................................................................... 15
3.5.6 Empty Signal for Concentrate Supply Drum (Ultromat®ATF only) ...................... 15
3.5.7 Liquid Concentrate Dosing Monitoring (Ultromat®ATF only) ................................... 15
3.6 Ultromat® Accessories ................................................................................................................................................ 16
3.6.1 Detachable Hopper; 50 L, 75 Land 100 L .............................................................................. 16
3.6.2 Automatic Hopper Loader for Powdered Polymers ........................................................ 16
3.6.3 BIG-BAG Batching Unit .......................................................................................................................... 16
3.6.4 Step Ladder ...................................................................................................................................................... 16
3.6.5 After Dilution Unit ............................................................................................................ .......................... 16
3.6.6 Lifting lugs ......................................................................................................................................................... 16

4 General Safety Guidelines ................................................................................................................................................. 17

5 Assembly and Installation ................................................................................................................................................. 17


5.1 Installation of the Plant .............................................................................................................................................. 17
5.2 Electrical Installation .................................................................................................................................................... 18
5.2.1 Connecting Mains Supply Cable ..................................................................................................... 18
5.2.2 Opening the Controller (see diagram 4) .................................................................................... 18
5.3 Fitting Options ................................................................................................................................................................... 18

ProMinent® page 3
Table of Contents

6 Controller .......................................................................................................................................................................................... 18
6.1 Design and Function .................................................................................................................................................... 18
6.1.1 Display and Operation Module ......................................................................................................... 19
6.1 .2 Display Supplement (Displays State) .......................................................................................... 19
6.1.3 Operating Elements ................................................................................................................................... 19
6.1.4 Operating State Displays and Plant Operation ................................................................... 20
6.2 Menu System ..................................................................................................................................................................... 20
6.2.1 Menu Layout .................................................................................................................................................... 20
6.3 Operating the Controller - Selecting a Menu Option ......................................................................... 21
6.4 Display Mode ..................................................................................................................................................................... 21
6.4.1 Normal Operation ........................................................................................................................................ 21
6.4.2 Interrupting Normal Operation .......................................................................................................... 21
6.4.3 Identcode Display ........................................................................................................................................ 21

7 Commissioning ............................................................................................................................................................................ 22
7.1 Assembly, Initial Tasks ................................................................................................................................................ 22
7.2 Checking Identcode ..................................................................................................................................................... 23
7.3 Start up Settings ............................................................................................................................................................. 23
7.3.1 Setting Feed Water Minimum Flow ............................................................................................... 23
7.3.2 Setting Feeder Screw Pipe Heater ................................................................................................ 23
7.3.3 Setting Prerinsing Time and Rinsing Delay Time ............................................................... 23
7.3.4 Agitators 1 and 2 .......................................................................................................................................... 24
7.3.5 Agitator 3 ............................................................................................................................................................ 24
7.3.6 Concentrate Pump Minimum Frequency ................................................................................. 24
7.3.7 Change Access Code ..................................,........................................................................................... 24
7.4 Concentration Settings .............................................................................................................................................. 25
7.5 Calibration Settings ...................................................................................................................................................... 25
7.5.1 Adjust Water Flow ....................................................................................................................................... 25
7.5.2 Calibration of Powder Feeder ............................................................................................................ 26
7.5.3 Calibration of Dosing Pump for Liquid Concentrate (Ultromat®ATF) ............... 26
7.5.4 Configuring Dosing Monitor for Liquid Concentrate (Ultromat®ATF) ............... 26
7.6 Service Menu ..................................................................................................................................................................... 27
7.6.1 Flow settings ................................................................................................................................................... 27
7.6.2 Testing agitator and powder feeder .............................................................................................. 27
(
7.6.3 Running Ultromat® empty ..................................................................................................................... 27
7.7 Settings of the frequency converter Altivar 11 ....................................................................................... 28
7.7.1 Function of the controls ......................................................................................................................... 28
7.7.2 Access to the controls ............................................................................................................................. 28
7.7.3 Setting of the parameters ..................................................................................................................... 28
7.7.4 Configuration of Ultromat'" ATF ("Speed controller" control option) .................. 30
7.8 Commissioning ................................................................................................................................................................. 30

8 Operating the Plant .................................................................................................................................................................. 30


8.1 Normal Operation ........................................................................................................................................................... 30
8.1.1 Preconditions for Correct Operation ............................................................................................ 30
8.1 .2 Supplying Dry Feeder with Powder .............................................................................................. 30
8.2 Switching On Mains Power and Mains Power Failure Procedure .......................................... 31
8.3 Emergency Measures .................................................................................................................................................. 31
8.4 Plant Idle ................................................................................................................................................................................ 31

page 4 ProMinent"
( Table of Contents

9 Operational Errors .................................................................................................................................................................... 32

10 Plant Malfunctions/Error Messages - Breakdown Advice ................................................................. 32


10.1 Fault Identification/Malfunctions/Breakdown Advice ....................................................................... 33
10.2 Malfunctions in the Water Inlet Pipe ............................................................................................................... 34
10.2.1 Water In-Flow Malfunctions ................................................................................................................ 34
10.2.2 Water Meter Malfunctions .................................................................................................................... 34
10.2.3 Solenoid Malfunctions ........................................................................................................................... 34
10.3 Powder-Feed Malfunctions .................................................................................................................................... 34
10.4 Malfunctions in the Wetting cone ...................................................................................................................... 34
10.5 Malfunctions in the Storage compartment ................................................................................................ 35
10.5.1 Storage compartment Runs Dry ...................................................................................................... 35
10.5.2 Overflow in Storage compartment ................................................................................................ 35
10.5.3 Contradictory Liquid level Messages in the Storage compartment ................... 35
10.6 Agitator Malfunctions .................................................................................................................................................. 35
10.7 Concentration Errors .................................................................................................................................................... 35
10.8 Error Messages in Initial Start Up ..................................................................................................................... 35
10.9 Hardware Fault Analysis ........................................................................................................................................... 36
10.10 Dilution Faults ................................................................................................................................................................... 36

11 Maintenance ................................................................................................................................................................................... 36
11.1 Inspecting the Dry Feeder and the Wetting cone ................................................................................. 36
11.2 Cleaning the Filter Insert in the Pressure-Reducing Valve ............................................................ 36
11.3 Opening and Cleaning the Solenoid Valve ................................................................................................. 36
11.4 Dismantling and Examining the Flow Meter (turboDOS) ................................................................ 37
11.5 Changing the Mains Power Safety Fuse in the Controller ............................................................ 37
11.6 Removing the Inspection Cover on the Three Compartment Tank ........................................ 37
11.7 Rinsing the Multi-chamber Tank ......................................................................................................................... 37

12 Appendix ............................................................................................................................................................................................ 38
12.1 Declaration of Conformity ........................................................................................................................................ 38
12.2 Assembly Drawing AT 400 ....................................................................................................................................... 39
12.3 Assembly Drawing AT 1000 ................................................................................................................................... 40
12.4 Assembly Drawing AT 2000 ................................................................................................................................... 41
12.5 Assembly Drawing AT 4000 ................................................................................................................................... 42
12.6 Assembly Drawing AT 8000 ................................................................................................................................... 43
12.7 Assembly Drawing ATF 4000 ................................................................................................................................ 44
12.8 Assembly Drawing ATF 1000 ................................................................................................................................ 45
12.9 Assembly Drawing ATF 2000 ................................................................................................................................ 46
12.10 Assembly Drawing ATF 4000 ............................................................................................................................... 47
12.11 Assembly Drawing ATF 8000 ............................................................................................................................... 48
12.12 Programming Menu Ultromati!l AT/ 96 ........................................................................................................... 49
12.13 Programming Menu Ultromati!> ATF/96 ........................................................................................................ 50
12.14 Commissioning Protocol ......................................................................................................................................... 51

ProMinent® page 5
General User Guidelines

General User Guidelines


Please read through the following user guidelines. Familiarity with these points ensures optimum
use of the operating instructions.

Key points in the text are indicated as follows:

• Enumerated points / Hints

Working guidelines:

IMPORTANT
Guidelines are intended to make your work easier.

Safety guidelines:

.,
~ •
. WARNING
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 ProMinent0
Transport and Storage of the Plant I Plant Information

1 Transport and Storage of the Plant


The Ultromat®plant may be moved only when it is em pty and using the correct lifting gear.
During transportation of the tank there should be nothing which might place pressure on the
tank walls. Heavy jolts and bumps should be avoided at all costs. When using fork lifts, use long
forks which extend to the full width of the tank.
If transportation is carried out by crane, even when lifting lugs are attached to the plant, fix the
slings in such a way as to avoid sheering forces at all costs. Sheering forces which act while the
tank is under transportation lead to damage of the tank walls and the welded seams.
Ultromat®models 4000 and/or 8000, if fitted with lifting lugs, can be lifted with a tie-bar only. The
tie bar must be at least 10 - 20 cm longer than the tank being transported.
For transportation and storage of the plant, the surrounding air temperature should be between -
5 °C to +50 °C . The plant should be stored in an area which is dust-free as far as possible, and
protected from rain, damp (no condensing water) and direct sunlight.
Direct sunlight leads to colour changes and distortion and/or tears forming in the coating
material.

IMPORTANT
( The Ultromat®should not be transported in temperatures below -5 °C due to the fact
that cold causes brittleness in the plastic coating, which can lead to damage to the
welded seams, tank walls and strengthening framework.

2 Plant Information
2.1 Applications
The Ultromat®AT/96 is a fully automatic polyelectrolyte preparation plant. It can be used
wherever liquid polyelectrolyte solutions need to be prepared automatically. Its central function,
which is to dissolve solids, makes the plant ideally suited to a variety of technical processing
applications, e.g. in the water treatment industry, waste water treatment and paper manufacture.
Ultromat®ATF/96 can be used with either powdered polyelectrolytes or liquid polymers.

2.2 Capacity
2.2.1 Ultromat® AT/96 (for powdered polymer batching):
The plant is designed for the fully automatic production of polyelectrolyte stock solution. It may
be used for nearly all commercial electrolytes in powder form.
Controlled by the Ultromat®program, concentrations may be preprogrammed within a range of
0.05 to 1.0 %. The viscosity of the polymer solution which is produced must not, however,
exceed the value of 1500 mPas. The instructions concerning viscosity of differing polymer
solutions can be found in the user's data documents from the individual polymer suppliers.
To fully exploit the batching range, it may be occasionally necessary to adjust the flow rate of
the water in-flow. Concentrations above 0.5 % can lead to a decrease in the effectiveness of the
batch capacity.
The maturation period of a stock solution is dependant upon the extraction rate and the
capacity (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 I for the AT 8000.

ProMinent'" page 7
Plant Information

2.2.2 Ultromat® ATF/96 (for powder and liquid polymer batching)


The Ultromat®ATF/96 can be used for the preparation of either powder or liquid polymers.
Ultromat® ATF/96 can be transferred from powder- to liquid-preparation mode using the
key-operated switch in the door of the control cabinet. This deactivates the dry feeder and
activates the concentrate dosing pump. The Ultromat®ATF/96 is also fitted with a dosing tube
for the injection of liquid concentrates. This tube can be fitted optionally with a back pressure
valve and thermal dosing monitor (only with eccentric screw pumps).
Liquid concentrate dosing pumps are supplied with a choice of the following control options:

Control option Description


Speed controller Internal Speed controller varies concentrate pump frequency up
to maximum 0.37 kW. The speed controller can be transferred via
a contactor from the concentrate pump (eccentric screw pump)
to dry feeder and vice-versa. Fitting an external fan will increase
the pump setting range. The external fan can be connected at the
control cabinet. It is not necessary to monitor temperature of
motor coil.
4-20 mA Control of gamma and Sigma pumps via 4-20 mA signal
(

2.3 Ultromat® AT/96 Dimensions

Type dimensions water inlet emptyl overflowl power agitator dry feeder
(mm) nominal opera- connector supply capacity
width tional dimension
weights

AT L = 1770 R 1" 1901 ON 401 1.5 kW 0.18 kW 1.3 - 29 Uh


400 B = 915 590 kg ON 25 750 rpm TO 18.20
H = 1250 IP 55
H1= 516
AT L =2410 R 1" 4001 ON 501 2.6 kW 0.55 kW 1.3 - 29 Uh
1000 B = 950 1400 kg ON 25 750 rpm TO 18.20
H = 1605 IP 55
H1= 866

( AT L =3070 R 1" 4501 ON 501 3.2kW 0.75 kW 1.3 - 29 Uh


2000 B = 1090 2450 kg ON 32 750 rpm TO 18.20
H = 1765 IP 55
H1= 1016
AT L = 3181 R 1%" 6001 ON 651 5.0kW 1.1 kW 6 - 132 Uh
4000 B = 1504 4600 kg ON 40 750 rpm TO 30.20
H =2268 IP 55
H1=1518
AT L =4434 R 2" 12001 ON 801 9.5 kW 2.2 kW 12 - 264 Uh
8000 B = 1910 9200 kg ON 50 750 rpm TO 38.20
H =2350 IP 55
Hi = 1520

page 8 ProMinent®
Plant Information

2.4 Ultromat® ATF/96 Dimensions

Type dimensions water inlet: empty/ overflow/ power agitator concentrate


(mm) nominal operational extraction supply dosing
diameter weights connector tube

ATF L 1770 R 1" 190/ ON 40/ 1.5 kW 0.18 kW ON15


400 B 915 590 kg ON 25 750 rmp
H 1250 IP 55
Hi 516
ATF L 2410 R 1" 400/ ON 50/ 2.6 kW 0.55 kW ON15
1000 B 950 1400 kg ON 25 750 rmp
H 1605 IP 55
Hi 866
ATF L 3070 R 1" 450/ ON 50/ 3.2 kW 0.75 kW ON15
2000 B 1090 2450 kg ON 32 750 rmp
H 1765 IP 55
Hi 1016
ATF L 3181 R 1Y2" 600/ ON 65/ 5.0 kW 1.1 kW ON 20
4000 B 1504 4600 kg ON 40 750 rmp
H 2268 IP 55
Hi 1518
ATF L 4434 R2" 1200/ ON 80/ 9.5 kW 2.2 kW ON 20
8000 B 1910 9200 kg ON 50 750 rmp
H 2350 IP 55
Hi 1520

N.B. power supply is used for device incorporating three agitators.

- - - - - - - - -- - - - - --
,-----"-- -,

.~ .
.~.
(

H1

______ ____,_L-_~~~~~~
:4 ~:
B L

Diagram 1: Ultromat®Dimensions

ProMinent" page 9
Description of Functions

3 Description of Functions
3.1 Plant Construction
All plant parts for powder pre-storage, powder feed , wetting , dissolving and maturing of
polyelectrolytes are assembled together to form a compact unit. The Ultromat® plant consists of
the closed three compartment tank (a), the water pipework (b) with wetting cone (c), the dry
feeder, (d) including a 20 I feed hopper, the agitators (e) and the control cabinet (f). Tanks,
wetting cones and dry feeders are made from PP. There is a choice of PVC or PP available for
the water pipework, fitted with brass mechanismus.

Diagram 2: Ultromat'" AT/96

The seals are made of EPDM. For the treatment of non-alkaline polyelectrolytes, unsaturated
hydrocarbons, which attack these seals, the plant can be fitted with Viton®seals.
The agitator shafts and agitator blades, and the dry feeder conveyor unit are made entirely from
stainless steel.

3.2 Description of Individual Units


3.2.1 Three-compartment Tank
. The closed PP tank unit with agitator tie bars, brackets for the dry feeder and control cabinet,
along with overflow, emptying and extracting connectors, is divided into three separate
chambers. Preparation, maturing and storage compartments guarantee a sufficient time lapse
and maturing period for the stock solution. The division of the tank furthermore prevents mature
solution mixing with freshly batched solution and allows continual extraction.

The liquid level in the storage compartment is monitored by a liquid level sensor. In addition to
the "maximum" and "minimum" contacts which start and/or finish the automatic batching
process, the unit is also fitted with an "empty" contact, which protects the system from running
when empty, and a further sensor to protect against over-fill (over-fill safety cut-out optional).
All inspection openings in the tank are protected by covers which are firmly screwed in position.

page 10 ProMinent'"
Description of Functions

3.2.2 Inlet water system and wetting equipment


The water pipework supplies the plant with the water required to dissolve the dosed powder.
The pressure control valve, which incorporates a strainer, limits and maintains the correct opera-
ting 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.
The wetting cone with mixing appliance, overflow, and level sensors to monitor overflow situat-
ions, maintains the intensive wetting of Polyelectrolyte powder with water. A manually operated
stop valve also allows the water supply to be cut off to allow maintenance work to be carried out.

overflow sensor r"=''-----.

C Iwetting cone

stop valve

Diagram 3: Water Apparatur with wetting cone

3.2.3 Powder Feeder


Further information about the construction and operation of the feeder may be found in the
appendix of the separate Operating Instructions Manual. Feeder screw pipe back-stop flap,
feeder screw pipe heater and the minimum fill level sensor for the dry feeder are standard
Ultromat®treatment plant components. The frequency to the feeder is changed to give quantity-
proportional dosing of polyelectrolyte powder to water.

A stable protective screen made from PP protects and surrounds the feeder and the
mixing equipment.

3.2.4 Agitators
The Ultromai® is fitted with two electric agitators. A third agitator can be optionally supplied for
the storage compartment. The agitators ensure adequate circulation of the solution in the
storage compartment. A single controller controls the agitators in both the preparation and
maturing compartments.

WARNING
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.

3.2.5 Control Cabinet


All the electrical control and command equipment required to operate the plant, in particular the
controller for the Ultromat®and the frequency inverter which controls the dry feeder, are located
inside the control cabinet, next to the mains supply circuit and the safety fuses. The Ultromat®
ATF control cabinet is also fitted with a key-operated switch for selecting powder or liquid
preparation modes.

ProMinent" page 11
Description of Functions

3.2.6 Ultromat EA assembly

~1_1_____x 1_2____1~21 ~

H9 H10H11 @
• < Empfindlichkeit >to

~~
LSAHH . H5
~~
EE8
1 K2

H6 H7
K3

H8
H2 H4
••••
H1 H3

16 ~
X19

P1 P2
LSH
LSL
•• H1 2
H1 3 LSH
LSAHH • H1 4
• H1 6
LSALL . H15 P3 P4 LSL • H1 7
2A3 LSALL • H1 8 X18

H1 9 -
• 11
X14
12 1
-
1
16

EJ ErEn:J~'B~B~B~' •••••••
H26 H27 H28 H29 H30 H31 H32 X17

X20 1 X20 I
X20 1 X20 1 X21 X21 X21 I I 1
X15 X16
121~
I1415 89 121131 611 4 5 8 9 12
1
12111

Diagram 4

The Ultromat-EA assembly is a compact function unit assembled on a circuit board.


It performs the following functions:
• Power supply unit 24 VDC, 500 rnA
• Relay for coupling the output signal (250 VAC, 3A)
• Optical isolator for disconnecting the input signal
• Liquid level relay for evaluation of the conductive liquid level electrodes

Output relay:
The switch status of every relay is displayed via a LED. The LED is lit if the relay contact is
made.

Relay LED Function


K1 H6 Alarm
K2 H7 Audio signal
K3 H8 Not used
K4 H9 Agitator 1 and 2
K5 H10 Agitator 3
K6 H11 Powder/liquid switch over
K7 H2O Heater
K8 H21 Closing cap TGD
K9 H22 Solenoid valve, water
K10 H23 Drainage (run dry)
K11 H24 Opertation
K12 H25 Alarm (parallel K1)

Setting the sensitivity of the liquid level relay:


The sensitivity of the liquid level relay can be adjusted with the potentiometers P1 and P2.
If the conductivity of the water for dilution falls, the sensitivity of the liquid level relay must
be increased . To do this, turn the potentiometers P1 and P2 to the right with a screwdriver.
Potentiometer P1 is responsible for the overflow level (LSAHH) and potentiometer P2 for the
minimum and maximum (LSALL, LSL and LSH) run dry levels. The potentiometer has a 15 -turn
( setting range.

page 12 ProMinent"
Description of Functions

The liquid level switching status is displayed via LEOs.

LED/liquid level Liquid level undershot Liquid level exceeded


H 5 (LSAHH) LED on LED off
H 12 (LSH) LED off LED on
H 13 (LSL) LED off LED on
H 15 (LSALL) LED off LED on

LED for displaying signal status:


The LEOs indicate the internal signal status of the Ultromat-EA assembly.
The meanings are given in the table below: :

LED Label LED lit:


H1 FLKok Liquid concentrate pump OK
H2 RWok Stirrer assemblies OK
(
H 26 Powder > min Power equipment present
H 28 Flow ok Fluid concentrate flow OK
H 29 Dilution on Post dilution switched on
H 30 Post dilution ok Water flow post dilution unit OK
H 31 FLK> MIN Liquid concentrate supply present
H 32 Remote control on External switch actuated
H5 Liquid level < LSAHH No overfilling
H 12 Liquid level > LSH Liquid level exceeded
H 13 Liquid level> LSL Liquid level exceeded
H 15 Liquid level > LSALL Liquid level exceeded
H 19 Frequency converter Frequency converter OK

Spare parts for the ULSA signal splitter:


Description Order no.:
F1 Fuse, 160 mA, T, 5x20 712048
F2 Fuse, 0,63 A, T, 5x20 712030
K1-K12 Relay, 250 VAC, 3 A 711340
2A3 Ultromat-EA assembly
(ULSa signal splitter el. assembly) 731049

3.2.7 Concentrate Pipework (ATF/96 only)


The Ultromat®ATF is fitted with the following pipework for delivery of liquid concentrates to the
batching compartment:

Type Large tubes Hose nozzle Options


ATF 400 ON 15 ON 15 flow monitor
non-return valve
ATF 1000 ON15 ON15 flow monitor
non-return valve
ATF 2000 ON 15 ON15 flow monitor
non-return valve
ATF 4000 ON 20 ON 20 flow monitor
non-return valve
ATF 8000 ON 20 ON 20 flow monitor
non-return valve

ProMinent" page 13
Description of Functions

3.3 Plant Function


The in-flow of the water is automatically turned on or off according to the operating state, by a
solenoid valve. A turbine counter continuously tracks and monitors the flow of water through the
plant. The dry feeder conveys the polyelectrolyte powder in proportion to the flow of water.
The powder falls into the wetting cone where it is wetted evenly by a partial flow of water. This
ensures that the dosing powder is prevented from forming Into lumps. The main flow of water is
administered by means of a mixing plant and creates light pressure at the hopper outlet. Once
there, an agitator completes the dissolving process to produce a solution. From the preparation
chamber the solution flows past a weir into the maturing chamber and finally reaches the
storage compartment after it has spent sufficient time maturing.
The solution in the chamber is ready to use and can then be extracted. The division of the tank
prevents, to a great extent, the matured solution from mixing with the freshly batched solution .

In order to prevent powder deposits from the wetting cone from entering the tank, even at the
start of the batching process, the activation of the dry feeder is controlled by a timer, rather than
by a solenoid valve, i.e. before the dry feeder starts to run, water flows in for a few seconds.
At the end of the batching process the opposite procedure takes place. When the maximum
level is reached in the storage compartment, the dry feeder is immediately switched off, but the
water continues to flow through for a few seconds more.
(
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.

3.4 Operating Methods


3.4.1 Preparation Operation
Once the minimum liquid-level in the storage compartment is reached, the Ultromat®starts the
batching process. The solenoid valve opens, and after the pre-rinse period the dry feeder
commences feeding powder. When the maximum liquid-level is reached , the controller switches
off the dry feeder and then closes the solenoid valve after the post-rinsing period.
The Ultromat® switches to "batching" mode.

3.4.2 Settings Configuration Option


All the necessary configurations required to commission the machine are entered when the
machine is in settings mode. In this mode, the controller deactivates any functions which might
interfere with settings. When calibrating the dry feeder, a process which involves dismantling the
wetting cone, the water supply solenoid valve remains closed. Feed can be activated and
stopped independently of water flow. The dry feeder remains switched off while water flow rate
( is configured .

3.4.3 Remote Control Option


The plant can be activated or stopped from a remote centre by selecting the "remote control"
option. The batching process is still carried out fully automatically, when plant is activated via
remote control. The configuration and display of the operating parameters are carried out on
site.

3.5 Ultromat® Options


There is a range of options available for the Ultromai® to improve plant efficiency.

3.5.1 Storage Compartment Agitator (Agitator 3)


The Ultromat®AT is supplied with two electric agitators. A third agitator for the batching
chamber can be supplied as an option.

page 14 ProMinent"
Description of Functions

3.5.2 Remote Control


Operating or stop states can be controlled via remote control. Ultromat®can be activated or
stopped using an external switch.
Operating signals are transmitted via a dry contact. The signals are as follows:

contact closed:
• Plant is operational
• 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.

3.5.4 Evaluation of After Dilution Unit


The after dilution unit is used to further dilute the batched polymer solutions. The polymer
solution is pumped out of the Ultromat® storage compartment into the after dilution unit.
A solenoid valve introduces dilution water into the unit. A flow meter, connected
downstream, with a low-flow contact, monitors the dilution water.
The "dilution unit values" option checks the rotameter minimum-liquid-levels contact. If the
min. contact indicates lack of water, Ultromat® operation is interrupted, and the discharge
pump
(polymer solution) is paused. The Ultromat® is fitted with a dry contact for control of the
discharge pump (discharge pump release). This contact is closed when liquid-levels in the
storage compartment reach "minimum liquid-level". It opens when liquid-levels fall below
the "minimum liquid level" once more. The discharge pump is normally controlled via an
external switch (motor start combination). As the discharge pump may be switched on and
off externally, there is an additional input on the Ultromat controller to detect signals from
the starter motor (dry auxiliary contact). The min. contact on the rotameter is only detected
when the discharge pump is running, closing the dry auxiliary contact on the starter motor. If
the discharge pump is not running, the dry contact is not closed and there is no detection of
min. contact on
the flow meter.

3.5.5 Power Socket for Automatic Hopper Loader


For connection of a conveyor unit the Ultromat®can be fitted with a power socket, including
an overload safety cut-out. This is fitted to the side of the control cabinet.

3.5.6 Empty Signal for Concentrate Supply Drum (Ultromat®ATF only)


The "concentrate drum empty" signal-option contains a sensor which can be located on the
outside of plastic hoppers. If the drum is metallic, this kind of sensor cannot be used. In this
case, a floating sensor may be introduced into the drum from above.

3.5.7 Liquid Concentrate Dosing Monitoring (Ultromat® ATF only)


The Ultromat®ATF/96 can be used either with liquid or powdered polymers. In "liquid"
preparation mode a pump injects the concentrate into the Ultromat® batching compartment.
Dosing monitoring can be carried out with eccentric screw pumps only.
The dosing monitor consists of a flow adapter and a thermal flow sensor. To set flow monitor
configurations select "set dosing monitor" settings menu.

ProMinenl® page 15
Description of Functions

3.6 Ultromat® Accessories


The following accessories are available for the Ultromat®AT/96 and ATF/96.

3.6.1 Detachable Hopper; 50 L, 75 Land 100 L


To enable operators to increase supply of dosing powder, detachable hoppers with
additional capacities of 50, 75 and 100 L are available.

3.6.2 Automatic Hopper Loader for Powdered Polymers


We supply a pneumatic conveyor unit for automatic filling of powder feeder hopper.
The conveyor unit can be connected straight to the powder feeder using an adapter.
A 50 L detachable hopper with connector adapter is recommended for the short periods when
the conveyor unit is being serviced.

3.6.3 BIG-BAG Batching Unit


A range of designs is available to suit different requirements. The special BIG-BAG feed station
is designed for use with the small conveyor unit, and a special cover attachment is available for
direct feed of extension hoppers.

3.6.4 Step Ladder


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.

3.6.5 Dilution Unit


As the Ultromat® plants can operate with highly-concentrated solutions, in many cases it is ap-
propriate to treat highly concentrated stock solutions by a dilution process. Polyelectrolyte
solutions with a higher concentration last longer, and so a dilution station connected
downstream increases the dosing and extraction capacity of the plant. Care must be taken,
however, that the viscosity of the stock solution does not exceed a value of
1500 mPa. The dilution stations, which are supplied as complete units, have been designed
specifically to fit the dimensions of the equipment, and for a dilution-lo-volume ratio of 1 : 5. A
choice of models is available.

3.6.6 Lifting lugs


4 lifting lugs facilitate securing and manoeuvring of plant.
(

page 16 ProMinent"
General Safety Guidelines

4 General Safety Guidelines

WARNING
The plant delivered is constructed to generally recognised technical
standards and is safe to operate as long as specified safety guidelines are
observed. When working with Ultromat® plant, however, there are certain
safety aspects which you must be aware of. These are given below.

• Throughout all installation and maintenance work, the plant must be disconnected from
the power supply. Measures must be taken to ensure that no unauthorised personnel
can interfere with the plant during this time. This applies especially for work on electrical
circuitry. The control cabinet must be kept locked at all times. Danger of Death!
• All work on the Ultromat®plant must be carried out by trained specialists only.
• For safety reasons the operation of the plant may only be assigned to persons who are
familiar with its function and who have been instructed correspondingly.
• The tank cover, which is screwed on and which covers the inspection openings, may
only be removed for maintenance purposes. On no account remove the cover and reach
( inside the tank chambers while the plant is switched on. The agitators may start to run
unexpectedly. Danger of Injury!
• Each time plant is connected to mains power, or when power is restored after a mains
power failure the agitators will automatically restart.
• Spilt polyelectrolyte powder or, occasionally polyelectrolyte solution spillages, are to be
removed immediately from the surrounding area - increased danger from
slippery surfaces!
• The warning notices attached to the plant must be observed.

WARNING
Individual re-fitting and alterations to the plant are not permitted and the
manufacturers will not be held responsible for any damage resulting from
such actions. 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.

5 Assembly and Installation


The plant is completely assembled by the manufacturer and undergoes function-testing prior
to delivery. The cabling between the control cabinet and the electrical units is connected
and ready for operation.

5.1 Installation of the Plant


For the plant installation a fixed (concrete) flat floor area must be available, which will
accommodate the dimensions and the operating weight of the plant. Furthermore, care must
be taken to ensure that the plant is easily accessible at all times for operating, maintenance
and filling with powder. The permissible surrounding temperature ranges from 5 °C to 40°C.
The plant must not be placed in direct sunlight. When connecting with water supply,
overflow and drainagepipes make sure dimensions are correct. Overflow and drainage pipes
should be fitted with gradients and must be able to operate without back-pressure.
The water must be of potable quality. It must be free from mechanical impurities and sus
pended particles.
The incoming water pressure must not be less than 3.5 bar, and not more than 6 bar.

ProMinent" page 17
General Safety Guidelines / Controller

5.2 Electrical Installation


The electrical installation must be carried out by a qualified electrician.

WARNING
The plant must be disconnected from power throughout all installation and
maintenance work. Measures must be taken to ensure that no unauthorised
personnel can switch on the plant during this time.

5.2.1 Connecting Mains Supply Cable


Connecting the mains supply cable must be carried out exactly in accordance with the circuit
diagram (in the control cabinet pocket). The mains cable is passed through a corresponding
opening in the control cabinet and connected correctly to the terminal block provided.
When connecting the electrical unit always pay attention that terminals are correctly arranged
and that the direction of rotation of the motors (agitators. dry feeder) is correct.

5.2.2 Opening the Controller


(
WARNING
Before opening the controller, ensure that the plant is not connected to the
power supply.

• To open the plastic housing, first of all remove the four countersunk screws in the corners of
the cover. The upper section is attached to the lower section by additional snap hooks.
• The snap hooks can be released by exerting pressure downwards onto the upper edge of
the cover using the index fingers, and simultaneously pulling forwards a little. Then the
whole upper section can be drawn forwards.
• Warning! Upper and lower sections must be separated carefully as they are connected to
each other by a short ribbon cable!
• Now the upper section can be placed in the 80 mm high insert using the two gUide-rails.
In this "parked state" all connector terminals and safety fuses are freely accessible.

5.3 Fitting Options


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.
(

6 Controller
6.1 Design and Function
The Ultromat®controller is housed in a rugged self-contained plastic housing (for installation into
electrical control panel, protection system IP 54). It combines the relevant microprocessor
controller and its terminal board with the necessary connector terminals, the mains connector and
the safety fuses along with all the insertion cards for inputs and outputs.

All information necessary for operating the plant, such as error messages, warnings and values,
along with the entire menu system, is displayed according to precedence on a two row LED
display.

Malfunctions due to power failures and electrical overload are prevented by a number of safety
measures. All stored parameter and configuration data is protected from breaks in the power
supply.

page 18 ProMinent®
Controller

6.1.1 Display and Operation Module

'+ =e001a ~l2l00 010 0 0010 @bJO ':f


1+2 3
La L4 l5 L6 L7 La L9 L10

l£ [ Ultromat AT I
@) O Ll1 @ I Cone
Feed
. 0 .11 %
=1277 lJh
I~ L2
(@)
TEST·KEY CHANGE- ENTER- CONFIRM key
key key

@)~@) ~
Ll

DOWN· BACK- UP·


key key key

@ I I @

Diagram 5: Control Panal,Ultromat" Controller

6.1.2 Display Supplement (Displays State)


L1 green LED displayed plant in operating state
LED off plant in stopped state
L2 red LED displayed malfunction (flashing light)
warning (continuous light)
L3 green LED displayed controlling feeder screw pipe
L4 green LED displayed controlling dosing (dry feeders for AT design
and/or concentrate pump for ATF option)
L5 green LED displayed controlling water in-flow
red LED displayed flow below set minimum flow
L6 green LED displayed controlling discharge pump (stock solution)
L7 green LED displayed controlling agitators, chambers 1+2
La green LED displayed controlling agitator, chamber 3 (option)
L9 red LED displayed powder low in dry feeder
L10
L11 green LED displayed functioning only in calibration mode and
in test modes
LCD display 2 lines, max. 16 characters each

6.1.3 Operating Elements

start/stop key switch Ultromat® into operating or stopped states


confirm key confirms an alarm warning
test key start/stop button for calibrating dry product metering hopper, liquid
concentrate pumpe, water feed setting and monitoring facility, test facilities
enter key saves a value, jumps to next menu point
change key change in the menu
down key alters numerical value
back key goes back in menu
up key alters numerical value
siren key separate key in door of control cabinet to cancel alarm
(does not confirm alarm!)

ProMinent® page 19
Controller / Commissioning

6.1.4 Operating State Displays and Plant Operation


• The Ultromat® is switched on and off using the main switch located on the side of the
control cabinet.
• Once switched on, the plant may be in the operating state (L1: green LED on) or in stopped state
(L1: red LED on). To stop and start the operating processes use the STOP/START key.
• A dry remote contact can be used to switch the Ultromat®into the stop state (only for
models fitted with "remote control" option). When operating process is stopped by remote
control, "F:!emote control, PAUSE" appears on the LCD display.
• The test key is used during the calibration procedure, to start or stop an action. Whenever
the test key should, or may be pressed during calibration, the LED (L11) will flash. Triggering
an action using the test key causes a green LED (L11) to light up, and it remains on
continuously until the action ceases.
• The red "Alarm" indicator (L2) is located next to the "Confirm" key. During normal operation
it is off. If a malfunction occurs, however, it flashes until the malfunction is corrected and the
error message is confirmed. Acknowledging the error removes the error message and turns
off LED. If there is more than one malfunction present, all texts will be displayed in turn, for
approximately two seconds each.
• The alarm siren is deactivated using the separate "Siren off" key in the front door of the
control cabinet. This does not deactivate the current alarm.
• Powder and liquid operating parameters are stored separately in the Ultromat®ATE Change
from one operating mode to the other by selecting "powder" or "liquid" using the keyoperated
switch in the door of the control cabinet. Prior to this, disconnect Ultromat®from the power
supply. 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.

6.2 Menu System


6.2.1 Menu Layout
The menu is divided into display level and settings level. In the display level, the operating state
of the plant alarms is displayed. In the settings level, the parameters for the control of the plant
can be altered, and calibration carried out (see also section 12.7 "Programming Menu").
If desired, the controller automatically changes the settings menu back to the display menu
after 10 minutes.
Display Menu

Access Code

Set Set
language
• • Concentration
water in-flow
Water in-flow, Calibrate
• minimum flow • dry feeder
Heating Calibrate
• on/off-times • concentrate pump
Water in-flow (pre/ Set
• post rinse period) • dosing monitoring
Agitators 1+2
• on/off times

Agitator 3
• on/off times
Concentrate •
• pump minimum
frequency

Change
• access code
Diagram 6: Menu Structure
page 20 ProMinent'"
Commissioning

6.3 Operating the Controller - Selecting a Menu Option

Enter key
To confirm and/or save a displayed value or setting

Change key
To change displays within a menu level

Back key
Goes back to the previous level, while in the operating menu.
The steps appear in the order given in the previous diagram.

Press Enter key to change from the display menu to the settings menu. Press Enter again, and
then enter access code (factory setting 1000). Then use "Change" key to toggle between
"Settings Start Up", "Settings Calibration", "Settings Concentration" and "Settings Service".
All the menus which follow may be selected by using the Enter key.
The entry of a value or parameter is carried out using the arrow keys " Decrease Value" and
"Increase Value" . Generally the last value that was set is displayed. A new value can be entered
( over this one. 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.

6.4 Display Mode


6.4.1 Normal Operation
The following messages appear in the controller display during batching operation:

making-up stock conc. =X.X %


feed = xxx L/h feed = xxx L/h

Once maximum liquid-level in the storage compartment is reached, the following messages
appear on the controller display:

stock full conc. = x.x %


discharge stock discharge stock

6.4.2 Interrupting Normal Operation


USing the Start/Stop key will stop and/or start normal operation. In the stop state the following
message will appear on the display:

stop
feed = 0 Llh

If the stop signal is a remote-control input, then the following message appears on the display:

I remote PAUSE

6.4.3 Identcode Display


Press the Change key to display the Identcode "ULSaTxxxxxxxxx" (as shown in the second
row of the controller software version (e.g. :02/4.1) and the operating mode, e.g. "Fluid" (F) or
Powder"T".
In case of claims and customer service requirements for operational malfunctions these codes
must be given to ProMinent Dosiertechnik GmbH.

ProMinent" page 21
Commissioning

7 Commissioning
7.1 Assembly, Initial Tasks
During assembly it is absolutely essential that the handling and positioning instructions given in
sections 1 and 5 are followed correctly. Make-up water, extraction and overflow pipes must be
connected up and checked to ensure they are water tight and in working order.
It is additionally necessary to connect the liquid concentrate supply pipe for Ultromat®model ATF.
Before starting up for the first time, mechanical and electrical connections must be checked
thoroughly to ensure that they are correctly connected up (e.g. motor rotation direction, power
supply etc.).
It must be ensured that the voltage, frequency and current going into the control cabinet comply
with the instructions given on the nameplate (on the right-hand side of the control cabinet).
Powder should be available in ready quantities and meet the required quality standards.
After switching on the main switch , the LCD displays the message "Stop feed = 0 L/h".
If a different message appears, use the Start/Stop key until the Stop message appears. When
using remote control option you may see "Remote PAUSE" on the display. In this case the plant
must be released from central switching station control.

7.2 Checking Identcode


Use the change-key in display mode to change to the Identcode display. Press the change key
again to return to normal operating display.

ULSA X X X X X X X 0 X X
I
I Remote control:
Model:
0= none
T = AT
1 = yes
(powder)
L = ATF
(Vario 4-20 mAl Re-dilution detector:
M= ATF
0= none
(speed controller)
1 = yes

Capacity range:
3rd Agitator:
0 = 400 Uh
0= none
1 = 1000 Uh
1 = yes
2 = 2000 Uh
3 = 4000 Uh
4 = 8000 Uh Overflow Safety Cut-Out:
0= none
Dosing monitoring: 1 = yes

0= none
Language:
1 = of liquid concentrate
D= German
E= English
Flow monitoring (water in-flow): F= French
0= turbine 67 imp.lL P= Polish
1= 10 pulseS/litre C= Czech
2= 1 pulse/Litre N= Dutch
3= 0.25 pulse/Litre H= Hungarian
i= Italien
Dlagramm 7. Identcode

page 22 ProMinent"
Commissioning

7.3 Start up Settings


Plant is supplied with the following default settings, which are accessed from the "settings
start up" menu:

Parameter Default values Range


Language D D, E, F, P, C, N, H
feed water minimum flow
AT 400: 5001/h
AT 1000:
AT 2000:
AT 4000:
AT 8000:
Heating on-time
12001/h
24001/h
50001/h
100001/h
5 sec.
} o - 12.000 I/h

1 - 10 sec.
Heating off-time 35 sec. 30 - 100 sec.
Prerinsing time 7 sec. 0- 30 sec.
Rinsing delay 5 min. 0- 30 min.
Agitator 1+2 on-time 15 min. 5 - 50 min.
Agitator 1+2 off-time 15 min. 5 - 50 min.
Agitator 3 on-time 5 min. 0- 20 min.
Agitator 3 off-time 10 min. 5 - 50 min.
Concentrate pump min. frequency 25 Hz 0- 50 Hz
Change access code 1000 1000 - 9999

Values are adapted to process requirements during commissioning .

7.3.1 Setting Feed Water Minimum Flow


If water volume falls due to pressure drop in the water supply, the water level in the wetting cone
falls. The water volume must be above 80 % of the set water in-flow quantity, to ensure there is
sufficient water entering the wetting cone. Too little water may cause dosed powder to clog the
wetting cone and interrupt the batching process.
Select "minimum flow" using Enter key and use up/down keys to raise/lower the value.

7.3.2 Setting Feeder Screw Pipe Heater

( Select "Heating on-time?" by pressing Enter key again. Click Enter key repeatedly until the
actual on time is displayed. Use up/down keys to increase/reduce time period.
Confirm with Enter key.
Alter/set off-time in the same way.

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.

7.3.3 Setting Prerinsing Time and Rinsing Delay Time


To prevent dosing powder adhering to the inside of the wetting cone, prerinsing and delay
periods can be programmed into the batching water flow. This ensures sufficient rinsing at either
end of the process.
After the solenoid valve opens, water flows for a few seconds until the wetting cone has been
rinsed sufficiently. After the prerinsing peri od is complete the flow rate should have levelled out
and the inside surface of the wetting cone should be completely wet.
Once the maximum level in the storage compartment has been reached, the dry feeder is
switched off. The solenoid valve is closed once the delay period has elapsed. The delay period
should be long enough to ensure sufficient rinsing of wetting cone.

ProMinent® page 23
Commissioning

7.3.4 Agitators 1 and 2


The agitators are automatically re-activated each time a new batching process begins. After the
maximum liquid-level has been reached in the third chamber the two agitators continue to run
for a pre-set period in pulse/pause mode.
Select menus: "Agitator 1+2 on-time" and "Agitator 1+2 off-time". Click on Enter and then use
Up/Down keys to alter values. Press Enter again to relay the new settings to the controller.

7.3.5 Agitator 3
The third agitator starts automatically once each batching process has commenced and runs in
pulse/pause mode. The choice of appropriate on-off intervals results in effective mixing without
damaging the matured macro-molecules.

7.3.6 Concentrate Pump Minimum Frequency


The "Concentrate pump min. frequency" parameter is only applicable for models, where the
concentrate dosing pump is controlled via the speed controller. During batching, frequency must
not fall below the speed controller minimum frequency.
At slow motor speeds the cooling effect of the fan on the motor coil is greatly reduced. This can
cause irreparable damage to the motor. Set the minimum permissible motor frequency when
pumps are not fan-cooled.
Where fans are fitted, the "Min. frequency" can be set to approx. 0 Hz. This greatly increases
the pump frequency-range.

7.3.7 Change Access Code


Select the final settings-menu: "Change access code" to alter the four-figure default access
code. Keep new code in a safe place.

;~~, .m:fuu:~:
j
: :I
~~~:~I~i.11~~ve, :: .• mu"
"

--r
: ! m • • m •••••••••• m u mm m ••••• ••
'

fuu:1f f~:~, lu~J~;o;tnuuunnnncT


1

Powder 0"
feeder

: Off.
-: , on.time • II- t

Innnul Inne. (5·50 min.) ~


~,..",., :UUUUI i
f -
:unu
Agitator 3

f
I . Innn I Innni
, o n-time
(020
I

. ) ..-
m"
~ I-time :
, (5·50 min.) : -

---+: f-time :..-


(5·50 min. ) ,

Diagram 8

page 24 ProMinent"
Commissioning

7.4 Concentration Settings


The Ultromat®can operate with liquid concentrates of 0.05 % to 1.0 %, as long as polymer
solution viscosity does not exceed 1500 mPas.
To set concentrations of less than 0.1 % and greater than 0.5 % the required concentration must
be achieved by correctly configuring the batching water flow. If plant operates 'at concentrations
of less than 0.1 % and greater than 0.5 %, plant capacity is reduced.
Select SUb-menu "Settings concentration" using Enter key. "Concentration" appears on the
display. Select the required concentration using the up/down keys.

7.5 Calibration Settings


The calibration menu appears only, when Ultromat® is stopped using the Stop key.
Select from the following configurations:

Calibration settings applicable Models where applicable Operations where


Set batching water in-floW AT and ATF Powder and liquid
Calibrate dry feeder AT and ATF Powder
Calibrate concentrate pump ATF Liquid
Set dosing monitor ATF Liquid

7.5.1 Adjust Water Flow


The flow of feed water should be adjusted as follows:

Ultromat® Waterflow
AT 400, ATF 400 15001/h
AT 1000, ATF 1000 15001/h
AT 2000, ATF 2000 30001/h
AT 4000, ATF 4000 60001/h
AT 8000, ATF 8000 120001/h

• In "Adjust water flow" menu, select "Water flow" using enter key. LED next to the Test key
on the control panel flashes
• Remove caps on both the regulating valves.
• Click on test key in the appropriate menu option. Solenoid valve opens and the current flow
is displayed.
• Use a large screwdriver (min. 10 mm) to adjust water-flow setting at the left-hand
adjustment T-piece (smaller set value). Water level in the wetting cone should level out at
approximately 15 to 20 mm below the overflow pipe outlet. Once a stable water level is
reached, the required water-rate is set at the right-hand regulator valve (larger set value).
The current flow can be read off the controller display.
• Once the operating state is stabilised, it may be necessary to re-regulate the water-flow to
the wetting cone, in order to ensure adequate rinsing.
• Press the T key once more to end settings procedure.

ProMinent® page 25
Commissioning

7.5.2 Calibration of Powder Feeder


• Unscrew and remove wetting cone.
• In the "Calibrate powder feeder" menu select "Powder feeder" using Enter key. LED next
to test key flashes.
• 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.
• Weigh collected powder and program the controller with the weight in grams using the
up/down keys.
• After pressing the Enter key the controller calculates the dosing capacity in grams/minute
and saves the value.
• After calibrating the dry feeder, reassemble the wetting cone.

7.5.3 Calibration of Dosing Pump for Liquid Concentrate (Ultromat® ATF)


• Determine unladen weight of the collector tank.
• Open feeder screw pipe.
• In the "Calibrate concentrate pump" menu, select "concentrate pump" using Enter key.
LED next to test key flashes.
• Press the Test key to start the concentrate pump. The concentrate enters the collector tank.
• Press the Test key again to stop the pump. Weigh polymer quantity collected and program
the controller with the weight in grams using the Up/Down keys.
• Pressing the Enter key instructs the controller to calculate the dosing capacity in
grams/minute and saves the value.

7.5.4 Configuring Dosing Monitor for Liquid Concentrate (Ultromat® ATF)


DOSing monitoring is only applicable for models including "frequency inverter" option,
controlling eccentric screw pump. It is not applicable for "4-20 mA" models.

Control option Pump Dosing monitoring


Speed controller • Eccentric screw pump yes
4-20 mA • gamma/ L no
• Sigma

• In "adjust flow control" menu, select "flow control" using Enter key. LED next to test
key flashes.
• Use arrow keys to select about 10 % less than the minimum flow value. Press Test key to
start concentrate pump.
• Push button on flow monitor to activate the "learn" process.
• Stop pump using test key.
• Press Enter to end configuration process.

Remark:
Minimum flow limit-values are set depending upon "Minimum frequency" parameters. To set low
flow-limit values, the minimum frequency in the "Concentrate pump minimum frequency" menu
must also have been re-set to a correspondingly low value. Once flow monitor has been
configured, the concentrate pump minimum frequency is readjusted to its previous value.

IMPORTANT
The concentrate pump minimum frequency must be re-set to 25 Hz, after configuration
of dosing monitoring. Lower values will cause irreparable damage to pump motor.

page 26 ProMinent"
Commissioning

7.6 Service Menu


7.6.1 Flow settings
The "flow setting" menu is required when the turboDOS or the contact water meter fails. Until
these functions are restored the Ultromat®can be operated in emergency operating mode. As a
flow meter no longer delivers a signal, a fixed value is entered in the "manual flow input" menu.
As a batch is processed the controller no longer obtains the flow values from the flow meter.
It refers instead back to the fixed value. The fixed value input must naturally correspond to the
previous intake value. 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".

7.6.2 Testing agitator and powder feeder


The agitator and powder feeder can be switched on and off manually. Select the corresponding
menu and press the T key.
The following menus are available
• Test agitator 1+2
• Test agitator 3
• Test powder feeder

7.6.3 Running Ultromai® empty


The "empty running" menu prevents a new batch from being processed in the Ultromat® and
enables the booster pump (transfer pump) connected downstream to continue to run until
material contents have dropped below the empty level.
Select the "empty running" menu option to activate the function and press the T key.

Warning:
dry running protection
out of service

ProMinent" page 27
Commissioning

7.7 Settings of the frequency converter Altivar 11


7_7_1 Function of the controls

• Exit of a menu or parameter or


return from the displayed value

'---_----'I,~-
to the last saved value • Three 7-segment displays

~ 8~---
• Call up of a menu or a parameter
or saving of the parameter or

~
displayed menu

• Change to the previous


menu or parameter or • Change to the next menu or
increase of the displayed value parameter or decrease of the
displayed value

7.7.2 Access to the controls

00
Shows the state ~xx ~
of the frequency converter
00 8
r--t; Fr---i - = - - 1
L ___ • ___ -,
I

0i0
I 8
Menu : Motor control

Menu: Application functions Menus

Menu: Monitoring

7.7.3 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)
This parameter is only displayed at first switching on.
It can, however, be changed any time in the menu. 50/60
ACC 0,1* Ramp-up time (s) 0,1 - 99,9 s
dEC 0,1* Run-down time (s) 0,1 - 99,9 s
LSP 0,0 Low speed at 4 rnA (Hz)
HSP 100* High speed at 20 mA (Hz)
ItH 1,5* Thermal motor protection (A) 0-3,1
SP2 10 2: preselection frequency (Hz) 0-200
SP3 25 3. preselection frequency (Hz) 0 - 200
SP4 50 4. preselection frequency (Hz) 0-200
Alt/ ACT 4A* Configuration analoque input (4-20 mAl

page 28 ProMinent®
Commissioning

Parameter "dre":
Parameter Value Description Range
UnS 230 Nominal motor voltage (rating plate) M 100 - 500
FrS 50 Nominal motor frequence (rating plate) (Hz) 40 - 200
StA 20 Stability of the frequency controller (%) 0 - 100
FLG 20 Gain of the frequency controller (%) 0-100
UFr 50 Ri compensation (%) 0 - 200
nCr 1,5' Nominal current fo the motor read from the rating plate 0,5 - 3,1
CLI 1,5' Motor limiting current 1,0 - 3,1
nSL 0' Slip compensation (Hz) 0-10
SLP 0' Slip compensation (%) 0 - 150
COS 0,78' Cos <p of the motor (rating plate) 0,50 - 1,00

Parameter "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 LlA
Lib no Assignment of the input Lib
tLS 0,0
PI no
rSF no Re-start at failures
rP2 Second ramp
LI . no Assignment of the input to control the second ramp
LC2 2. Curent limitation
Ll1 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
dO Analoque 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 inactiv
rEC Call up saved configuration
Inl The factory-set defaults become the current configuration

Note: (' ) These settings deviate from the values which are entered as defaults after returning to the factory-set values via the
parameter >FCS=lnk.

ProMinent® page 29
Commissioning / Operating the Plant

7.7.4 Configuration of Ultromat® ATF ("Speed controller" control option)


After selecting "Liquid" operating mode, "Thermal motor protection = ItH" parameter must be
adjusted to correspond to Iquid concentrate pump. The "HSP = high speed at 20 rnA"
parameter must not be changed in liquid mode, as the speed controller is controlled by 4-12 rnA
current signal. Maximum frequency is 50 Hz.

7.8 Commissioning
Assuming set-up and installation have been correctly carried out, the three inspection openings
are closed firmly and the feed hopper is filled with the appropriate dosing powder. After setting
all operational parameters and completing calibration the plant can be started up.
Press the Start/Stop key to set the plant running. The plant commences operating and the
automatic batching process will begin. During this first phase the plant must be monitored
carefully. Check particularly that the level sensors are functioning correctly the first time a
controlling position is reached.
The error message "Storage tank empty" is unavoidable at this stage, as all compartments are
empty. This error message must therefore be confirmed.

NOTICE
Before starting the batching process the operating personnel must ensure that
the emptying valves for the preparation and maturing chambers are closed.

8 Operating the Plant


8.1 Normal Operation
8.1.1 Preconditions for Correct Operation
To ensure malfunction-free operation of the Ultromat® plant there are important basic preconditions.
The first of these are that the set-up and installation has been carried out according to the
instructions given. It is vital that the operating parameters are set within reasonable limits and that
calibration has been carried out conscientiously. This is particularly important as far as the level
sensors are concerned. These cannot carry out their monitoring functions effectively if not correctly
adjusted. It is important to note that there should be no on-site changes to parameters for the speed
controller. In addition to these basic preconditions there is a series of points which must be taken into
consideration when working with the plant itself. In particular the general safety notes (see section 4)
must be observed.
The operation of the plant is only permitted to trained personnel who are familiar with the plant. The
work of operating staff is limited chiefly to filling the feed hopper with powder, the rapid correction of
malfunctions when operation is interrupted, and maintenance of the Ultromat®. In addition, staff are
expected to monitor the processes regularly, and make sure a" plant components are working
correctly. One aspect of this, for example, is the occasional checking of display lights using the Test
key. The control of the plant itself takes place automatically, however. Controller settings need not
normally be carried out further during operation.
The plant can be completely shut down or re-started using the Start/Stop key during any phase of
operation. An exception, however, is the re-starting of the plant after a malfunction occurrence.
The general procedure involves the removal of the cause of the malfunction (see section 10 for more
details) before confirming the corresponding error message. Each error message can, however, be
altered to a warning by pressing the "Confirm Alarm" key, so that the plant, if necessary, can resume
provisional operation. 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.

8.1.2 Supplying Dry Feeder with Powder

NOTICE
When filling the dry feeder, take care that operating personnel are not likely to
slip on spilt polyelectrolyte powder. This can make surfaces very slippery when
there is moisture present. It should be cleared up immediately.
l

page 30 ProMinent"
Operating the Plant

If the feed hopper is not filled automatically, using one of the optional accessories, the dosing
powder hopper must be continually checked and filled regularly. Filling can take place during
operation. The feed hopper cover must actually be removed and the dosing powder carefully
poured in.

8.2 Switching On Mains Power and Mains Power Failure Procedure


a) Switching on mains power
Each time the mains power is switched on, agitators commence operating regardless of the
liquid level of the chambers. The plant only starts, however, when the batching process starts
once the minimum switching position is reached in the storage compartment. If there is a power
failure, however short, during the batching process, the batching process will not commence
when the power is switched back on. When the mains power is switched on, furthermore, the
warning light and siren will be activated for around 0.5 seconds.
b) Mains power failure procedure
After a power failure or a long break in the power, which has led to re-activating the controller,
the plant recommences operating according to the state in which it was before the power
failure. If the storage compartment levels are within the specified range, batching will not begin,
even if, prior to the power failure, a batching process had been underway.

& WARNING
~ After a power failure the agitators will start running automatically.

8.3 Emergency Measures


In an emergency the plant must be disconnected from the mains power using the main control.
This will automatically cause the plant and all electrical systems to shut down.

WARNING
Using the "Start/Stop" key on its own is not enough in an emergency as the
control is based on a toggle system and does not differentiate between two
distinct switch states.

8.4 Plant Idle


Usually the plant is shut down using the Start/Stop key. If shut down is followed by a period
( where it is foreseeable that the plant will be lying idle for some time, the Ultromat®should also
be disconnected from the mains power using the main switch. The main switch must be used in
order to prevent unauthorised reactivation of the plant. During periods for longer than 2 days.
When Ultromat® is not in use, all tank compartments must also be completely emptied.
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 31
Operational Errors / Plant Malfunctions/Error Messages - Breakdown Advice

9 Operational Errors
In order to avoid, as far as is possible, entering operational parameters incorrectly in the
setup period, access to those menus relevant for the correct operation of the plant is limited.
Only a small group of personnel have access to the code menus. These must be people who
are familiar with the way the plant functions, and who are permitted to enter or change
operating parameters. It must be restated that the maximum viscosity value for
concentration settings must not exceed 1500 mPas.
The preset parameter values for the speed controller may not be altered on site. The
parameters have been preprogrammed in the factory for use with the appropriate dry feeder.
A possible operational error can arise when the cause of an error in the plant is not removed ,
and the confirm key has been thoughtlessly pressed. The original malfunctions can lead to
more severe ones, which will threaten the plant operation simply because the plant has
recommenced operating (see section 10).
In general, the danger from any form of operational error can be minimised as long as the
Ultromat® is handled sensibly and with due care. Continuing function checks during
operation forms as much a part of this as does following the steps given in the relevant
sections of this instruction manual. Sources of malfunctions which can be easily solved are
very often due to incorrectly set emptying valves and stopcocks in the water inlet pipes.
Making sure the dry feeder hopper is filled with fresh material in good time is crucial to
ensure troublefree operation .

~
WARNING
! '. To prevent possible dangers from any remaining risks, follow all safety
precautions when working with the Ultroma~ plant.

10 Plant Malfunctions/Error Messages - Breakdown Advice


A plant malfunction is signalled acoustically via the warning siren and visually via the red
warning light on the controller display in the control cabinet. In addition, the cause of the
malfunction will be displayed in the controller d isplay. The warning siren can be deactivated
using the separate "Siren Off" key located in the front door of the control cabinet. The error
analysis can take place based on the error message.
In order that the plant can recommence operation after a malfunction occurrence the
"Confirm Alarm" key must be pressed to remove the error message once the cause of the
malfunction has been removed.
When an alarm is triggered, agitators continue to run in pulse/pause mode.
The (polymer solution) discharge pump release, connected downstream, is not affected.
Possible malfunctions can arise, due to manufacturer's settings, which may affect the
warning or display systems in the plant. If a malfunction should arise which does not appear
in this list, or if a malfunction described in the list cannot be solved using the guidance given
in the breakdown advice section, then please contact our customer service department.

WARNING
If, to remove the cause of a malfunction in the system, it is necessary to
carry out work on the Ultromat® itself, then ensure that the plant is discon-
nected from mains power throughout and that it cannot be reactivated by
unauthorised personnel. Agitators continue to run for the preset period in
pulse/pause mode even after an error signal or when plant has been
stopped using Stop-key.

It is crucial to effective plant operation that the level sensors are working correctly. When
onsite settings are carried out, however, it may be found that a proximity sensor or a
concentrate flow sensor has been set too sensitively, or suddenly responds to different
operating conditions and gives a false warning signal for a nonexistent malfunction as a
consequence. 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 32 ProMinent"'
Plant Malfunctions/Error Messages - Breakdown Advice

10.1 Fault Identification/Malfunctions/Breakdown Advice


Fault Message on Effect Delay Red Alarm Action
LCD display LED relay
Warnings
In-flow monitor Water flow low Dosing, 3 sec. On Off Increase in-flow
stopped
in-flow active
Concentrate Min. 5 sec. On Off Increase in-flow
pump minimum frequency!
frequency
Powder/liquid Power Stop state 1 sec. On Off Switch on/off
mains operation down first switch
selection activated
In-flow monitor Water flow high 3 sec. Off Off Adjust in-flow

Malfunction
( Agitator Agitator Stop state 1 sec. Flashing On Correct fault
malfunction error
Minimum Stock Stop state 5 sec. Flashing On Check level
sensor liquid empty LSALL
level indicator
Water in-flow Water flow Stop state 20 sec. Flashing On Check water
below min . low in-flow
volume
Dry feeder Lack Stop state 3 sec. Flashing On Refill dry feeder
powder level of powder
Overflow Wetting Stop state 3 sec. Flashing On Correct fault
wetting cone cone error
Level sensor Stock level Stop state 5 sec. Flashing On Check level
defect, error sensor
compartment 3
Concentrate Fluid Stop state 2 sec. Flashing On Check motor-
pump error pump error protection
switch
Speed controller Inverter Stop state 5 sec. Flashing On Check speed
malfunction error controller
Overflow Stock Stop state 1 sec. Flashing On Check LSAHH
compartment 3 overfill level sensor
Dilution monitor Dilution error Stop state 3 sec. Flashing On Correct fault
Concentrate Concentrate Stop state 10 sec. Flashing On Replenish
drum empty low concentrate
Dosing monitor Flow contr. error Stop state 20 sec. Flashing On Replenish
concentrate
Controller Slot un" failure Stop state 1 sec. Flashing On Check
malfunction circuit board
Power Plant Off On 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 33
Plant Malfunctions/Error Messages - Breakdown Advice

10.2 Malfunctions in the Water Inlet Pipe


10.2.1 Water In-Flow Malfunctions
If the water in-flow rate falls below the set minimum value for longer than 3 seconds the dry feeder
will be de-activated and the message "Water Flow Low" will appear in the display. After a total of
20 seconds of continuing low water flow a malfunction will be registered. The water inlet valve is
closed. The message "Water Flow Low" remains on the display.
If the water flow reaches the set minimum value again within the next 20 seconds the dry feeder
will control back on after the "prerinse" period has elapsed.

Possible causes and countermeasures:


• Dirt in the pressure reducing valve. Solution: Clean filter-insert in pressure reducing valve.
• Operating pressure is too low. Solution: First of all check the strainer in the pressure
reducing valve visually. If there is no dirt in there, reposition the throttle in the pressure
reducing valve. Keep checking the water level in the wetting cone as you do this.
• The stop valve in the water pipe is not fully open. Solution: Turn tap CCW as far as it will go.

10.2.2 Water Meter Malfunctions


If the flow meter does not register flow when a batching process is in operation, the error
message "Water Flow Low" appears. It is assumed that the turbine inside the flow meter is not
running freely. The water meter should therefore be completely dismantled and cleaned.

10.2.3 Solenoid Malfunctions


During malfunction the solenoid will no longer open and close correctly.
Possible causes and countermeasures:
• Solenoid connections have worked loose. Solution:
Check the cable connection and fix if necessary.
• The throttle hole or the pilot hole in the valve outlet is blocked. Solution:
Open the solenoid carefully and clean the inside of the housing.
• The membrane inside the valve is defective. Solution:
Replace with new valve.

10.3 Powder-Feed Malfunctions


When the level sensor in the dry feeder signals "powder low", the controller stops the plant
operation.
( Fault-analysis information for the dry feeder may be found in the separate operating manual for
the dry feeder under section 7 "Problem Solving Measures".

10.4 Malfunctions in the Wetting cone


If the warning sensor for the overflow monitor in the wetting cone is activated, the error message
"Wetting Cone Error" appears. At the same time the batching process is automatically
interrupted. The dry feeder is switched off and the solenoid valve will close as well, after a short
interval.
Possible causes and counter-measures:
• The wetting cone is blocked with dosing powder. Solution: In case of emergency dismantle
wetting cone (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 34 ProMinent'"
Plant Malfunctions/Error Messages - Breakdown Advice

10.5 Malfunctions in the Storage compartment


10.5.1 Storage compartment Runs Dry
If the sensor which detects when the chamber is running dry triggers the "stock empty", then
"stock empty" will appear in the display.
Once the alarm has been confirmed, the discharge pump is paused until the minimum liquid-
level in the storage compartment is reached.
Possible causes and counter measures:
• All chambers are empty. Solution cannot get past the weir into the storage compartment.
Solution: Ensure beforehand that all emptying valves are closed. Start plant operating and
wait until all chambers have filled up sufficiently, and working solution can be
continually extracted.
• Extraction rate exceeds the plant capacity. Solution: In exceptional cases and within narrow
boundaries it is possible to raise the extraction capacity at the cost of the resting period of
the Polyelectrolyte solution (taking into account dry feeder capacity). Otherwise the dosing
capacity can be correspondingly increased by installing a diluting station.

10.5.2 Overllow in Storage compartment


If the Ultromat® does not control off the batching process once the maximum level has been
reached, the overfill sensor (optional) will detect the riSing level and interrupt the batching
process. The error message "Stock overfill" will appear in the display. The controller will stop the
batching process and close the solenoid.

WARNING
On no account remove inspection cover and reach inside the chamber if a
malfunction occurs. The agitator is still in operation and can commence turning
unexpectedly.

Possible Causes and Counter measures:


• The liquid level control that finishes the batching process has not triggered when the
maximum level has been reached. Solution: Control off the plant with the main switch, in
order to stop the agitators. Then dismantle the liquid level sensor and clean. Following
replacement, check the control functions.

10.5.3 Contradictory Liquid level Messages in the Storage compartment


If the level sensors in the storage compartment send out two contradictory signals the display
will read "Unlogicallevel". The level switch should be cleaned if necessary and its controlling
relay should be checked.
(
10.6 Agitator Malfunctions
The monitoring of the agitators is carried out by the motor protection switch. When a defect
occurs, however, only the error message "Agitator Defect" will appear in the display.
In the event of malfunction it should be checked whether the motor protection switch has
triggered. The relevant motor should be checked for damage and should be replaced if necessary.

10.7 Concentration Errors


If the water flow is that high, that the dry feeder cannot convay enough powder to achieve the
preset concentration, the message "water flow high" will appear. No alarm will be triggered, but
the actual concentration will be displayed. In this case reduce the water flow.

10.8 Error Messages in Initial Start Up


If the extraction compartment is empty when plant commissioning takes place, the message
"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 35
Plant Malfunctions/Error Messages - Breakdown Advice / Maintenance

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. If the water flowing through the dilution unit falls below the preset
measured variable, the error message "Dilution error" will appear. Countermeasures involve
identifying the cause of the problem and restoring water flow.

11 Maintenance

WARNING
The plant should be disconnected from the mains power throughout all
maintenance work, and there must be no possibility that unauthorised
personnel can reactivate the plant.

11.1 Inspecting the Dry Feeder and the Wetting cone


The dry feeder should be regularly checked during operation to ensure it is operating correctly.
It is not normally necessary to move the protective screen as observation should be possible
using the inspection window. This is assuming, however, that the window is cleaned from time
to time. For the dry feeder to operate smoothly, pay attention in particular that the solenoid
locking flap opens and closes correctly and that the dosing powder is travelling through the
feeder effectively. There is no need to check the dry feeder drive mechanism in general. The
gearing is supplied permanently lubricated. If the plant is correctly operated, only the felt rings
which form part of the drive shaft seal will need replacing.
At the same time as inspecting the dry feeder, the wetting cone should also be inspected. When
doing this, make sure that the conical washing-in area of the hopper is completely under water
during operation and that no powder lumps are forming.

11.2 Cleaning the Filter Insert in the Pressure-Reducing Valve


( The amount of dirt in the pressure reducing valve can easily be judged by examining the trans-
parent filter container. At the latest, when 2/3 of the filtration inserts have become clogged with
dirt, the filter insert should be cleaned. As the rate at which filtration inserts are becoming
clogged increases, the amount of water entering the plant is reduced. This leads to possible
faults due to insufficient water in-flow.
To dismantle the filter insert, the plant should be placed into the stopped state. As the pressure
reducing valve is located upstream from the solenoid valve, the stop valve should always be
manually closed. The exact procedure for dismantling and reassembly of the insert may be
found in the appendix of the manufacturer's instruction manual.

11.3 Opening and Cleaning the Solenoid Valve


Before opening the solenoid valve the stop valve, located upstream, should be completely
closed to close off the water flow. It is not necessary to dismantle the valve to open it. The four
bolts should be unscrewed and the valve cap along with the rinsing insert removed (take care
with the cable!). Next remove the inner parts and inspect the membrane for damage. At this
point, the housing, in particular the throttle hole and the small pilot hole in the valve outlet, can
be cleaned. Take care, when re-assembling, that the parts are put together in the correct order.
Further instructions and the relevant diagram can be found in the appendix of the
manufacturer's instruction manual.

page 36 ProMinent®
Maintenance

11.4 Dismantling and Examining the Flow Meter (turboDOS)


For safety reasons, when dismantling the flow meter too, the stop valve should be closed
manually. The plant is effectively shut down. To dismantle the turbine rev. counter remove the
corresponding screws in the water pipework. Then the turbine wheel inside the water meter can
be checked to ensure it is running freely, and cleaned if necessary. When handling the flow
meter always be careful with the cable.
When re-assembling, check direction of flow has been taken into account.

11.5 Changing the Mains Power Safety Fuse in the Controller

~ WARNING
~ To change the safety fuse the plant should be disconnected from the mains
power - Danger of Death!

The mains power safety fuse is located in a safety-fuse holder in the controller. It is accessed by
opening the controller housing and placing the upper section in the "parked state". After
( releasing the bayonet fitting on the safety fuse connector, the defective safety fuse can be
removed and replaced with a new one. Refasten the bayonet fitting and close the housing.

11.6 Removing the Inspection Cover on the Three Compartment Tank

WARNING
When plant is controled on do not remove the inspection cover. The agitators
can start running unexpectedly - Danger of Injury!

Generally-the plant should only be operated with the inspection cover fixed firmly in position. Only
the cover on the storage compartment may be removed during operation when inspecting the liquid
level and to monitor the level sensors (controlling correctly). We recommend that care be taken,
however, and on no account should you reach inside the chamber.
You mList always remember to check that before the plant is put into operation, all covers are in
position and fastened down.

11.7 Rinsing the Multi-chamber Tank


In order to remove remaining polyelectrolyte solution and to prevent clogging of the dosing system
( the tank must be thoroughly rinsed with water if it is to be left idle for any length of time. 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 37
Appendix

12.1 Declaration of Conformity

EC Declaration of Conformity

We, ProMinent Dosiertechnik GmbH


1m Schuhmachergewann 5 - 11
o - 69123 Heidelberg

hereby declare that, on the basis of its functional concept and design and in the version brought into
circulation by us, the product specified in the following complies with the relevant, fundamental safety
and health stipulations laid down by EC regulations.
Any modification to the product not approved by us will invalidate this declaration.

Product description : Polyelectrolyte preparation system, Ultromat

Product type : AT 1 ATF 1 AF 1 ATP 1 A TFP 1 A TO 1 ATFD 1 MT

Serial number : see type identification plate on device

Relevant EC regulations : EC - machine regulation (8913921EEC) subsequently 931441EEC


EC - low voltage regulation (73123IEEC)
EC - EMC - regulation 8913361EEC subsequently 921311EEC

Harmonised standards used, EN 292-1, EN 292-2, EN 563


in particular: EN 60204-1
EN 50081-112, EN 50082-112

National standards and other


technical specifications used,
in particular :

Date/manufacturer's signature : 12.03.02

The undersigned: Dr. Rainer V. Dulger, Executive Vice President R&D and Production

page 38 ProMinent"
Appendix

12.2 Assembly Drawing AT 400

d
--- A

Typenschild
nameplate
Plaque signaleliqua
A

Hauplschalter
main switch
Seclionneur

a chamber 3 chamber 2 chamber 1


b DN25 DN25 DN 25

1770
1632

l
,I "
.-II- _

"'m
: ~
1 JL
= \
Die au sgefOhrten Abmessungen konnan beding! durch den eingesetzten Depending on the used materials, dimensions Tolerance generale +/- 1,5 liee a la matiere utilisee.
Werksloff urn +/. 1,5 von den angegebenen MaBen abweichen. shown In this drawing may tolerate +/- 1.5.

Positionen: Positions: Positions:

StandardausfUhrung : standard equipment: Version standard:

a. SeMlter PP a. tank PP a. Cuve en PP


b. Wasserverrohrung b. water piping b. Armature hydrauliqua
in PVClMessing. made of PVCrorass, En PVClLaiton
aile Dichtungen in EPDM all gaskets made of EPDM taus Jes joints en EPDM

c. EinspOl- und Vermischungseinrlchtung c. mixIng vessel C. Armature d'humidilicaUon at de melange

d. Trocke ngutdosierer PP d. powder feeder and hopper d. Doseur de pulverulent. PP


inkl. Kulisse. Heizung, inc!. crank, heating, closing cap avec bomer de protection, bague chauffanle,
Verschlusskappe, Lockerungsrad aerating wheel volet d'arret, roue d'ameublissement

e. ROhrwerke in 1. und 2. Kammer e. stirrer in chamber 1 & 2 e. Agitateur dans les chambras 1 at 2
f. SchaltschrankiSleuerung f. con trol panel Coffret de commande

nicht zum Liererumrang der StandardausfOhrung standard equipment not includes L'agitateur de la chambre 3 ne fait pas
geM rt das ROhrwerk in Kammer 3 eleclric stirrer in chamber 3 partie de la version standard

ProMinent" page 39
Appendix

12.3 Assembly Drawing AT 1000

-- A
Typenschild
nameplate
Plaque signalelique
A

Hauplschaller
main switch
Seclionneu(

a b chamber 3 chamber 2 chamber 1


DN25 DN25 DN25

ca.2410

2276

Die ausgefOhrten Abmessungen konnen beding! Depending on the used materials. dimensions Tolerance generate +/. 1,5 Ilee a la maliere ulilisee.
dutch den eingeselzten Werkstoff um +/- 1,5 von shown in this drawing may tole rate +/- 1.5 .
den angegebenen Mal3en abweichen.

Positionen: Positions: Positions:

StandardausfOhrung : standard equipment: Version standard :

a. Beharler PP a. tank PP a. Cuve en PP


b. Wasserverrohrung b. water piping b. Armature hydraulique
In PVClMessing, made of PVC/crass, En PVC!l...ailan
aile Dichlungen in EPDM aUgaskets made of EPDM taus les joints en EPDM

c. EinspOl- und Vermischungseinrichtung c. mi)(jng vessel C. Armature d'humidification et de melange

d. Trockenguldosierer PP d. powder feeder and hopper d. Doseur de pulverulent. PP


inkl. Kulisse, Heizung, incl. crank, healing, closing cap avec boitier de protection, bague chauffante,
Verschlusskappe, Lockerungsrad aerating wheel valet d'arret, roue d'ameublissemenl

e. ROhrwerke in 1. und 2. Kammer e. stirrer in chamber 1 & 2 e. Agitateur dans les chambres 1 al2

SchallschranklSleuerung f. control panel Coffrel de commande

nicht zum Ueferumfang der StandardausfOhrung standard equipment not includes L'agilateur de la chambre 3 ne fait pas
gehorl das AOhrwerk in Kammer 3 electric stirrer in chamber 3 partie de la version standard

page 40 ProMinent"
Appendix

12.4 Assembly Drawing AT 2000

_A Typenschild
A
nameplate
Plaque signaletique
e

Hauplschalter
main switch
Seclionneur

Kammer 2

a b chamber 3 chamber 2 chamber 1


DN32 DN32 DN32

3070
2916

Die ausgefOhrten Abmessungen kennan hadingl durch den eingesetzten Depending on the used materials, dimensions Tolerance generale +/- 1,5 lies a la matiere utilisee.
Werkstoff urn +/- 1,5 von den angegebenen Mar3en abweichen. shown in this drawing may tolerate +/- 1.5 .

Positionen: Positions: Positions:

StandardausfOhrung : standard equipment: Version standard:

a. Behalter PP a. tank PP a. Cuve en PP


b. Wasserverrohrung b. water piping b. Armature hydraulique
in PVCIMessing, made of PVClbrass, En PVClLaiton
aile Oichtungen in EPDM all gaskets made of EPDM taus les joints en EPOM

c. EinspOI· und Vermischungseinrichtung c. mixing vessel c. Armature d'humidification et de melange


d. Trockenguldosierer PP d. powder feeder and hopper d. Ooseur de pulverulent. PP
inkl. Kulisse, Heizung, incl. crank, healing, closing cap avec boitier de protection, bague chauffante.
Verschlusskappe, Lockerungsrad aerating wheel volet d'arret, roue d'ameublissement

e. ROh rwerke In 1. und 2. Kammer e. slirrer in chamber 1 & 2 e. Agitateur dans les chambres 1 et 2

SchallschranklSteuerung control panel CoUret de commande

nichl zum Lieferumfang der StandardausfOhrung standard equipment not includes L'agitate ur de la chambre 3 ne fait pas
geh6rt das ROhrwerk in Kammer 3 electric stirrer In chamber 3 partie de la version standard

ProMinent" page 41
Appendix

12.5 Assembly Drawing AT 4000

Kammer 1 Kammer 2 Kammer 3

chamber 3 chambe r 2 chamber 1


DN40 DN40 DN40

Die ausgefOhr!en Abmessungen konnen beding! durch den eingeselzten Depending on the used materials, dimensions Tolerance generale +/- 1,5 lise a la matiere utilisee.
Werkstolf um +/- 1,5 von den angegebenen Marlon abweichen. shown in this drawing may tolerate +/- 1.5 .

Positionen: Positions: Positions:


Sta ndardau sfUhrung : s tanda rd eq uipment: Version standard :
a. Behaller PP a. tank PP a. Cuve en PP
b. Wasserverrohrung b. water piping b. Armature hydrauUque
In PVClMesslng, made of PVClbrass, En PVC/Laiton
aile Dichtungen in EPDM all gaskets made of EPDM tous les joints en EPDM
c. Einsp01- und Vermischungseinrichtung c. mixing vessel c. Armature d'humidificalion et de melange
d. Trockengutdosierer PP d. powder feeder and hopper d. Doseur de pulverulent. PP
inkl. Kulisse, Heizung , incl. crank, heating, closing cap avec boiller de protection, bague chauffante,
Verschlusskappe, Lockerungsrad aerating wheel volet d'arret, roue d'ameublissemenl

e. ROhrwerke in 1. und 2. Kammer e. stirrer in chamber 1 & 2 e. Agilaleur dans les chambres 1 el 2
f. SchallschranklSteuerung f. control panel f. Coffrel de commande

nicht zum Lieferumfang der StandardauslOhrung standard equipment nolincludes l 'agilateur de la chambre 3 ne fail pas
gehort das AOhrwerk in Kammer 3 electric stiffer in chamber 3 partie de la version standard.

page 42 ProMinent'"
Appendix

12.6 Assembly Drawing AT 8000

DN80

Ii!
~

DN50

b
4434
a
4200

~----------- -----------= ------- ----- .-- ---- ---

"

o
;;;
o
;;;

b
a

Die ausgefOhr1en Abmessungen kOrlnen bedingt durch den eingesetzten Oepending on the used malerials, dimensions Tolerance generale +/- 1,5 liee
Werkstoff urn +/. 1,5 von den angegebenen MalJen abwelchen. shown in this drawing may tolerate +/- 1.5 . a la matil;lre utitisee.

Positionen: Positions: Positions:

StandardausfUhrung : standard equipment: Version standard :

a. BeMlter PP a. lank PP a. Cuve en PP

b. Wasserverrohrung b. water piping b. Armature hydraulique


in PVClMessing, . made of PVCtbrass, En PVClLailon
aile Oichtu nge n in EPOM all gaskets made of EPDM taus les joints en EPDM

c. EinspOr· und Vermischungselnrichtung c. mixing vessel c. Armature d'humidification et de melange


d. Trockengutdosierer PP d. powder feeder and hopper d. Doseur de pulverulent. PP
inkl. Kulisse, Heizung. incl. crank, heating, closing cap avec boilier de protection, bague chauffante,
Verschlusskappe, Lockerungsrad aerating wheet volet d'arre!, roue d'ameubrissement

e. ROhrwerke in 1. und 2. Kammer e. stirrer in chamber 1 & 2 e. Agilateur dans les chambres 1 et 2
SchaltschranklSteuerung control panel Coffret de commande

nicht zum Lieferumfang der SlandardausfOhrung standard equipment not Includes L'agilateu( de la chambre 3 ne fait pas
geh6rt das ROhrwerk in Kammer 3 electrIc stirrer in chamber 3 partie de la version standard.

ProMinent" page 43
Appendix

12.7 Assembly Drawing ATF 4000

d A A
Typenschild
nameplate
Plaque signalelique

Hauplschalter
mainswilch
Sectionneur

chamber 3 chamber 2 chamber 1


DN 25 DN25 DN25
a b

ca. 1770
1632

300 ,I
~ :'ll L.t±::"-
··, ,.., JC J _1-0_ '
----;
--
Ho=
II~
I -~ 7 r~· l t«='
}./~ l
"" '+·: '''"""
1", ~t ~lal---
mit Option 7
~ und DHV
~

0; !------- Ho= ~
,, /t
...... -- ---- t= ~
~ " ~ ,
~
"

I
,,
~
lEE " II
,""" II""
!. - -...-~-
_J[ ~
!
0
,
- - --1 '=-
rw---
~r'
g
0
~

1.S-tache VergroBerung
I
g
t::I \e Zulauf Flussigpolymer

( Die ausgefUhrten Abmessungen kannen bedingt dutch den eingesetzten Depending on the used materials, dimensions Tolerance genera Ie +/. 1,Sliee a la matiere utillsee.
Werkstoff urn +1-1,5 von den angegebenen MaBen abwelchen. shown In this drawing may tolerate +/-1.5 .

Positionen: Positions: Positions:


StandardausfOhrung : standard equipment: Version standard:

a. Behalter PP a. lank PP a. Cuve en PP


b. Wasserverrohrung b. water piping b. Armature hydraufique
in PVClMessing, made of PVClbrass, En PVClLaiton
aile Dichlungen in EPDM all gaskets made of EPDM tous les joints en EPDM

c. EinspUl- und Vermlschungseinrichtung c. mixing vessel c. Armature d'humldilication et de melange


d. Trockengutdosierer PP d. powder feeder and hopper d. Doseur de pulverulent. PP
inkl. Kulisse, Heizung, locI. crank, heating, closing cap avec boitier de protection, bague chauffante,
Verschlusskappe, Lockerungsrad ae rating wheel volet d'amM, roue d'ameubHssement

e. ROhlWerke In 1. und 2. Kammer B. stirrer in chamber 1 & 2 e. Agitateur dans les chambres 1 el 2
SchallschrankiSteuerung control panel f. Colfret de commande

nicht zum Lieferumfang der SlandardausfOhrung standard equipm ent not includes L'agitateur de la chambre 3 ne fail pas
gehort das ROhlWerk in Kammer 3 electric stirrer in chamber 3 partie de la version standard

page 44 ProMinent'"
Appendix

12.8 Assembly Drawing ATF 1000

---
A
Typenschild
nameplate
Plaque signaltHique
A

Hauptschatler
main switch
Sectionneur

Kammer 2 Kammer 3

b chamber 3 chamber 2 chamber 1


ON2S ON2S ON2S

2410
2276
480

+
mit Option 7

~i ~
~i
Ii (i)


&
Ii ,1&
, ~ ""- '/ '

{i~
~
r-r
~I ~ ,,
& ~
, ~-'
I~
, // ",-
:
:, :, '"
II
Ii
1.1
11"f" 0
]" re::'~I~ r ~
I
~~~~7 ~~_
"

~
~
B

1.5-fache VergrOl3erung
Zulauf FlUssigpolymer

Ole ausgefQhrten Abmessungen kennen bedlngl Depending on the used materia/s, dimensions Tolerance generale +/- 1,5 lIee a la matiere utilisee.
durch den eingesetzten WerksloH urn +/- 1,5 von shown in this drawing may tolerate +/- 1.5.
den angegebenen MaBen abweichen.

Positionen: Positions: Positions:


StandardausfUhrung: standard equipment: Version standard:

a. BeMlter PP a. tank PP a. Cuve en PP


b. Wasserverrohrung b. waler piping b. Armature hydraulique
in PVC/Messing, made of PVC/orass, En PVClLailon
aile Dichtungen in EPDM aU gaskets made of EPDM taus les joints en EPDM

c. EinspUl- und Vermischungseinrichtung c. mixing vessel c. Armalure d'humidilicalion el de melange


d. Trockengutdoslerer PP d. powder feeder and hopper d. Doseur de pulverulent. PP
inkl. Kullsse, Heizung, incl. crank, heating, closing cap avec boilier de protection, bague chau!fante,
Verschlusskappe, Lockerungsrad aerating wheel valet d'arret, roue d'ameublissement

e. ROhl\verke in 1. und 2. Kammer e. stirrer in chamber 1 & 2 e. Agitaleur dans les chambres 1 et 2
SchallschranklSleuerung f. conlrol panel f. Coffret de commande

nfcht zum Lieferumfang der StandardausfUhrung standard equipment not includes L'agitateur de la chambre 3 ne fait pas
geh6rt das ROhrwerk in Kammer 3 electric stirrer in chamber 3 partie de la version standard.

ProMinent" page 45
Appendix

12.9 Assembly Drawing ATF 2000

- A
Typenschild
nameplate
Plaque signaletique
A

('
chamber 3 chamber 2 chamber 1
DN32 DN32 DN32

ca. 3070
2916 49db~~q\IF
mit Option 7

Die ausgefOhrten Abmessungen konnen bedingt Depending on the used materfals, dimensions Tolerance g{merale +/. 1,SHee a la matiere utllisee.
durch den eingesetzlen Werkstofl urn +/- 1,5 von shown in this dra\ving may tolerate +/- 1.5.
den angegebenen MaBen abwelchen.

Positionen: Positions: Positions:

StandardausfOhrung : standard equipment: Version sta ndard:

a. 8eh ~iIter pp a. tank PP a. euve en PP


b. Wasserverrohrung b. waler piping b. Armature hydraulique
in PVClMessing, made of PVClbrass, En PVClLailon
aile Dichtungen in EPDM all gaskets made of EPDM tous les joints en EPDM

c. EinspOI- und Vermischungselnrichtung c. mixing vessel c. Armature d'humldificalion et de melange


d. Trockenguldosierer PP d. powder feeder and hopper d. Doseur de pulverulent. PP
inkl. Kullsse, Heizung, Incl. crank, healing, closing cap avec boilier de protection, bague chauffante,
Verschlusskappe, Lockeru ngsrad aerating wheel volet d'arrel, roue d'ameublissement

e. ROhrVlerko In 1. und 2. Kammer e. slirrer in chamber 1 & 2 e. Agltateu r dans les chambres 1 et 2
SchaltschranklSteuerung f. control panel Coffrel de commande

nicht zum Ueferumfang der SlandardausfOhru ng standard equipment not Includes L'agitateur de la chambre 3 ne fait pas
geMrt das ROhrwerk in Kammer 3 electric stirrer in chamber 3 partie de la version standard.

page 46 ProMinent®
Appendix

12.10 Assembly Drawing ATF 4000

- A A

Kammer 1 Kammer 2

3181 chamber 3 chamber 2 chamber 1


DN40 DN40 DN40
2946

r-----.. . . .
,
j
= ....-

: ~
: 1
. . . .= ................-
....- ...--........i~

I ~
T"'";----...--..... . . . . . . . . . . . .'$.l
- ...........................

I I
I :
I - 41-----------
:
-j"~.jj-_-I-_ _~
~
I ------- -

945

Die ausgefOhrten Abmessungen kennen bedingl Oepending on the used materials, dimensions Tolerance generale +/. 1,5 liea a la matiere utilisee.
dUTch den eingesetzten Werksloff urn +/- 1,5 von shown in this drawing may tolerate +/- 1.5 .
den angegebenen MaOen abweichen.

Positionen: Positions: Positions:

SlandardausfOhrung : standard equipment: Version standard:

a. Behalter PP a. tank PP a. Cuve en PP


b. Wasserverrohrung b. waler piping b. Armature hydraulique
in PVCIMessing, made of PVClbrass, En PVClLaiton
ane Dichlungen in EPDM all gaskets made of EPDM taus les joints en EPDM

c, EinspOl- und Vermlschungseinrichlung c. mixing vessel c. Armature d'humidificalion et de melange


d. Trockenguldosierer PP d. powder feeder and hopper d. Doseur de pulverulent. PP
inkl. Kulisse, Heizung. incl. crank, healing, closing cap avec boilier de protection, bague chauHante,
Versch!usskappe, Lockerungsrad aerating wheel volet d'anet, roue d'ameublissement

e. RGhrwerke In 1. und 2. Kammer e. slirrer in chamber 1 & 2 e. Agitateur dans les chambres 1 et 2
SchallschrankJSteuerung conlrol panel Coffret de commande

nicht zum Lfeferumfang der StandardausfGhrung slandard equipment not includes L'agitateur de la chambre 3 ne fail pas
gehort das RGhrwerk in Kammer 3 electric stirrer in chamber 3 partie de la version standard.

ProMinent® page 47
Appendix

12.11 Assembly Drawing ATF 8000

DN80

.,o

DNS{)
(

b
a
4200

,I ....-~-- ---- ------ -- --------- --- - - -------- -- --- ---- ---------- --- --- -- - --- --- ---- ---------- -- ----- - ---- --- 1

i""="""'===:== ""%========:====l'=Ur-
~ - == ====== "'==:=============r=rmr- ===== === ======:==== ==; -
,
II I ~ II I I I illi L_
I I ~ II I 1 I illl -+fI·-t~i--+--
:1 ! ~ !! 'i ! ! !I!I ~

C:-I:j~~:;;;:I:~[fi~~:~~;~;=~=~=;-=~ -=-=~ :~H1l1~1!- -1


!I I 1 : il lI lI lI - 0

I :~ I ! II I ! !!!i
,: I I I IIII
, 1 1 III:
I I III I
:
~ l\ ! i !!I l\
F1~~~~~~~~~~==~~
I,
~
__ _____ _____ ____ ____
I I ri l l __
~~~~=~=_==~=~_~_~;_~_~~~~~~,
_ _ __ ___ ___ ____ ___ ___ _ ___ ~

b
a

Die ausgefUhrten Abmessungen kOrlnen bedingl durcll den elngesetzlen Oepending on the used materials, dimensions Tolerance gi!nerale +/-1,5 lIee
Werksloff urn +/. 1,5 von den angegebenen MaBen abwelchen. shown in this draWing may tolerate +/- 1.5 . a la malillre utilises.

Positionen: Positions: Positions:

StandardausfUhrung : standard equipment; Version standard;

a. BeMlter PP a. lank PP a. Cuve en PP


b. Wasserverrohrung b. water piping b. Armature hydraulique
In PVClMesslng, made of PVCforass, En PVClLaiton
aile Dlchtungen in EPOM all gaskets made of EPOM taus les joints en EPDM
c. EinspOl- und Vermischungseinrichtung c. mixing vessel c. Armature d'humidification et de melange
d. Trockengutdosierer PP d. powder feeder and hopper d. Ooseu r de pulverulent. PP
Inkl. Kulisse, Helzung, Incl. crank, heating, closing cap avec boilier de protection, bague chauffante,
Verschlusskappe, Lockerungsrad aerating wheel valet d' arr~t, roue d'ameublissement

e. Auhrwerke in 1. und 2. Kammer e. stirrer in chamber 1 & 2 e. Agitateur dans les chambres 1 el 2
f. SchallschranklSteuerung f. control panel f. Coffre! de commande

nlcht 2um Ueferumfang der StandardausfOhrung standard equipment nol Includes L'agllateur de la chambre 3 ne fait pas
gehort das ROhrwerk in Kammer 3 electric stirrer In chamber 3 partie de la version standard.

(
\

page 48 ProMinent"
~

""CI
~
==
:i"
CD
;:;

~ ~
Ident-Code -to-
Software-Version --....
l •

Betrlebsart:
T '" Pulver
F '" FIO~:;Ig .....
I\)
:...
i J
~
[ settings I\)

~ ~
[ settings IJ "'C
tJ. 1011 password
a
cc
...
III
[ 1 J
settings
start up?
settings
calibration?
[ seffings
concentration? [ settings
service?
1
3
3
~ 1 ~l ~1 t s·
Iill ~ 1
language
C,D,E,F,H,I,N,P
~ r--[ adjust
waterflow
waterflow
xxxx Vh'
~
[ concentration
H Q,20%
1 [ waterflcm
input
l ~ {G me""'"9 ~
--~ flow value
~
CC
s::
(1)
J I
~l .I
::J
~l ~1
feed water minimum flow
minim um flow t-L- XXXX IIh ~ t:

~ ~ c:
heati ng heating on
y 1 J ~I!i agitator
start/stop J [ (::.manual water
,, ',Ih 1
flew value ;::;:

~
on·time i'" xx seconds calibrate
powder feeder
powder feeder
CD tJ. xxx g/min ...
powder calibr
xxx g/min
' +2 now value
a3
heating
off-time
heating off
tax seconds
(t)
powder feeder ~ 1 III
prerinsing time prerinsing time
xxx seconds
ill
[, start I stop
agitator3
1 '1
t,!. xx seconds
ill
powder feeder
"XXX g r-
~ 1 ~
rinsing delay rinsing delay
t,L. xx seconds
[ill start/stop
co
C'I
agitator 1+2 agitator 1+2 on powder feeder
on·time t'"xx minutes

agitator 1+2 agitator 1+2 off


~ 1
off-time

agitator 3
t J. xx minutes

ag!tatDr30n
[il running
empty
J
WARNING
dry running protection
out of service.
on-time f.!.XX minutes

agitator 3 ag!tator 3 off


off-time f.!- xx minutes

change new access code


access code f.l. xxxx

l>
"C
"0 "C
(1)
m
'"
co :::s
.j:>. a.
CD
><
~

U
Dl
(0
»
'0
(1)
c:n '0
o (1)
:::::I
c..
x'

~ ~~
Ident-Code --..
Software-Ve~lon -.

Betr1ebSilrt:
T = PulVer
F = F1Q~slg

......
J
~ l ~
I\)
settings
:...
Co)

settings
tJ. 1011 password
~
"'C
(3
settings
start up?
r
settings
cali bration?
l ~ [
1
settings
concentration?
l [ settings
service?
J
<C
~
3
~1 ~1 ~T ~ 1
language
C,D,E,F,H,I, N,P
~ ~[ adjust
waterflow
'I, ~
waterflow
xxxx I/h'
1- ~
J~
l concentration
1.1. 0,20%
l [ water flow
input J- ~ ·r m..,,"o9
flow value
~ I@]
3
:i"
<C
s:
feed water
minimum flow
minimum flow
tJ. XXXX 1Il1
[®]1 .I @}J 1 @}Jl (1)
::::I
heating heating on
l 1 I@]
~ [c~ agilator
start/stop 1 [ Omanual water I@] ftowvalue C

~
1+2
on-time tl- XX seconds calibrate
powder feeder
powder feeder
C!> fJ. xxx: g/min ..
powder calibr.
xxx g/min
flow value n 111h
1 c:
;::;
heating
off-time
heating off
tax seconds
tD
powder feeder
[@] 1 (3
xxx seconds
~ start I stop 3
prerinsing time prerinsing time CD agitator 3
t.J. xx seconds powder feeder
I- ~
I@J ~ ,;xxxg ®
rinsing delay rinsing delay
t,!. xx seconds
[@] 1 ~
l~ J
agitator 1+2 agitator 1+2 on ~ ~
start I stop
powder fe eder
~
on-time tJ.XX minutes
~
agitator ' +2 agitator 1+2 off
lc calibrate {("ncentrate pump
concentrate pu mp tt)tJ. xxx g/min'"'
concenlr. calibr.
xxx g/min ~ 1 0)

off-time tJ..xx minutes


&on~~~~~p
D start I stoppump,J
l2'concentrate
agitator 3 agltator30n
on-time

agitator 3
tJ. XX minutes

agitator 3 ort
[®] concentrate pump
~ "xxx 9 I-- ~ 1 WARNING
[~ runnIng
off.time

concentrate pump
f.l. XX minutes

min. frequency
1
empty
J dry running protection
out of service.

min . frequency

change
access code
t.J. x Hz

new access code


N XXXX -r adjust
f1owcontIol
1 flow control
cI> tJ. xxx g/min ...
• Possible In stop mode onty
(use stop key)

l
s:
S'
(1)

~
Appendix

12.14 Commissioning Protocol

Ultromat® AT/96 and ATF/96 Commissioning Protocol

Ultromat type:
AT/96 0400 01000 02000 04000 08000
ATF/96 0400 01000 02000 04000 08000

Ident-code: Software version: Project number:

IULSA
I~2/4.1
I0I
( example T

Calibration settings:
Powder Liquid
Concentration %
Calibrated feed rate g/min
Water in flow Uh
Flow monitor switch threshold g/min

Commissioning settings:
Commissioning parameters Default setting Powder Liquid operation
operation setting
setting
AT 400 min. water in flow 500 Uh
AT 1000 min. water in flow 1200 Uh
AT 2000 min. water in flow 2400 Uh
AT 4000 min. water in flow 5000 Uh
AT 8000 min. water in flow 10000 Uh
Heater on time 5 sec
Heater off time 35 sec
In flow pre rinse period 7 sec
In flow post rinse period 5 sec
Agitators 1 + 2 on time 15 min
Agitators 1 + 2 off time 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:

Client: Date:

Location :

ProMinent® page 51
CLIENT CONSULTANT

( qJ. PUBLIC WORKS AUTHORITY


STATE OF QATAR
KE~ KEO INTERNATIONAL CONSULTANTS
DOHA, STATE OF QATAR

PROJECT: DOHA SOUTH SEWAGE TREATMENT WORKS PHASE II EXP. DOCUMENT TiTlE: Sludge Handling System Final Dossier
PROJECT CODE : DA 07/08 C 40 G

File No.10

10.1. Dewatering Centrifuge Package (Part 3 of 5)

10.1.1. Polymer Plant- Ultromat

10.1.1.3. Drawings

10.1.1.3.1. Assembly Drawing

CONTRACTOR:

(
LARSEN & TOUBRO CONSORTIUM LARSEN &TOUBRO •GALFAR Glltar
ALMISNAD

SUB-CONTRACTOR:
xyLem Le t's Solve W ate r
CONTRACT NO: C2010/33
~
------

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Position en: Positions:
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a.B.h.lttrPPin~.SchallS(hr",kk,nsol. a lankPP ind. consol. for control panel
b. Wasserverrohrung b. water piping
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~ l: ______ c. Einspiil- und Vermischungseinrichtung c. mixing vessel


d. TrotkenguldosiererPP d. powder feeder and hopper

~
, I , inkt. Kul1sse. Helzung. incl. crank. heating. closing up
~
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e. stirrer in ch21mber 1, 2,3
f. lerminal bDX

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PMSY 6011004717 Werksloff
materIal -
Ret Xndorunglll, changee. :zmlny NOlO lim<
31.10.2011 Skarda Bezeichnung/description/nazeV
c.,r. Ultromat ATF 2000/96 - S
Ibm IIHll2758-1vL
Spectra + wetting cane
ProMinent Systems .........
Fiignerow fIl7, 33601 Blo~ce, CZ ~-It./m.iIg "'fV1Ja l
T~. 378 227100 fax. J7B 227588 6011004717-00-01-00 IV1
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CLIENT CONSULTANT

(Ql PUBLIC WORKS AUTHORITY


STATE OF QATAR

PROJECT: DOHA SOUTH SEWAGE TREATMENT WORKS PHASE" EXP.


KE~ KEO INTERNATIONAL CONSULTANTS
DOHA, STATE OF QATAR

DOCUMENT TITLE: Sludge Handling System Final Dossier


PROJECT CODE: DA 07/08 C 40 G

File No.10

10.1. Dewatering Centrifuge Package (Part 3 of 5)

10.1.1. Polymer Plant- Ultromat

10.1.1.3. Drawings

10.1.1.3.2. Terminal Box

CONTRACTOR:

(
LARSEN & TOUBRO CONSORTIUM LARSEN &TOUBRO •GALFAR Gllfar
ALMISNAD

SUB-CONTRACTOR:
xyLem Let's S o lve W a t e r
CONTRACT NO: C2010/33
CLIENT CONSULTANT
PUBLIC WORI(S AUTHORITY
STATE OF QATAR
KE~ KEO INTERNATIONAL CONSULTANTS
DOHA, STATE OF QATAR

PROJECT: DOHA SOUTH SEWAGE TREATMENT WORKS PHASE" EXP. DOCUMENT TITLE: Sludge Handling System Final Dossier
PROJECT CODE: DA 07/08 C 40 G

File No.10

10.1. Dewatering Centrifuge Package (Part 3 of 5)

10.1.1. Polymer Plant- Ultromat

10.1.1.3. Drawings

10.1.1.3.3. Wiring Diagram

CONTRACTOR:

LARSEN & TOUBRO CONSORTIUM LARSEN &TOUBRO •GALFAR Gllrar


ALMISNAD

SUB-CONTRACTOR:
xylem Let's S o lve W ater
CONTRACT NO: C2010/33
----

Pro Ject -No , PMHD 116017396 !

DesCliption
, TERMINAL BOX FOR UL TROMA T ATF 2000/96 - S
Drawing-No . PMHD-2011601739 - 1
Customer /Pro ject
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Net plan 827 889
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Description
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Drawing-No. PMHD-2011601739
Cus tomer /Pro jed
ProMinent Dosiertechnik GmbH
Net plan 827 889
Drawn
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0-69123 Heidelberg
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Cabling ace. to ProMinent-ST ANDARD


Terminal strip reference
Current circuit Colour DIMENSION OF CROSS SECTION

-xc = SUPPLY LINE AND MAIN CURRENT CIRCUIT


MAIN CURRENT CIRCUIT BK ace. to load

-X1 = CONTROL CURRENT CIRCUIT 230VAC , 110VAC ace. to load


Neutral conductor BU

-X2 = CONTROL CURRENT CIRCUIT 24 VAClVDC Protective conductor GNYE ace. to load

- X3 = MEASUREMENT E.G. 0I2-10V, O/4-20mA CONTROL CURRENT CIRCUIT 230V AC , 110V AC


( L230V )
-X4 = EXTERN VOL TAGE BN O,7Smm2 or larger ace. to load

CONTROL CURRENT CIRCUIT 230VAC , 110V AC


-X024 = Potential terminal strip -24 VDC / L024 V ( L0230V, L0110V )
BNWH O,7Smm2 or larger ace. to load
-X0230 = Potential terminal strip L0230V
Control current circuit 24 VAC

( Conductor L24 V ) RD O,7Smm2 or larger ace. to load

Control current circuit 24 VAC I


Device identification in wiring diagram !

( Reconductor not grounded L024V ) BURD O,7Smm2 or larger ace. to load


( Reconductor grounded L024 V ) RDWH O,7Smm2 or larger ace. to load
- 10 K 1 M Control current circuit +24 VDC ( Positive pole) OG O,7Smm2 or larger ace. to load
C
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00
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Revision date neme DESCRIPTION Net plan 1 - A....DEC
~~D~
date name
CABLING-STANDARD Ultromat ATF 2000/96 - S 8891 + E10
gez. 08.11.11 Vaidi~

gepr 08.11.11 Bender


1m SchuhmachergewaM 5-11
0-69123 Heidelberg
Drawing-No., { Project-No.:
PMHD-2011601739
IProMinent Dosiertechnik GmbH
Customer/Project
827

12
151m
5Im
2
TABLE OF CONTENTS

POS. UNIT SHEET TITLE OF SHEET DATE DRAWN INSTALLED IN


1 A DEC 1 COVER SHEET 08.11.11 Vaidis El0
2 A DEC 2 CABLING-STANDARD 08.11.11 Vaidis El0
3 B INH 1 TABLE OF CONTENTS 08.11.11 Vaidis El0
4 C STU 1 LIST OF PARTS 08.11.11 Vaidis El0
5 D MAS 1 ELECTRICAL CABINET 08.11.11 Vaidis El0
6 D MAS 2 MOUNTING PLATE 08.11.11 Vaidis El0
7 E STR 1 POWER SUPPL Y / OUTPUTS 08.11.11 Vaidis El0
8 E STR 2 POWER SUPPLY - CONTROLLER / SIGNAL SEPARATION 08.11.11 Vaidis El0
9 E STR 3 POWDER FEEDER . LIQUID POLYMER PUMP. STIRRER 1 - 3 - HEATER. WINDING SENSOR 08.11.11 Vaidis El0
10 E STR 4 OUTPUTS CONTROLLER 08.11.11 Vaidis El0
11 E STR 5 OUTPUTS CONTROLLER 08.11.11 Vaidis El0
12 E STR 6 OUTPUTS CONTROLLER. POTENTIAL FREE CONT ACT 08.11.11 Vaidis El0
13 E STR 7 INPUTS CONTROLLER 08.11.11 Vaidis El0
14 E STR 8 INPUTS CONTROLLER. CONTROL HORN ALARM 08.11.11 Vaidis El0
15 E STR 9 INPUTS CONTROLLER 08.11.11 Vaidis El0
16 F KPLAN 1 TERMINAL STRIP - XO 08.11.11 Vaidis El0
17 F KPLAN 2 TERMINAL STRIP - Xl 08.11.11 Vaidis El0
18 F KPLAN 3 TERMINAL STRIP - X2 08.11.11 Vaidis El0 I
19 F KPLAN 4 TERMINAL STRIP - X3 08.11.11 Vaidis El0
20 F KPLAN 5 TERMINAL STRIP - X4 08.11.11 Vaidis El0

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gez. 08.11.11 Vaidi~ Ultromat ATF 2000/96 - S 827 8891 +El0

gepr 08.11.11 Bender


1m Schuhmachergewann 5-11
D-69123 Heidelberg
Drawing-No" t Project-No.: I
CustomerjProject 1 SlID 1
,- PMHD-2011601739 ProMinent Dosiertechnik GmbH 1 SlID
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LIST OF PARTS

ORDER-NO.
POS. BMK ProMinent DESIGNATION DIMENSION/TYPE ORDER-NO. MANUFACTURER
1 1U10 ELECTRICAL CABINET 800x1200x400 CM 5117.500 Rittal
2 1U10 CABLE FLANGE CM 5001.140 Rittal
3 1F7 1027720 CIRCUIT BREAKER S201 - B10 2CDS251001R0105 ABB
4 1F8 1027720 CIRCUIT BREAKER S201 - B10 2CDS251001R0105 ABB
5 1M8 COOLING UNIT 500W 240V 50/60Hz SK 3382.100 Rittal
6 101 700334 MAIN SWITCH 25A,3-POL. KG64BT303/D-A032E Deutsche Solenoid
7 102 1002444 AUXIL. SWITCH 2S+20 LA1 KN22 Schneider Electric
8 102 741057 MOTOR ST ARTER 2,5-4,OA, 230VAC, 50-60Hz GV2-M08K1P7 Schneider Electric
9 102 741060 RC - PROTECTIVE BONDING CIRCUIT 110-250VAC LA4-KA1U Schneider Electric
10 102 741061 AUXIL. SWITCH 1S+10 GV2-AE11 Schneider Electric
11 104 741060 RC - PROTECTIVE BONDING CIRCUIT 110-250VAC LA4-KA1U Schneider Electric
12 104 741061 AUXIL. SWITCH 1S+10 GV2-AE11 Schneider Electric
13 104 741057 MOTOR STARTER 2,5-4,OA, 230VAC, SO-60Hz GV2-M08K1P7 Schneider Electric
14 104 1002444 AUXIL. SWITCH 2S+20 LA1 KN22 Schneider Electric
15 105 741057 MOTOR ST ARTER 2,5-4,OA, 230VAC, SO-60Hz GV2-M08K1P7 Schneider Electric
16 105 741060 RC - PROTECTIVE BONDING CIRCUIT 110-250VAC LA4-KA1U Schneider Electric
17 105 741061 AUXIL. SWITCH 1S+10 GV2-AE11 Schneider Electric
18 105 1002444 AUXIL. SWITCH 2S+20 LA1 KN22 Schneider Electric
19 109 741053 MOTOR PROTECTION SWITCH 1,6-2,5A, 230VAC, SO-60Hz GV2-ME07 Schneider Electric
20 1T9 741041 TRANSFORMER 500VA 200-5001230V 00866070 Murrelektronik
21 2A1 1007545 UL TROMA T - CONTROL ULSa ULSAMOO010101D ProMinent
22 2A3 731049 SIGNAL SEPARA TION ProMinent
23 3A2 1037913 FREOUENCYINVERTER Altivar 12 1 230 V 0,37 kW ATV12H037M2 Schneider Electric
24 3F8 1027738 CIRCUIT BREAKER S201 - K4 2CDS 251 001 R0337 ABB
25 3K5 700904 THERMISTOR RELAY 2W, 230V,+ RESET MK 9163.12/100 E.Dold&Siihne
26 3K6 700904 THERMISTOR RELAY 2W, 230V,+ RESET MK 9163 .121100 E.Dold&Siihne
27 3K7 700904 THERMISTOR RELAY 2W, 230V,+ RESET MK 9163.121100 E.Oold&Sehne
28 3K9 1037731 COUPLER RELA Y 4W, 230VAC 58.34.8.230.0060 Finder
29 308 741053 MOTOR PROTECTION SWITCH 1,6-2,5A, 230VAC, 50-60Hz GV2-ME07 Schneider Electric
30 3T8 TRANSFORMER 500VA 240,415V 1 110,240V 86025 Murrelektronik
31 5K3M 701242 CONTACTOR 3H+1S 230V LC1-SK06+LA 1-SK10 Schneider Electric
32 5K3M 701247 VARISTOR MODUL 110-250V LA4-SKE1U Schneider Electric
33 5K4M 701242 CONTACTOR 3H+1S 230V LC1-SK06+LA 1-SK10 Schneider Electric
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;:s 39 8S6 1006189 LABEL CARRIER ZBZ-33 Schneider Electric
.c 40 8S6 1024097 LABEL POWDER-LIQUID TMxO .8 Schneider Electric
0-0
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"1': 42 8S9 1006176 AUXIL. SWITCH 1S+10 ZB5-AZ105 Schneider Electric
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LIST OF PARTS Ultromat ATF 2000/96 - S 827 8891 + E10
1m Schuhmachergewann 5·11 Drawing-No. ,[ Project-No.: -,-customerjProject 1 SHIT! 1
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gez. 08.11.11 Vaidi~ 827 8891 El0
1m Schuhmachergewann 5-11 Drawing No"t Project No.: Customer/Project I SlID t
gepr 08.11.11 Bender D-69123 Heidelberg PMHD-2011601739 12 SlID
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gez. OB.l1.11 Vaidi§ t.ruVUVUDl1l.10'UU1.) POWER SUPPLY I OUTPUTS Ul tromat ATF 2000/96 - S 827 889
1m Schuhmachergewann 5-11 Drawing-No., t Project No.:
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1 I 2 I 3 I 4 I 5 I 6 I 7 I 8 I 9 I 10

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PROJECT: DOHA SOUTH SEWAGE TREATMENT WORI(S PHASE II EXP, DOCUMENT TITLE: Sludge Handling System Final Dossier
PROJECT CODE: DA 07/08 C 40 G

File No.l0

10.1. Dewatering Centrifuge Package (Part 3 of 5)

10.1.1. Polymer Plant- Ultromat

10.1.1.4~ Manuals, Data sheets and Drawings of Components

10.1.1.4.1. Pressure Reducing Valve

CONTRACTOR:

(
LARSEN & TOUBRO CONSORTIUM LARSEN &TOUBRO •GALFAR Gllfar
ALMISNAD

SUB-CONTRACTOR:
xylem Le t 's S o lve W ate r
CONTRACT NO: C2010/33
---------------~ ------

( o
o
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0'1 Advantages Set range
0'1
I'- o high reproducibility of setting pressure o DMV 755 DN 10 - DN 50 1,0 - 9,0 bar
• great operating security and long service life o DMV 765 DN 10 - DN 50 0,5 - 9,0 bar
o steady low vibration controlling
Working pressure (secondary pressure)
§: • safe mounting with stainless steel bolts
• set pressure minus flow depending pressure reduc-
'1 •
0'1
hermetically sealed by diaphragm with crimped 0- tion:
rings
• DMV 755 1,0 - 9,0 bar
• low maintenance
o DMV 765 0,5 - 9,0 bar
oI • pressure settings at any time, also during operation
0\
0\ • simple connection to the pipeline Constant working pressure
I'-
• radial demountability even after mounting • Difference between maximal and minimal secondary
M
• short compact dimensions In case of threaded necks pressure due to primary pressure fluctuations:
M
approx. ± 0,2 bar
r;; • direct mounting on any valve support by metal In-
§: serts in the body, the movability of the union nuts is Hysteresis
0'1 not effected
v • difference between opening and closing pressure:
+ approx. 0,1 - 0,4 bar
c Application
~
• chemical plants Size
~ • water treatment • DN 10 - DN 50
( '0 •
:> electroplating
N
DIBt approval
o Utilisation
ID o PVC-U Z-40.23-193
N
M
I
o Directly controlled by the operating fluid the DMV o PP Z-40.23-194
o 755/765 reduces the primary pressure to working

II)
pressure caused by system and keeps the operating • PVDF Z-40.23-195
Cl) pressure constant.
co Valve body, piston and separation disc
~ Type of fluids o PVC-U (polyvinyl chloride)
Ii; Technically clean, neutral and aggressive fluids provid- • PP (polypropylene)
:0 ed that the valve materials are resistant at the opera- o PVDF (polyvinylldene fluoride)
~ ting temperature. Refer to the ASV resistance guide.
D
J:
Media temperature Valve bonnet
• see pressure/temperature diagram • PP-GFR

Pressure rating Moulded diaphragm


• PN 10 at +200C • EPDM, PTFE-coated on fluid side

Operating pressure
~ • PN 10
.0
':3
til
~
-----------~~~~ li<
Pressure Reducing Valve DMV 755, DMV 765 ...e,
Vl

tT
rr
CD

Valve seat seal the material of the valve Is resistant against. ~


o EPDM For other media see the ASV resistance guide. ~
o FPM Durablltlty of wear and tear parts Is depending on the s;!O
operating conditions of the application. ~
O-ring sealings at union ends Values < 0 °c (PP < +10 0c) on request with exact data 8
o EPDM of operation .
• FPM Sectional drawing pressure reducing valve
Connection screws type DMV 765
o stainless steel 1.4301
Connection
o body with threaded necks acc. to DIN 8063 complet-
ed with: •
o
• union nut made of PVC-U, PP or PVDF W
I

tv
o Insert with socket end made of PVC-U, PP or 0'1
o
PVDF tv
• a-ring In EPDM or FPM g<
::T
On request we deliver: o
• Insert with spigot end for fusion welding made of
PP or PE
• dimensions acc. BS, ANSI and JIS on request
• body with spigot ends for solvent or fusion welding
acc. to DIN ISO
We kindly ask for your Inquiry. diaphragm

Mounting seat valve


• variable "
\0
\0
I
o
Flow direction
o direction of flow always in direction of arrow ~
+
Colour "'"
\0

0 body PVC-U grey, RAL 7011 :3


V1
PP grey, RAL 7032
( PVDF opaque (yellowish white) secondary side primary side "
W
W

• bonnet PP-GFK orange, RAL 2004


Valve function and design "
\0
\0
Pressure/temperature diagram I

Under operation cond itions the ASV valve DMV 755/ ~


765 Is always open which means It is balanced between 0
the Inlet pressure (primary side) and the lower outlet/
working pressure (secondary side) . At any rise of work- ~
Ing pressure at the valve outlet a pressure compensa- =<
tlon via the control bore takes place at the area below ~
the diaphragm. The higher working pressure activates <f
the large diaphragm and lifts the piston against the e-
spring force. The flow reduces and the working pres- CD
sure drops down until balanced condition is reached g:
again. When the working pressure drops the described b.
procedure reverses. The spring force opens the valve CD
against the lower pressure force below the diaphragm. ~
The flow rises until the balanced condition is reached 0
again. ~
A
@
M d.ii
Temperatur (0C)
If the secondary pressure is additionally Increased by
'"~
The pressure/temperature limits are applicable for a the back pressure, the pressure reducing valve works ~
e
computed operating life factor of 25 years at PN 10. as a non-return valve. This pressure can lead to the de- CD
tT
struction of the valve piston. y' rr
The values are a guide for harmless fluids (DIN 2403) CD
0.
CD
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Q)

oj
-----------~-----
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Pressure Reducing Valve DMV 755, DMV 765
.aIII
I
>
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Valve setting and adjustment Non-observance of the specified instructions and safety
@
..., regulations may cause damage to hea lth and/or dama-
U
The presetting or readjustment Is made by removing ge to assets. ../
...,Itl the protection cap at setting control screw with a coun -
c ternut and by reading the set pressure from the ASV di- * DVS = German Welding Society
8 aphragm pressure gauge guard type 902 in the pipe
Q) system. The counternut can be leaded .
"0
oj
.0 Pressure reducing va lve with pressure
.0
Q) gauge
...,::lIII
I On request the valve can be equipped by the manufac-
>
III turer with a gauge (adhere to the resistance guide) .
Itl
;i
:;: Flow diagram (see page 11)
:;:
There are two different applications the pressure re-
( 0
0
ducing valves can be used for. The difference has to be
seen in the way of valve setting at static or dynamic
N
0\
I
system pressure cond itions.
0\
I"-
DMV 755 with factory-made pressure gauge
M
M
I"-
Lfl

§:
0\
V
+
X
~
0
I
0\
0\
I"-

M
M
I"-
Lfl

§:
0\
V
+ G 1/4"
c
0
u. Operating instructions

0
.c
..... b'UHii(.]~1
( 0
:> Safe operation of the valve can only be ensured if it is
N
0 properly Installed, operated, serviced or repaired by
\0
N
qualified personnel according to its intended use while
M
I
observing the accident prevention regulations, safety
0 regulations, relevant standards and technical regulati-
Lfl
ons or data sheets such as e.g DIN, DIN EN, DIN ISO
and DVS* for example.
~
The intended use includes adhering to the specified li-
.....E mit values for pressure and temperature as well as
Ul
...Q) checking the chemical resistance with regard to the
III
Q) operating conOitions.
i(5 For this purpose, ensure that all components getting in
:r: contact with the media are "resistant" in accordance
with the ASV resistance guide.
t!J The owner/user must inform the authorized qualified
~

ci personnei instructed to perform the assembly, inspec-


U tion and/or maintenance work of any potential danger
015 emanating from the machine line/medium, and ensure
:r: that suitable safety measures are observed. This also
.0
E includes the consideration of local regulations and laws
t!J of the territories of use. .
Q)
.0
.0 If the authorized qualified personnel does not have any
..., operating and maintenance instruction this is to be re-
:::l
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quested prior Installation, ma intenance or repair.
>
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Pressure Reducing Valve DMV 755, DMV 765 lJ)
.....
e:
cr
cr
It>
Dimensions, DMV 755, DMV 765 with union socket ends for solvent or fusion welding Gl
3
cr
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s;!>
n
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A
Gl
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2.
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tv
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0

cr
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+
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§
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DMV755 DMV 765 W
W

'oJ
<D
<D
I
diinensi 63 0
50
2 "
QI
X
+
P,PJ,Ps:i:G"rJ 5jZ,p "'"
<D
PVDF 54,0 §
W,.O V1
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348,0 W
1205,.0 W
200,0 'oJ
2~li ~,0 \0
\0
207,0 I
tv
M8 0
0
147,0
65,0 :E
:E
:E
kg ~standard value~ 0,
III
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0,:1, 4,6 l!I-
0,8 5,2 e
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1,0 0-
V cr
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C.
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0,8 0,8 i ,9 5,2 5,4 5,6 n

1,0 1:'0 ~,.2 ~,0 6(2 6.,4 0
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1,2 1,2 2,5 65 6,7 6,9 nr
~
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.....
III
e
ro
cr
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4 {:.~. - .' ~. . ," : .'. ,." " . 330154 - 2007/01/17


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Pressure Reducing Valve DMV 755, DMV 765
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~ Dimensions, DMV 755 und DMV 765 with spigot ends for solvent or fusion welding
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v
+
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0'1
0'1
r-. DMV755 DMV 765
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r-.
Lfl
25 32 63
S0'1
20 25 50
v 3J4 iI. 2
+
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~ kg (standard value)
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0,7 4,1
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Q,!l 5;0
i"0 1,0 5,5

:c DFM 765
19 1,>p 2,.0 5,~ SA
::.: PVC 2,3 6,0 6,2
(3 P:\IIDF 2,5 6,5, '6'/ 1
cl!
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'330154 , - 2007/01/17 , " , , 5


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- - - - -(fJ})- - Gi<
Pressure Reducing Valve DMV 755, DMV 765 ,....
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e,
0'
0'
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Ident number for DMV 755 with union socket ends for solvent or fusion welding Gl
3
0'
.boc,!y },P d (!l) ~~ l:6 20 25 50 63 :x:
1,0 - 9,0 bar sealing 12"
FPM 119321 119322 119323 119324 l! 19325 119326 119327 Q
EPDM 119314 119315 119316 119317 119318 1193i 9 119320 A
Gl
body pvc d (mm) 16 20 25 32 40 50 63
:r:
1,0 - 9,0 bar s~alrng Q..
FPM 119307 119308 119309 119310 119311 119312 119313 ~
ERDM 1'1 9300 1i1.'9301 119302 1f9'303 l'f930~ 1193'05 119306 ~.

.bod.v, P~DF 1" 2'0' 25 32 40 50 63 "'


VJ
1,0 - 9,0 bar @
1193[37 co
1193315 119338 11 9,3},,9 :11934'0 1:19341 ro
119329 119330 11'9 331 119332 119333 119334 V1

Ident number for DMV 765 with union socket ends for solvent or fusion welding o
W
IV
CTI
16 20 25 32 40 50 63 o
IV
<
1i9}6~ 11§i36 4 U~ 366
119356 119357
1,}:9365
119358 119359
1~93§.§
119361
1}'939,9
119362 ~
o
16 20 25 32 40 50 63

119350 119351 119352 119353


119343 119 44 fr9345 11:9346

:2'0 25 32 40 63'

11 ~378 !I.l!9379 H 9 3,80 U9381


119371 119372 119373 '119374 '-l
\0
\0
I
Ident number for DMV 755 with spigot ends for solvent or fusion welding o

'32 Ql1
16 ~9 25 x
+
q 2"069
122062
12·2 070
122063
12 '07..1
122064
1!Q tO:;l~
122065
122073
122066 ~
""
\0

.9
V1
20 -..J
16 25 32 40 50 63 w
w
122056 122057 122058 122059 '-l
12 z0~9 !li2?OSO i22'051 ':&;12052 \0
\0
I
IV
2'0 25 3 '2, 40 50 o
o
122084 1220'8,6 122087 ~220if§ :;:
122077 122079 122080 122081 :;:
:;:
.ill
Ident number for 765 with spigot ends for solvent or fusion welding ~
~
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bO,dy PP d ~mm~ 16 ~o 25 32 140 50 ro
0'
0,5 - 9,0 bar sealing 0'
1221lH 1'22113 122iW5 l:2211;Z ro
FRM 122Jli il.2 r i 21I4 J:? 2116 C.
EPDM 122104 122105 122106 122107 122108 122109 122110 ro

body' pvc d (mm) 16 20 25 32 40 50 63 8::J
0,5 - 9,0 bar se.!lJl/ fg liT
FPM 122097 122098 122099 122100 122101 122102 122103 ~
@
EPDM 12202 0 122091 1'22092 122093 1"22'094 1220'9 5 122096 OJ
~
body; PVDF 1'6 20 25 '3 2 40 5.0 63 ~
e
0,5 - 9,0 bar n>
0'
1~2'1,26 12212 12'2 1!29 12·21:30 122'131 0'
n>
122119 122120 1221.22 122123 122124 C.
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330154 - 2007/01/17
(

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ai
_____________~ -----e
.0
.0
Q)
Pressure Reducing Valve DMV 755, DMV 765
il
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Spare part and parts list
ro
@
.....
u
.....cro
1- ' 14

18~
0 14
u 18
7 7
Q)
"0
4 2.4 4
ai 15
.0
.0
2.7
Q)
16 2.3
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I 5 ~
~ 5
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2
ro
~
3: 12 12
3:

t, 0
0 2-- 10
N 10
d-
O>
" 9 1 3
2.5
2.6 3
6 @ 2.2

e-'-'
M
M 1
"
lI)

§:
8 1
3
2.1
11
13
0> 29 29
'<t 2.8
+ 28 26
X 27 27
{E 8
0

I
0>
0>
r-..
M
M --31
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§: ~ -----21
----26
0>
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+ DMV755 DMV765
C
~
guantity
0
:5 i
( 0
;:; 1
N
1
0
\0
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N
M
1
0
I
1
1
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CO 1
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ID 1
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1
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1
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u 1
clS 1:
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E
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.0
.0
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'.< 3301'54 :- 2007/01/'17 · " , ," '" ", 7


, i '. ~ ...:.....
'l.'~} : ~, ~ .. : . . . , . ' ,I '~,' '
l>
~
Pressure Reducing Valve DMV 755 ~
c:'
cr
ON 10 cr
Characteristic curves DMV 755 CD
G)
The valve curves show the primary pressure or working 3
pressure PA above the flow Q In I/h . cr
:r
Parameter Is the set pressure PE at Q = 0 I/h. 10 :
R'
9 C ~Ps ()
The curves are valid for water at +20°C.
The respective top and lower curve (at same PE) show
'-
co
.n
~
8
:Po~
,= ?
A
G)
the reseat Ps respectively opening pressure progres- o. 7
C
sion po. ~
:J 6
III
III
~ 5 C
0.
Ol 4
c:
:2
(;
3 ,
s: 2 :

( 1
~
o
0 I
0 100 200 300 400 500 600 700 800 W
N
CJ\
flow Q I/h o
N

ON 15
g:<
ON 20 ::J'
e

10
10 ·
.... ....
co
.n
i)
c::: ; 1-- p. co
.n
9
,~ l....... p•.
,
0.
~ 8 Po-":" . = ~
0.
8
Po'--'; :=
~ 7
c:: ~ 7
~
:J :J
III
III
~
0.
6
5 c::
== III
III
~
0-
6
5 ,c -
= -...J
\/)
\/)
Ol
c: '4 :::::::
Ol
c: 4 :::: o
I

:2
.... J :2
e 3 '-
C e 3 ~
3:
:1 ~
i 3:
2 " x
+
~
~
1 I; \/)

0 I

0 200 400 600 800 1000 1200 1400


0 :9111
0 500 1000 1500 2000 2500 3000 -...J
flow Q I/h flow Q I/h W
W

-...J
\/)
ON 25 ON 32 \/)
I
N
o
o
10 10
I-
co 9 C :1-; p. '-
co 9 ~,
. P
.n .n s
c1
Q)
l-
8
7 C
po·...... ·
= 0-
~
~ 8
7 C::
lpo~
I
::J :J
III
III
Q)
6
= III
III
~
6 ~
~
'- 5 0. 5
0- C
Ol
Ol
c: 4 ::; c: 4
:2
L- 3
:2
'-
-=
0 C e 3 I;
3: 3: ::;
2 : 2
, C 1 c::
0 0
0 1000 2060 3000 4000 5000 0 1000 2000 3000 4000 5000 6000 7000 8000 9000
flow Q I/h flow Q I/h

(
(

u
v
c.i
------($)-~
.0
.0
V
Pressure Reducing Valve DMV 755, DMV 765
....1/1
:J
I
>
1/1
ON40 ON 50
III
@
11
2c: 1.0 . 1.0 .
0
u 9 ·
• c::::
~=====;=~.~~~.~ps~·=====~==~
9
V 8 .
"0 8 .
iii 7 . Po-"
c:;:======~==~~~==~~==~~~==
.0

6~~~~~~~~~~=
.0
67
V
....
:J : -=:, -=:

45~~=;=~=~===~~=~=~~==~:::
III
>
I 5c:
1/1
III . : 4 .

~ 3 C:::
==
?;
3Ct~~~~~~~==~~=
2 : 2 .
0
0
N
le- 1 =:::::::::=====~~~_
0\
I
o. o.
0\
,.... .0 2000 4000 6000 8000 10000 .0 2000 4.000 6000 BOOO 10000 12000

f"l
flow Q I/h flow Q I/h
,....
f"l
.
III

8 ON 10
0\
Characteristic curves DMV 765
V
+ The valve curves show the secondary or working pres-
X sure PA above the flow Q in I/h.
{E Parameter Is the set pres!1ure PE at Q = 0 I/h.
0
I The curves are valid for water at +20oC.
0\
0\
,.... The respective top and lower curve (at same PE) show
the reseat Ps respectively opening pressure progres-
f"l sion Po.
f"l
,....
III

8
0\
V
+
c:
Ii: , i
0
.s::.
lr~~==~~===i~===
1-
.0
( ....0
.0 100 200 300 400 500 600 700 600
:>
N flow Q I/h
0
\0
N
f"l
I
0 ON 15 ON 20
III
V

I
C!l
~
Ul
L-
V

I
1/1
V
~
'0 f
:r:
Cl
~

ci
u
= I
o1l
:r: I
.0
E
Cl
I
f
v
.0
.0 o 200 400 ·600 600 1000 1200 1400
500 1000 1500 2000 2500 300.0
....
::J
(/) flow Q I/h flow Q I/h
>
(/)
( «
-----------~ --~~
Pressure Reducing Valve DMV 765
ON 25 ON 32

10 · 10 .
i
L.
to 9c::: .-.-. P
s .0
L.
to 9 I::: :-- Ps
.0
« 8 · « 8 ;P6-' :
0.
~ 7 t
Po'-fI>..
== 0.
~ 7
F
:J
'"~ 6 ' =
:J
'"~
IJ)
6 ;

5 (
=
0. 5 C 0.

:Q
01
c 4 . = Ol
c
:Q
L.
4
,
L.
0 3 C 0 3 C
:; :;
~ 2
( 2
o
1 ~ 1 C I
W
0 IV
o· 0\
o
0 1000 2000 3000 4000 5000 0 2000 4000 6000 8000 IV
flow Q I/h flow Q I/h <
5'
g:
o
ON40 ON 50 •
cil
::>
+
./>
10 . 10 · <0
§
L.
to
9e: 1 - P~
L.
to
g e ' ~' Ps ' U1
.0 .0 '..!
«
0.
OJ
8 :
7c:
po'~
-= «
0.
~
8 ·
7 '
C
, P6-"
==
W
W

L.
::> '..!
::>
IJ) 6 . ;' =1 IJ)
III
6· =l <0
\0
l3
L. 5 ' ~ 5 C o
I

0. !':: 0.
Ol 4 ,i :; 01
c 4 :
c:
:Q :Q
3 ' L.
3 ~
~
L.
0 0
:; :; 2'
2 I
I
1 I: 1 i:
o· 0 '
( 0 2000 4000 6000 8000 10000 0 2000 4000 6000 8000 10000 12000

flow Q I/h flow Q I/h '..!


<0
<0
t!.>
o
o
Operation conditions T - -- - - - _ . _ -- - - "
1 -.'!!
.. _-
0 see diagram III
~ i
I

~ .
L.
to

PE set pressure
.0
«
0.
p.
p. !, ~Ps
>-,
.el i

PA working pressure (secondary pressure) ~


J '-. i :

Ps closing pressure
::>
III

'"~
Po
P,,-.... I I -
Po opening pressure 0.
01
Ps - Po hysteresis c:
:g 8:J
PE - PA flow depending pressure reduction 0
:; fiT
1+
@
OJ

~
0
0 Q
CD
flow Q I/h cr
cr
CD
C.
CD
"0
Q)
-----------~ -----
ai
.0
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Q)
Pressure Reducing Valve DMV 755, DMV 765
....til::I
~ Application of pressure reducing valve
@ "' 1. Secondary pressure - system closed
tl If shut-off valve opens the working pressure PA drops
J9
c by the opening pressure Po.
0
u
Q)
"0
ai
.0
.0
Q)

....::Itil e. g. to keep tank at shut-off valve


I DMV constant reduced pressure
> closed

~---©~~~~~
, ~--~~__~'J~--~~
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3: 0> j
( 0
0
N
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(1)
(1)
I"- primary pressure secondary pressure
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9: 2. Secondary pressure - system dynamically flowing


(1)
v Ifshut-offvalve closes the working pressure PA rises by
+ the closing pressure Ps.
><
~
0
I
(1)-
(1)
I"-
necessary slow-down or pressure loss by respective shut-off valve
DMV plpelength or other components open
M
M
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9:
(1)
v
+
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0 primary pressure secondary pressure
....0
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lI) Malfunctions, possible causes and remedy


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Pressure Reducing Valve DMV 755, DMV 765 !4
c:
c:r
c:r
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Installation M d.J. G)

o Depending on the type of connection the pipe ends Consider tightening torque or mounting of pressue g.
have to be properly prepared acc. to all technical gauge: max. 3Nm ,;' I
~
standards. n
o Valve to be radially installed acc. to all technical _ k,·ii f'
standards between the pipe ends. Do not allow elastomer components, especially the A
In case of flange connections the torques of the EPDM sealing elements, to come into contact with syn- ~
screws to fasten the flanges have to be observed. thetic or mineral ol/s, grease or cleaning agents. Dan- I

o After proper installation the pipe system with all ger of swelling . Only appropriate grease should be used Q.
such as e.g. silicone grease. ,;' ~
components has to be tested for leakages. iii'
(f)
Cl>
Pressure gauge execution ....
Disassembly Ul
If the valve is equipped with a pressure gauge, the @
- k(·$· pressure gauge may be tightened with max. 3Nm only. g'
Adhere to the operating Instructions.
( We recommend
o If required protection clothes must be worn.
o installing of filter or strainer (see print No. 330034) ?
o The pipe section Is to be shut-off and to be emptied. directly before the valve for avoiding impurities e.g. Kl
Ensure a safe pressure release. at valve seat. ~
N
o Any fluid rest is to be disposed properly. <
0"
Valve bonnet S-
o
• Position the valve upright.
• Remove cap (Item 18).
o Loosen counternut (item 16) and adjustment screw
(Item 15), for type DMV 765 counternut (item) and
adjustment screw (Item 2.2), so far that the spring
(item 8) Is totally released .
• Loosen and remove housing screws (Item 19, 20)
from valve body (item 1) and bonnet (item 2).
• Bonnet (item 2) to be pulled off upwards. Remove
spring (item 8), pressure plate (item 6) and steel
ball (Item 9), for type DMV 765 only the spring
(item 8). ~
x
Valve body and diaphragm +
o Perform the disassembly as already described §
""
\0

above. lJ1
'.I
( o Spring plate (item 4) with piston (item 12), dia- W
W
phragm (item 5), separation disc (item 3), gasket I
(item 29) and piston guide (item 28) to be pulled out '.I
of the valve body (Item 1). Remove the O-ring seal- \0
\0
Ings (item 13, 27 and 11) with a blunt tool. N
I

Loosen screw (item 14) and remove piston guide o


o o
(item 28). Release screw (item 14) out of piston
(Item 12). Remove gasket (item 29). Piston ~

(item 12) to be lifted upwards out of separation


disc (Item 3). Remove O-ring sealing (item 10) out
~
w
(f)
of separation disc (Item 3) with a blunt tool. Remove <
diaphragm (Item 5). ~
c
Cl>
Assembly c:r
c:r
Cl>
In the reverse order as described above . 0.
Cl>

- ~[.)j 8
During assembly check the correct position of the sep- 6r
aration disc bore and the control bore . ,;' 1=1-
@
o diaphragm, gasket, O-ring sealings to be checked w
for damages, dimension deviations, shore hardness
etc. Replace if necessary. ~
£!
• screw torques (lubricated screws): Cl>

M6 and M8: approx. 6Nm Subject to technical modifications g:


Cl>
0.
( Cl>
)
CLIENT CONSULTANT
PUBLIC WORKS AUTHORITY
STATE OF QATAR .
KE~ KEO INTERNATIONAL CONSULTANTS
DOHA, STATE OF QATAR

PROJECT: DOHA SOUTH SEWAGE TREATMENT WORI(S PHASE II EXP. DOCUMENT TITLE: Sludge Handling System Final Dossier
PROJECT CODE : DA 07/08 C 40 G

( File No.10

10.1. Dewatering Centrifuge Package (Part 3 of 5)

10.1.1. Polymer Plant- Ultromat

10.1.1.4. Manuals, Data sheets and Drawings of Components

10.1.1.4.2. Solenoid Valve

CONTRACTOR:

(
LARSEN & TOUBRO CONSORTIUM LARSEN &TOUBRO •GALFAR Gllfar
ALMISNAD

SUB-CONTRACTOR:
xyLem Le t's Solve W ater
CONTRACT NO: C2010/33
- -- - -- f/) ~----=---=---=-

o
o
N ,
~
f'.,
Function Wiring scheme
M 0 pilot operated
~ 0 normally closed (NC) NC A
~ normally open (NO)

[]~-_: {_[J . .:_


0
8
0'1
v
+
x
Mode of operation
In a deenergized state, the medium pressure Is built up
] <r:
{J!. by a servo bore on the upper side of the diaphragm (2),
the valve is closed.
1-----'
P
o
J, When energized, first only the pilot valve opens, I.e. the
~ plunger and the connected pilot diaphragm (5) are A
lifted and a relief well becomes free. This causes a pres- NO
~ sure drop above the diaphragm (2) and the valve opens
!?; because of the medium pressure.
S In the pilot valve a liquid filling (standard: silicone oil) L.lJ>
0'1 supports the closing effect of the spring (11). The pilot
v diaphragm (5) separates the medium from the plunger
~ (10) or from the atmosphere. After releasing the union
~ nut (8) - in depressurized system - the pilot valve
can be removed without problems for cleaning the ser-
o vo bores. The coil Is fastened with an acorn nut (15) be- Viscosity
~
2
ing 360° adjustable against the valve body. up to approx. 38 mm /s (cSt)
( 5 The solenoid valve type 160 has a very resistant ther-
8l moplastic .construction even against external mechanl- Body material
~ cal effects. o PVC-U
M ,
o o PP
M d'" o PTFE
Lfl For perfect function a differential pressure of min.
Jl 0,3 bar is necessary. <:.>
Seals
....~
Ul
L
Design • EPDM
QI
ID Seat valve with diaphragm, plunger sealed. • FPM
~ Ambient temperature
"6 Type of fluids
:r: o max. +SO°C
o Technically clean neutral or aggressive fluids or gas-
~ eous media provided that the components getting in
contact with the medium are resistant at the opera- Media temperature
8 ting temperature according to the ASV resistance see pressure/temperature diagram
ol:S guide.
:r: Connections acc. to DIN/ISO
E Nominal diameter
• pvc- U: spigot end for solvent welding
~ • DN 15 - DN 50
• PP: spigot end for fusion welding
.c
.c
:aUl Pressure range • PTFE: female threaded socket
> 0 0,3 - max. 6 bar (see table)
( ~
___________~ ~s~~
Electrical part switching times
o OpeninQ: 30 ms - 150 ms
Plug socket
• Closing: 50 ms - 1 sec
• acc. to DIN 43650
Protection
Nominal voltage
• IP 65 with plug socket mounted
• 230 V 50 Hz
o EEXM II T4 execution on request!
• 24 V DC
_ ~(.i' ~
Voltage tolerance
For Ex execution the operating or system pressure Is
o ±1O% acc. to VDE 0580 reduced by about 20%. :r
Pilot operated valves are not suitable for cristallizinJj Q.
Power consumption media. Q:) :f
~.
o 230 V 50 Hz: 6,5 VA
Mounting .,<Tl
~
o 24 V DC: 5 watt
Coil preferably In upright position, arrow always In
0>
Duty factor direction of flow. <Tl
1I1
• 100% ED
oI
W
N
Pressure/temperature diagram 0\
o
N
<
~
,f -_.._._--"-
::r
PVDF o
,,
61
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I _ _ I-- .. _ ~ ".. ~~~ _ .. _.-+. _~_. _: '-l

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o

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§
o 20 40 60 80 -40 -20 0 20 40 60 80 100 120 1I1
'-l
W
temperature (OC) W

Pressure/temperature diagram
The pressure/temperature limits are applicable for the
stated nominal pressures and a computed operating life
factor of 25 years .
The values are a guide for harmless media (DIN 2403),
to which the material of the valve Is resistant.
For other media see the ASV resistance guide.
The durability of wear and tear parts depends on the
operating conditions of the application.
For temperatures below OOC (PP < +10°C) please spe-
cify the precise operating conditions of the application.
n
o
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or
~
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8 36 wide
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ai view "A"
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g:, Dimension

~DN G H L M
[;) (rn m) (inch) (mm) (mm) (mm)
§: '1.5 it.2 ~9 6 '5
0'1 20 3/4 63 10 M6
v
+ 2-5 1 63 aro M6
32 11/4 91 12 MB
40 !I. If/r2 9'll] 12 M8
50 2 109 12 M8
o
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- - - - -($)- -
Ident number
:l>
Vl
<
Vl
rt
pvc-u C'
0-
0-
ro
24VOC G)
PVC-U 3
0-
EPOM IjPM EPDM :::J:
69244 69246 69245 69247 l'!'
69248 6925() 6'9249 69251 n
p
69252 69254 69253 69255 ;:0;
69256 §:92'58 6925 ~ 69260 G)

69261 69263 69262 69264


69265 692'6y 6926'6 6,9268
pp
voltage
ON
~mn:!) EPOM FP.M EPDM
15 45369 48067 45143
20 463V9 11333% 45144 o
25 45370 46390 45145 W
N
32 4:32'9,1 <18'068 451'46 (J)

4"8069 o
40 42323 45147 N
fsp ~8066 4.3~,5.7 · 451.'4'8 <
g:
:T
PTFE o

69270
692 73
69277
6 ' 81
69285 "-I
M21l'9 10
10
I
o
Sectional drawing and parts list
2J
x
d,!!!i!gmitlen
14 "_,, 15 16 valve body +
.j>.
Cliap.hr;.agm ,...,
10

cover .8
so e s U1
"-I
12··- _" pilot diaphragm W
W
11 .__
"-I
10
10 -- - ---, 10
r0
9 ... , o
o
8

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ro
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ro
, >', ," £".

~,:4 . " ,'; " ",~,' ' .... -: , ::.. '-,' " '" -"'.', " 330082 - 2008/07/14
~~1~:- .. ;'';'tr~~l;,~'''''' ~~ ~'?,;-!. . :: ~~: ..
1-' ;1>'/i ~,:" .' ~ ,", ;.! '.:' ~ I -'
I
CLIENT CONSULTANT

(~ KE~
PUBLIC WORKS AUTHORITY KEO INTERNATIONAL CONSULTANTS
STATE OF QATAR DOHA, STATE OF QATAR

PROJECT: DOHA SOUTH SEWAGE TREATMENT WORKS PHASE II EXP. DOCUMENT TITLE : Sludge Handling System Final Dossier
PROJECT CODE : DA 07/08 C 40 G

( File No.l0

10.1. Dewatering Centrifuge Package (Part 3 of 5)

10.1.1. Polymer Plant- Ultromat

10.1.1.4. Manuals, Data sheets and Drawings of Components

10.1.1.4.3. Transformer

(
/

CONTRACTOR:

(
e
L.ARSEN .& TOUBRO CONSORTIUM LARSEN &TOUBRO •GALFAR Gllrar
ALMISNAD

SUB-CONTRACTOR:
xylem Le t's Solve W ate r
CONTRACT NO: C2010/33
(

MET Single phase control and isolation transformer P: SOOVA IN: 240·41SVAC OUT: 110-110·20VAC

Single·phase · Control and Isolation transformers


Power: 500 VA

Image

· (EN 61558)
. touch protected (EN 60529) IP20
. Isolation class T60/B

, A~provals

e'iUus

Technical Data
Isolation class T60/B
!.el11per~tur~r~nge ... _ ~2.Q:::~~O '~~_".<'condensatio~ .. ..................... ................ ...................... ..
.~ou~tin~l11e~ho.d . .. ...... ... . ... Ketholel11~u~ting
~ushcur~t _. _ _____ - __~!l.~~ (240VAC) ;33.6~~5...'!..A~ ____.- .-- ___.. _.. _ _ _ _ .~~~_____. _~ __ ........
Input
'.'P..lJ~~.~t~~e 240/415 VAC
_ •• _ _ _ _ • _ __ • ••• _ _ _• , _• • 0_. _ _ _ ••• _ • •• _ _ _ _ 0 • • _ • • - • • • • • . _ • • • _ _ _ _ •• _ • • • • • • _ .•••_ ••• _ • • •••• • _ _ • _ _ _ _ _• • • • • • • • •• _ . _ _ _ _ .~. _ _ _ • _ _ _ _ _ •••• _ • ••• • • •. _ _ . _ • • • •• • • _ . _ . _ _

FrequenC¥ ..... ..____ 50/60 Hz


Short·circuit current ········--·-······-- ·-··- ST33-A(240·iiACF29.7 A(41S·vAcj--··-·-----· -·····-- --··-

( ,Inp.~~u~~~~~t .._. _ ==-


. -------I~~l2~Q~~C); ~:3~~(~~~Y~SL- -- --- ··---===-. ....._....._
Output
Output voltage 110/240VAC
General data
Standards ... (E.~ . ?1558.~2·4),(E~62041.)(ateg?ryO ...
Iesti~?I~tio~~oltage ... .................. .. ... .... . ........... ~k~(p:iI11Isec:L .. _.__ __ .. .
Dimensions Hx Wx D 112.6 x150 x170 mm
Fixingce~~~s_a_x_b_ x_
c _ __ 90 x122 x 7 mm
Drill ...hole0
......... .......... 7 xllmm
Commercial data
Gross \\I~ig.~t 8150
N ~wei~t _ 7900
lJIJei~htu.nit ... . ..... ..... .. ~ral11
Basic unit .................... .. _ . pc:
Customs tariff number 85043180
Unit(piece) ... 1
limited value 1

All data on this data sheet was compiled carefully.


liability regarding correctness, completeness, and actuality is limited to gross negligence. Created: 01/12
Murrelektronik GmbH I FalkenstraBe 3, D·71570 Oppenweiler I Fon +49719147-0, Fax +49719147-130 I info@murrelektronik.com I www.murrelektronik.com
stay connected
Circuit diagram

INPUT OUTPUT
415V
• 0
~ 110 V
240V ~ • 61100 V

@
0
• ~
a
20V

Dimension drawing

I
\ b
I~

(
w

All data on this data sheet was compiled carefully.


liability regarding correctness, completeness, and actuality is limited to gross negligence. Created: 01/12
Murrelektronik GmbH I FalkenstraBe 3, D·71570 Oppenweiler I Fan +49719147-0, Fax +49719147-130 I info@murrelektronik.com I www.murrelektronik.com
I e)
I

(,

(
CLIENT CONSULTANT

(~ KE~
PUBLIC WORKS AUTHORITY KEO INTERNATIONAL CONSULTANTS
STATE OF QATAR DOHA, STATE OF QATAR

PROJECT: DOHA SOUTH SEWAGE TREATMENT WORKS PHASE II EXP. DOCUMENT TITLE : Sludge Handling System Final Dossier
PROJECT CODE: DA 07/08 C 40 G

File No.l0

10.1. Dewatering Centrifuge Package (Part 3 of 5)

10.1.1. Polymer Plant- Ultromat

10.1.1.4. Manuals, Data sheets and Drawings of Components

10.1.1.4.4. Cooling Unit

CONTRACTOR:

l.ARSEN & TOUBRO CONSORTIUM LARSEN &TOUBRO· GALFAR Qllrar


ALMISNAD

SUB-CONTRACTOR:
xylem Le t's S o lve W ate r
CONTRACT NO: C2010/33
Schaltschrank-
KOhlgerat
Cooling unit
Climatiseur
Koelaggregaat
Kylaggregat SK 3359.xxx SK 3385.xxx
SK 3382.xxx SK 3386.xxx
Condizionatore
per armadi SK 3383.xxx SK 3387.xxx
SK 3384.xxx
Refrigerador
para armarios
I';I~D-:;'\"-m
~-!J ';I~i::J..= ':J ~

M()ntage-, Installations-und Bedienungsanleitung ..


. Assembly and operating instruCtions .
Manuel d'installation et de maintenance
Montage- en bedieningshandleiding '

,"
Montage- och
-
.
'hanteringsamiisning .
, .

Istruzioni dHnontaggio e funzionamento


Instrucciones de montaje

FRIEDHELM LO H GROUP -RITTAL


Contents
1 Notes on documentation .......... 4 5 Commissioning ................ 19
1.1 Associated documents .. . . .. ... .. . . .... 4 6 Operation ..................... 20
1.2 CE labelling ............... .. ......... 4
1.3 Retention of documents ................ 4 6.1 Control using the Basic controller ...... 20
1.4 Symbols used .................. . ..... 4 6.1 .1Properties ......... .... . . . . . ... . . . .. . . 20
6.1.2 Operating and error display . . .... . ..... .. 21
2 Safety notes .................... 4 6.1 .3Test mode for the Basic controller .. . . . . .. . 22
6.1 .4Setting the temperature .... . . ... . .. . .. . . 22
3 Device description ........ . ...... 5 6.1 .5Resetting the Basic controller . . . ... . .... . 22
3.1 Functional description ............ .. ... 5 6.2 Control using the Comfort controller .... 23
6.2.1 Properties . .. . . . . . .. . . . . . .... . . .. . .. . .23
3.1.1 How it works . . . . . ... . . . ....... ..... .. . 5
3.1.2 Controller . .. . . . .. ... .... . . ... ..... ... . 5 6.2.2 Launching test mode . . ... .. .. . .. . ...... 23
3.1.3 Bus mode (Comfort controller only) . . .. . .. . 5 6.2.3 General programming information . ... . . . . .23
6.2.4 Variable parameters .. . .. . ... ... . . . . . ... 24
3.1.4 Safety equipment .. . .. . . . . . . . . . . .... .. . 6
3.1.5 Condensation . . .... . .. .. . .. . . . . . . . . . . . 6 6.2.5 Programming overview . . .. .. . . ..... .... 25
3.1 .6 Filter mats ....... . . .. ......... . . . .. .. . 6 6.2.6 Defining system messages
3.1 .7 Door limit switch .. . ......... . ...... . . . . 6 for evaluation ...... .. . . . ... . .. . ...... .26
3.1 .8 Additional interface X3 .... ... . .. . .. . . . . . 7 6.2.7 Setting the master-slave identifier .. . . . .. . .27
6.2.8 Evaluating system messages . . ..... ... . .. 27
( 32 Properusage .. . . . .................... 7
6.2.9 Resetting the Comfort controller . .. .. .. . .. 29
3.3 Scope of supply ...................... 7

4 Assembly and connection ........ 7 7 Inspection and maintenance ...... 29


4.1 Choosing the installation site . . ......... 7 7.1 General ............................ 29
7.1.1 Compressed air cleaning .. . .... . ... .... . 29
4.2 Assembly instructions ........ .. ....... 7
4.2 .1 General . .. .. . . . ...... . . . . ... . . . . ..... 7
8 Storage and disposal. ........... 31
4.2.2 Layout of the electronic components
in the enclosure . . .. . ... . . ... . .. . . .. ... . 8
9 Technical specifications . . ....... 32
4.3 Fitting the cooling unit ................. 8
4.3.1 Cutting out the enclosure ....... .. . .. . . . . 9
10 List of spare parts ........ . ..... 35
4.3.2 Top mounting of the cooling unit ..... . . ... 9
4.4 Connecting the condensate discharge ... 10
11 Appendix:
4.5 Notes on electrical installation ......... 10
4.5.1 Connection data . . . . . .. . . .. . ..... . .. .. 10 Cut-out and hole sizes ........... 37
4.5.2 Overvoltage protection 11.1 Dimensions for assembly ..... ....... . 37
and supply line load . ... . . .. .. ...... . .. 10
4.5.3 Three-phase devices ... . . . .. ..... . ... . 11
4.5.4 Door limit switch . .... . . . .. .. . ... . ..... 11
4.5.5 Notes on the flicker standard .. ..... . .... 11
4.5.6 Potential equalisation . ... .. .. . . ........ 11
4.6 Carrying out the electrical installation ... 11
4.6.1 Bus connection
(only in conjunction with several units
with a Comfort controller) ... . . . . .. . . .... 11
4.6.2 Connection X3 for serial interface . .. . ..... 11
. 4.6.3 Installing the power supply . . ..... ....... 13
4.7 Finalising assembly .... . ...... . ...... 19
4.7.1 Installing the filter media . . .. .. . ... .. . . . . 19
4.7 .2 Fitting the cooling unit. . .. ......... .. . .. 19
4.7.3 Setting the filter mat monitor
(only with Comfort controller) . . . . ... . .. .. 19

RID AL cooling unit assembly and operating instru ction s 3


1 Notes on documentation
1 Notes on documentation 2 Safety notes
These assembly instructions are aimed at tradesper- Please observe the following general safety instruc-
sons who are familiar with assembly and installation tions when assembling and operating the unit:
""""".................J of the cooling unit, and at trained specialists who are - Assembly, installation and servicing may only be
familiar with operation of the cooling unit. performed by properly trained specialists.
- Do not obstruct the air inlet and air outlet of the
1.1 Associated documents cooling unit inside and outside the enclosure
There are two sets of instructions for the unit types (see also section 4.2.2).
described here: - The heat loss of the components installed in the
- Assembly and installation instructions enclosed enclosure must not exceed the specific useful
with the unit in the form of a paper document cooling output of the cooling unit.
- Assembly, installation and operating instructions - The cooling unit must always be transported in a
enclosed with the unit in the form of a PDF file vertical position.
(Adobe Acrobat) on CD-ROM . - Use only original spare parts and accessories.
We cannot accept any liability for damage asso- - Do not make any changes to the cooling unit other
ciated with failure to observe these instructions. than those described in these instructions or asso-
Where applicable, the instructions for any accesso- ciated instructions.
ries used also apply. - Risk of burn injuries! For cooling units with auto-
matic condensate evaporation, the surface of the
1.2 CE labelling thermal element will get very hot during operation,
The declaration of conformity is supplied with the unit and will remain so for some time afterwards.
as a separate document. - The mains connector of the cooling unit must only
be connected and disconnected with the system
1.3 Retention of documents de-energised . Connect the pre-fuse specified on
These instructions and all associated documents the rating plate.
constitute an integral part of the product. They must
be given to the plant operator. The plant operator is
responsible for storage of the documents so they are
readily available when needed .

1.4 Symbols used


Please observe the following safety instructions and
other notes in this guide:
Symbol for an Instructed action:
• The bullet point indicates that you should perform
an action .
Safety and other instructions:

A! Danger!
Immediate danger to life and limb!

Caution!
Potential threat to the product
and its environment.

Note:
Useful information
and special features.

4 RIITAL cooling unit assembly and operating instructions


3 Device description
3 Device description This circuit is filled with a readily boiling substance ,
the refrigerant. Coolant R134a (CH2FCF3) is chlorine-
Depending on the model chosen, your cooling unit
free. Its ozone destruction potential is 0, making it
may vary in appearance from the illustrations con-
very eco-friendly. A filter dryer (5) which is integrated
tained in these instructions. However, the functions
into the hermetically sealed cooling circuit provides
are identical in principle.
effective protection against moisture, acid, dirt parti-
cles, and foreign bodies within the cooling circuit.

PSAH
I'"'=--"'-b Condenser (3)

pressure-
operated "'-
2 switch
Compressor ~ .y Filter dryer (5)
(2)

Extern al circuit
Intern al cirCUit -I .- .- .
.,.J
,
-~-R
j 'Temperature
control

Evaporator coli (1) J.>"<C><)


~
Expansion valve (4)
6. 7,8
Evaporator fan

Fig. 2: Cooling circuit


9 In the evaporator coil (1), the liquid coolant is con-
verted to a gaseous state. The energy needed for
this purpose is taken from the enclosure air in the
/"7..<0-----+- 10
form of heat. which has the effect of cooling the
enclosure air. In the compressor (2), the coolant is
---- H7t1r*--+-- 11 heavily compressed , so that it achieves a higher
temperature inside the condenser (3) than the ambi-
12 ent air. This means that excess heat may be emitted
to the ambient air via the surface of the condenser,
as a result of which the temperature of the coolant
drops and it is converted back into liquid. It is
Fig. 1: Unit description re-injected into the evaporator coil via a thermostatic
Legend expansion valve (4), which causes it to cool down
1 Enclosure further, and is then once again able to absorb the
2 Air outlet holes energy from the enclosure air in the evaporator coil.
3 Rating plate The whole cycle begins again.
4 Louvred grille for air inlet
5 Display 3.1.2 Controller
6 X2 master-slave connection (underside of the unit) RITTAL enclosure cooling units are fitted with a con-
( 7 X1 terminal strip (underside of the unit) troller for setting the functions of the cooling unit.
8 X3 optional serial interface (underside of the unit)
Depending on the design, this is either a Basic con-
9 Dispatch bag
10 Twin-threaded bolt troller (display of the operating status via LED) or a
11 Condenser Comfort controller (display plus extended functions,
12 Condensate discharge see chapter "6 Operation", page 20).

3.1.3 Bus mode (Comfort controller only)


3.1 Functional description
The serial unit interface X2 allows you to create a bus
Enclosure cooling units are designed to dissipate
connection with up to ten cooling units using the
heat from enclosures by cooling the air inside the
master-slave cable (shielded, four-wire cable, Model
enclosure and so protect the temperature-sensitive
No. SK 3124.100). This allows you to implement the
components. It is mounted on the roof of an enclo-
following functions:
sure.
- Parallel unit control (the cooling units in the network
3.1.1 How it works can be switched on and off simultaneously)
The cooling unit (compression refrigeration system) - Parallel door status message ("door open")
is comprised of four main components (cf. Fig . 2): - Parallel collective fault message
the evaporator (1), the coolant compressor (2), the
condenser (3), and the control or expansion valve
(4), which are connected by suitable pipework.

RIITAL cooling unit assembly and operating instructions 5


(' 3 Device description
~~= Data is exchanged via the master-slave connection. 3.1.6 Filter mats
During commissioning, assign an address to each The cooling unit condenser is finished all over with a
unit that also includes the identifier "master" or dirt-repelling, easy-to-clean RiNano coating. In many
"slave". cases, therefore, the use of filter media is unneces-
sary, particularly in the case of dry dusts.
3.1.4 Safety equipment For dry, coarse dust and lint in the ambient air, we
- In the cooling cycle, the cooling unit has a tested recommend installing an additional PU foam filter
pressure-operated switch to EN 12 263 which is mat (available as an accessory) in the cooling unit.
set to maximum PS (admissible pressure); this Depending on the incidence of dust, you will need
operates via an automatic reset device whenever to replace the filter from time to time.
the pressure drops again. For air containing oil condensation, we recommend
- Temperature monitoring prevents the evaporator the use of metal filters (also available as an accesso-
coil from icing over. If there is a risk of icing, the ry). These may be cleaned with suitable detergents
compressor switches itself off and automatically and reused. When used in textile plants with heavy
switches itself back on again at higher tempera- lint contamination, lint screens should be used (avail-
tures. able as an optional extra).
- The refrigerant compressor and the fans are Function of the filter mat monitor:
equipped with thermal winding shields to protect Dirt on the filter mat is automatically determined by
against excess current and excess temperatures. measuring the temperature difference in the external
- In order to allow a reduction of pressure inside the circuit of the cooling unit. As the level of filter mat
compressor and hence a safe restart, once it has soiling rises, the temperature difference will increase.
been switched off (e.g . upon reaching the set tem- The nominal value of the temperature difference in
perature via the door limit switch function or via the external circuit adapts automatically to the rele-
de-energising), the device will switch back on with vant operating points in the performance diagrams.
a delay of 180 seconds. Hence there is no need to readjust the nominal value
- The device has floating contacts on the connection for different operating points of the cooling unit.
pins (terminals 3 - 5), via which system messages
from the device may be polled, e.g. using a PLC 3.1.7 Door limit switch
(1x change-over contact Basic controller, 2x nor- The cooling unit may be operated with a floating door
mally open contacts Comfort controller). limit switch connected . The door limit switch is not in-
cluded with the supply (available as an accessory,
3.1.5 Condensation Model No. PS 4127.000).
At high levels of humidity and low temperatures in- The door limit switch .function causes the fans and
.' side the enclosure, condensation may form on the the compressor in the cooling unit to be switched off
evaporator coil. after approximately 15 seconds when the enclosure
The cooling units have an automatic electrical con- door is opened (contacts 1 and 2 closed). This pre-
densate evaporator. The thermal component used vents the formation of condensation inside the enclo-
for this purpose is based on self-regulating PTC sure while the enclosure door is open. In order to
technology. Condensate arising on the evaporator prevent damage to the unit, it is equipped with an
coil is collected in a tank in the internal circuit of the ON delay: The evaporator fan cuts back in with a
cooling unit. When the water level rises, the water delay of approximately 15 seconds after the door
enters the PTC thermal component and is evapo- has been closed, while the condenser fan and com-
rated (through-flow heater principle). The water pressor switch on after approximately 3 minutes.
vapour streams out of the cooling unit with the airflow
from the external fan.
Note:
The PTC thermal component is permanently con-
nected and has no switch point. It is protected - No external voltage must be applied to
against short-circuits with miniature fuses (F1.1, the door contacts (terminals 1 and 2).
F1.2). If the fuse has tripped, any condensation is - For Basic controller cooling units with
drained off via the safety overflow. 230/115 V and 400 V/2-phase connec-
In the case of a malfunction or a failure in the thermal tion, the evaporator fan remains
component, the condensation water is routed out of operational even with the door open.
the unit via a drain pipe at the side or rear for safety
reasons. For this purpose, a hose must be connect-
ed to the condensate nozzle (see "4.4 Connecting
the condensate discharge", page 10). Condensate
hoses are available as accessories (refer also to the
accessories section in the RITIAL Catalogue).

6 RID AL cooling unit assembly and operating instructions


4 Assembly and connection
3.1.8 Additional interface X3 4 Assembly and connection

cc::r Note:
The electrical signals at the interfac e are
of an extra-low voltage (not extra-low safety
4.1 Choosing the installation site
When choosing the installation site for the enclosure,
please observe the following:
voltages to EN 60 335). - The site for the enclosure, and hence the arrange-
An additional interface card may be connected to ment of the cooling unit, must be carefully selected
the 9-pole SUB-D connector X3 in order to incorpo- so as to ensure good ventilation . Depending on the
rate the cooling unit into higher-level monitoring siting of the unit, if several units are installed direct-
systems (available as an accessory, interface card ly adjacent to one another, the distance from the
Model No. SK 3124.200). wall must be at least 200 mm.
- The cooling unit must be installed and operated in
3.2 Proper usage a vertical position (maximum deviation: 2°) .
RIDAL enclosure cooling units were developed and - The site must be free from excessive dirt and
designed in accordance with the state-of-the-art and moisture.
the recognised rules governing technical safety. - The ambient temperature must not exceed 55°C.
Nevertheless, if used improperly, they may pose a - It must be possible to fit a condensate discharge
threat to life and limb or cause damage to property. (see "4.4 Connecting the condensate discharge",
The unit is only intended for cooling enclosures. Any page 10).
other use is deemed improper. The manufacturer will - The mains connection data as stated on the rating
not be liable for any damages caused as a result of plate of the unit must be guaranteed.
improper use, or for incorrect assembly, installation
or use. All risk is borne solely by the user. 4.2 Assembly instructions
Proper usage also includes the observation of all
valid documents and compliance with the inspection 4.2.1 General
and servicing conditions. - Check the packaging carefully for signs of damage.
Traces of oil on damaged packaging are an indi-
3.3 Scope of supply cation of refrigerant loss and leakages. Packaging
The unit is supplied in a packaging unit in a fully damage may be the cause of a subsequent func-
assembled state. tional failure.
Please check the delivery for completeness: - The enclosure must be sealed on all sides (lP 54).
Increased condensation will occur if the enclosure
! aty. Description i is not airtight.
Enclosure cooling unit - In order to avoid excessive condensation inside
Dispatch bag : the enclosure, we recommend installing a door
- Insulation plate (only for SK 3383.xxx, limit switch (e.g. PS 4127.000) which deactivates
SK 3384.xxx, SK 3385.xxx) the cooling unit when the enclosure door is opened
- Sealing frame (see "3.1.7 Door limit switch" , page 6).
- Plug-in terminal strip
- Assembly and installation instructions
- Assembly, installation and operating
instructions on CD-ROM
- Declaration of conformity
Drilling template
Tab. 1: Scope of supply

RIDAL cooling unit assembly and operating instructions 7


4 Assembly and connection
4.2.2 Layout of the electronic components
in the enclosure

Caution!
Risk of condensation!
When arranging the components inside
the enclosure, please ensure that the
cold airflow from the cooling unit is not
directed at active components. Please
also ensure that the cold airflow is not
directed at the warm exhaust airflow
from active components such as con-
verters. This may lead to an air short-
circuit and therefore prevent adequate
climate control, or may even cause the
cooling unit's internal safety devices to Fig. 4: Targeted air routing inside the enclosure
cease cooling operation.

Note:
ccJ When using the cover bungs, only a maxi-
mum of 1 or 2 cold air outlet openings may
be sealed. depending on the unit type.

SK 3383.xxx SK 3359.xxx
SK 3384.xxx SK 3382. xxx
SK 3385.xxx SK 3386.xxx
SK 3387.xxx

Fig. 3: Never direct the cold airflow at active components

Exercise particular caution with the airflow from the


blowers of built-in electronic components (ct. Fig. 3).
Components for targeted air routing are available as
accessories - please refer to the RIDAL catalogue
"System climate control" .
~!_J
,\ max.2x
I
max. 1x
Note:
When using an air duct system. care must Fig. 5: Cover bungs
be taken to ensure that it is laid straight and
without kinks wherever possible. This mini-
mises the resistance to the cold airflow.
It is important to ensure even air circulation 4.3 Fitting the cooling unit
inside the enclosure. Under no circum- The enclosure cooling unit is mounted on top of the
stances should air inlet and outlet openings enclosure roof:
be obstructed. otherwise the cooling per- To this end. the roof plate must be cut out as per the
formance of the unit will be reduced. Ensure drilling template included with the supply.
a suitable distance from electronic compo-
nents and other installed enclosures so that Note:
the required air circulation is not obstructed Pre-configured. reinforced roof plates
and prevented. with cut-outs to match your enclosure are
One cold air outlet from the cooling unit available as accessories; refer to the
must be kept open at all times when RIDAL catalogue "System climate control".
operating with the air duct. to prevent the
accumulation of cold air inside the unit.

8 RIDAL cooling unit assembly and operating instructions


4 Assembly and connection
4.3.1 Cutting out the enclosure
• Stick the supplied drilling template onto the roof of
the enclosure using adhesive tape.
There are dimensioning lines on the drilling template
to suit the installation type for your cooling unit.

ti\
!
Risk of injury!
Carefully deburr all cut-outs to prevent
injuries caused by sharp edges.
• Make the cut-outs including the line width as per
the drilling template.
Deburr the cut-outs. Fig. 8: Apply extra seal for condensate tray

• Mount the cooling unit on the enclosure roof.


4.3.2 Top mounting of the cooling unit
• Screw the supplied twin-threaded bolts into the
• Stick the supplied sealing frame onto the cut-out core holes in the plastic base on the underside
roof plate. of the cooling unit with a maximum of 5 Nm.
• Secure the unit using the supplied washers and
nuts.
(
Note:
In order to achieve a permanent seal be-
tween the cooling unit and the enclosure,
the mounting surface should be reinforced
or supported if necessary. This is particu-
larly applicable with large roof areas.

Fig. 6: Sealing frame on roof plate


<!S¥.bo$OiS~O!i!ofIt!5"""''''.II!oEB.;iJoi&........ ~...~...m'8<GI'''''.eoeolBO\ll''''''
• Stick the supplied insulating plate underneath
I U
the plastic base of the cooling unit (only for
SK 3383.xxx, SK 3384.xxx, SK 3385.xxx). U
- -

10
oeom0Q4049oCl1oGoIIoEiIoeoe-e-m . . .
-

$
r- - - .' r-'-

0
-

oIDo(I}+eoeJ-atoeI-eoEDoCMIIoEMBoatoIIJ-eoe
-LJ ~'W U

Fig. 9: Roof plate reinforcement for the TS 8 enclosure


Accessories for roof plate reinforcement with TS:
Punched rail
U nut
Fastening bracket
Threaded block
(refer also to Accessories in the RITIAL Catalogue)

Fig. 7: Insulating plate underneath the plastic base


of the cooling unit

• Stick the supplied additional seal onto the con-


densate tray from below (ct. Fig . 8).
Bend the seal upwards at the perforated points
and stick down the seal.

RITIAL cooling unit assembly and operating instructions 9


4 Assembly and connection
4.4 Connecting the condensate discharge 4.5 Notes on electrical installation
A condensate discharge hose (0 112") may be fitted When performing the electrical installation, it is im-
onto the cooling unit. portant to observe all valid national and regional
........_--' The condensate discharge regulations as well as the provisions of the respon-
- must be laid with a suitable and constant gradient sible power supply company. Electrical installation
(no siphoning) must only be carried out by a qualified electrician
- must be laid without kinks who is responsible for compliance with the existing
- must not have a reduced cross-section if extended. standards and regulations.
The condensate hose is available as an accessory 4.5.1 Connection data
(refer also to Accessories in the RITTAL Catalogue).
- The connected voltage and frequency must corre-
spond to the values stated on the rating plate.
- The cooling unit must be connected to the mains
via an all-pin isolating device, which ensures at
least 3 mm contact opening when switched off.
- No additional temperature control may be connec-
ted upstream of the unit at the supply end.
- Install the pre-fuse specified on the rating plate
to protect the cable and equipment from short-
circuits.
- The mains connection must ensure low-noise
potential equalisation .

4.5.2 Overvoltage protection


and supply line load
Fig. 10: Connecting the condensate discharge - The unit does not have its own overvoltage protec-
• Connect a suitable hose to one of the two conden- tion. Measures must be taken by the operator at
sate nozzles and secure using a hose clip. the supply end to ensure effective lightning and
The unused condensate nozzle should be sealed overvoltage protection. The mains voltage must
accordingly. not exceed a tolerance of ±10%.
• Lay the condensate hose, e.g. into a drain. - In accordance with IEC 61 000-3-11, the unit is
intended solely for use at sites with a continuous
current-carrying capacity (incoming mains power
supply) of more than 100 A per phase ·and with a
1/2" supply voltage of 400/230 V. If necessary, the
power supply company must be consulted to en-

/
sure that the continuous current-carrying capacity
at the point of connection to the public grid is
sufficient for connection of such a unit.
- The fans and compressors in single- and three-
IDIDI , phase units are intrinsically safe (thermal winding
protection). The same also applies to all transform-
er versions and to special-voltage units which are
likewise equipped with a transformer.
- Install the slow pre-fuse specified on the rating
Fig. 11: Lay the condensate discharge plate (miniature circuit-breaker with "K" character-
istic, circuit-breaker for plant or transformer
protection) to protect the cable and equipment
from short-circuits. Select a suitable circuit-
breaker in accordance with the information speci-
fied on the rating plate: Set it to the minimum speci-
fied value. This will achieve the best short-circuit
protection for cables and equipment.
Example: Specified setting range 6.3 - 10 A; set to
6.3 A.

10 RIDAL cooling unit assembly and operating instructions


4 Assembly and connection
4.5.3 Three-phase devices 4.6 Carrying out the electrical installation
- The three-phase version must be connected to a
TN network with star earthing via a circuit- 4.6.1 Bus connection
breaker for plant protection (current setting as per (only in conjunction with several units
the rating plate). Three-phase units with special with a Comfort controller)
voltages must be protected with a circuit-breaker When using several cooling units, the serial device
for transformer protection (category AC-3) as per interface X2 can be used to connect up to ten cooling
the rating plate. units with the bus cable (Model No. SK 3124.100).
- Units designed for three phase 400/460 V feature
additional monitoring of the rotary field or the ab- Note:
sence of a phase. If the rotary field is incorrect or a The electrical signals at the X2 interface are
phase is absent, the unit will not run . of an extra-low voltage (not extra-low safety
voltages to EN 60 335-1) .
4.5.4 Door limit switch
- Each door limit switch must only be assigned to When interconnecting, please note the following:
one cooling unit. - De-energise the cooling units to be connected .
- Several door limit switches may be connected in - Ensure proper electrical insulation.
parallel and operated on one cooling unit. - Make sure the cables are not laid in parallel to
- The minimum cross-section of the connection power lines.
cable is 0.3 mm 2 for a cable length of 2 m. - Make sure that the lines are short.
We recommend the use of a shielded cable.
- The line resistance to the door limit switch must not Caution!
exceed a maximum of 50 n. Regarding the last slave unit in the
- The door limit switch only supports a floating con- group, do not, under any circumstances,
nection; no external voltages. connect the remaining socket of the
- The contact of the door limit switch must be closed Y cable SK 3124.100 into interface X3
when the door is open. of the cooling unit!

The safety extra-low voltage for the door limit switch 4.6.2 Connection X3 for serial interface
is provided by the internal power pack: Current The interface card (Model No. SK 3124.200) may be
approx. 30 mA DC. connected to X3. This is used to evaluate system
• Connect the door limit switch to terminals 1 and 2 messages in a PLC, for remotely setting parameters
of 'the connector. and monitoring, or for integration into the facility
management system.
4.5.5 Notes on the flicker standard
The flicker limits specified in standard EN 61 000-3-3
or -3-11 are adhered to, provided the supply im-
pedance is less than approx. 1.5 n.
Where necessary, the unit operator should measure
the connected impedance or consult the responsible
power supply company. If there is no way of influ-
encing the supply impedance and sensitive installed
components (e.g. BUS) are subjected to interfer-
ence, a line reactor or starting-current limiting device
should be connected upstream of the cooling unit to
restrict the startup current of the cooling unit.

4.5.6 Potential equalisation


RIDAL recommends connecting a conductor with a
nominal cross-section of at least 6 mm 2 to the poten-
tial equalisation connection point on roof-mounted
cooling units, and incorporating it into the existing
potential equalisation system.
According to the standard, the PE conductor in
the mains connection cable is not classified as an
equipotential bonding conductor.

RITTAL cooling unit assembly and operating instructions 11


( 4 Assembly and connection
(" ' - - . -- '. ... ._.. .. .. . ' . - . ""':

: ' _' _ ' _ '_ ' _ '_~_~_~_ ' W , _. _._ ._~


1 ~ _____
f '~
L_____ , ,

----- i UOunit
!. .. ... ·. ._·. .• ' w _. ·· • .• .• j
i

Fig. 12: Connection example: Master-slave operation


Legend
( 1 Serial interface (Model No. SK 3124.200) X2 Master-slave connection Sub-D, 9-pole
2 Serial interface cable X3 Serial interface Sub-D, 9-pole
3 Master-slave bus cable (Model No. SK 3124.100) St. Sub-D connector, 9-pole
RTI RITIAL TopTherm cooling units Bu. Sub-D jack, 9-pole
Xi Supply connection/door limit switch/alarms Adr. Address

d X21 x21 x~ xd xd
Adr.: 06 Adr.: 11 Adr.: 12 Adr.: 13 Adr. : 14 Adr.: 15
1
x, • ILWI IpEj' I21'I 41s1x,
2
1"lgj L~p§ '1 *14 Is l x,. 11 ~ FE'
2
2 3 4 5
2 2
I 2
x,. 1"lgjL~pEj '121 ' 14151 x,. 1"I L~ L~pij '1 2 1'14Isl x, • 1 "I L~ Ljfij '1 21' 14151
X2
x,.
~

'"
N

~
~::;
- - - -
- - - Adr.: 16

I
-==f1 2F:=dJ ~ ~ ~ 6l--- '----
3 4 4 3 2

Fig. 13: Connection example: Door limit switch and master-slave operation
Legend
1 Master cooling unit
2 Slave cooling units
3 2-door enclosure with two door limit switches
4 Enclosure with door limit switch

12 RIDAL cooling unit assembly and operating instructions


4 Assembly and connection
4.6.3 Installing the power supply • If you would like the system messages from the
• Complete the electrical installation as per the cooling unit to be evaluated via the system
wiring plan inside the cooling unit underneath the message relay, you should also connect a suitable
cable shaft cover (see Fig . 39 on page 30, marked low-voltage cable to connection clamps 3 - 5.
with an arrow).

SK 3359.100/.200/.110/.210/.140/.240, SK 3382.100/.200/.110/.210

~ Mains
/;5
i X1 L1 ~ PE 1
f·_· ············ .~ ..... .
i T1!' - i
I _'
A2

I
!_._--(-r;-J,GIa--
© ll ITF1]3
U- NTC I red 1))----t/' --- I6
~
Sl
Power
N
NTC E blue L /
Kx Term 1)----+-__--'

F2=~~lF2
A1

M1 M2 I~;3 I ........ J
~~~---~~-----~~
~~ C2
. T
[--'-------1 d;·, J." 1
;!'·;L'.'~'._:-;-:-_~
®A!@!
l- 'i
M2 1
1- ;i
M4 ;
.•.•.•.•.•. _~.~._ .•. _ . • .• .•.•.•.•.•.•.•. _ .•... 1 ...•.•.•.•.•.•.•...•..... j

Fig. 14: Electrical wiring plan no. 1

RIDAL cooling unit assembly and operating instructions 13


4 Assembly and connecUon

SK 3359.500/.600/.510/.610/.540/.640, SK 3382.500/.600/.510/.610

Fig. 15: Electrical wiring plan no. 2

SK 3383.1 xO, SK 3384.1 xO, SK 3385.1 xO

~~R I
A2 ~D

NTC I red lJ>--lr"'-------1§j


NTC E blue tJ " §]
Term ->--,P-- - --'

Only for 3383.xxx and 3384.)00( Only for 3385.YXX

Fig. 16: Electrical wiring plan no. 3

14 RITIAL cooling unit assembly and operating instructions


( 4 Assembly and connection

SK 3383.5xO, SK 3384.5xO, SK 3385.5xO

A1

Only for 3383.xxx and 3384.)()O( Only lor 3385.xxx

Fig. 17: Electrical wiring plan no. 4

SK 3383.700

A2

(
~~~~V3~2~"------~N~
TC~lre~d-~
Kl NTcEb'uell~
Kx Term-}--T'-'------'
A1

M2

Fig. 18: Electrical wiring plan no. 5

RITIAL cooling unit assembly and operating instructions 15


( 4 Assembly and connection
SK3383.800

~
{6
X1~=i!-'----'-C'-rY--i'-'-r-,:.J
5 X2r
O~~O'r£3r°
o'l,'t@
,;- _ ._ "- - - -
,
i

i ~~~~-' -~ -2~~ 1 Serial I NTC l redt~


Kl NTC E blue -~
Kx NTCCWllite l~
NTcAyerr owl~
A1 Level greenl~
Term l>-r'-'- ----'

M1 M2

M1 M2 M3

Fig. 19: Electrical wiring plan no. 6

SK3384.700

Fig. 20: Electrical wiring plan no. 7

16 RITIAL cooling unit assembly and operating instructions


II
4 Assembly and connection
SK 3384.800

3
K1
;"f'f
'2lI""M~1 seliall NTc l ledt~
NTCEblue-~
~ - --{- - PE Kx NTC C white l~
; NTcAyellOw l~
A1 Level greenl~
Telm l>-7'-'-----'

M1 M2

Fig. 21: Electrical wiring plan no. 8

SK 3386.1401.240, SK 3387.1401.240

~
/6
I
X1
l-- -- --------- -
A2 ILO I ~)"' L2
0

7
, ~
,
) §I

F2

Fig. 22: Electrical wiring plan no. 9

RIITAL cooling unit assembly and operating instructions 17


4 Assembly and connectBon

SK 3386.540/.640, SK 3387.540/.640

Fig. 23: Electrical wiring plan no. 10

Legend
Note:
Ai
A2
Power PCB
Basic or Comfort controller cO For technical data refer to the rating plate.
A3 Starter relay and RC element
B1 Temperature sensor, internal temperature
B2 Icing hazard temperature sensor
AC DC
B3 Temperature sensor, external 1
B4 Temperature sensor, external 2 cos f =1 lIR =20 ms
B5 Condensate warning sensor (optional) I max. = 2 A I min. = 100 mA
C1-C4 Running capacitors U max. = 250 V U max. = 200 V
E1 Condensate evaporator U min. = 18 V
F2 PSAH pressure-operated switch I max. = 2 A
F3 Bimetal contact compressor
F11/F12 Miniature fuses, condensate evaporator Tab. 2: Contact data
K1 Relay collective fault 1
K2 Relay collective fault 2
L1 LED operational green
L2 LED alarm red
M1 Compressor
M2 Condenser fan
M4 Evaporator fan
R1 Potentiometer for setting the temperature
S1 Door limit switch
(without door limit switch: terminal 1, 2 open)
T1 Transformer (optional)
Xi Main terminal strip
X2 Master-slave connection
X3 Optional interface

18 RITIAL cooling unit assembly and operating instructions


5 Commissioning
4.7 Finalising assembly 4.7.3 Setting the filter mat monitor
(only with Comfort controller)
4.7.1 Installing the filter media Function of the filter mat monitor:
The cooling unit condenser is finished all over with a Dirt on the filter mat is automatically detected by
dirt-repelling, easy-to-clean RiNano coating. In many measuring the temperature difference in the external
cases, therefore, the use of filter media is unneces- circuit of the cooling unit (see "6.2.5 Programming
sary, particularly in the case of dry dusts. overview", page 25). As the level of filter mat soiling
For dry, coarse dust and lint in the ambient air, we rises, the temperature difference will increase. The
recommend installing an additional PU foam filter nominal value of the temperature difference in the
mat (available as an accessory) in the cooling unit. external circuit adapts automatically to the relevant
For air containing oil condensation, we recommend operating points in the performance diagrams.
the use of metal filters (also available as an accesso- Hence there is no need to readjust the nominal value
ry). When used in textile plants with heavy lint con- for different operating points of the cooling unit.
tamination, lint screens should be used (available as
an optional extra).
• Pull the louvred air inlet grille from the enclosure.
• Insert the filter mat into the louvred grille as shown 5 Commissioning
in Fig. 24 and push it back onto the enclosure.
Caution! Risk of damage!
( The oil must collect in the compressor
in order to ensure effective lubrication
and cooling.
Do not operate the cooling unit for
at least 30 min. after assembling the
equipment.
• Once all the assembly and .installation work is com-
plete, switch on the power supply to the cooling
unit.
Fig. 24: Install the filter mat The cooling unit starts running:
- With Basic controller: The green operating LED
4.7.2 Fitting the cooling unit ("line") is illuminated.
• Connect the connector to the rear of the display. - With Comfort controller: The software version of the
• Place the louvred grille onto the unit at the front, controller first appears for approx. 2 sec., then
and press it down until you hear it snap into place. the enclosure internal temperature appears in the
7-segment display.
You can now make your individual settings on the
unit, e.g. set the temperature or (with Comfort con-
troller only) assign the network identifier, etc. (refer to
the "Operation" chapter).

Fig. 25: Connect the display and attach the louvred grille

RIITAL cooling unit assembly and operating instructions 19


(
6 Operation
6 Operation 6.1.1 Properties
You can operate the cooling unit using the controller - Four voltage variants are supported:
on the front of the device (Fig. 1, no. 5, page 5). - 115 V
..................... Depending on the model, the unit is equipped with a - 230 V
Basic or Comfort controller. - 400 V, 2-phase
- 400/460 V, 3-phase
6.1 Control using the Basic controller - Integral start-up delay and door limit switch
For unit types SK xxxx.1 00/.11 0/.140 and function
SK xxxx.200/.21 0/.240. - Protective function to prevent icing
- Monitoring of all motors (compressor,
condenser fan , evaporator fan)
- Phase monitoring for three-phase units
- Visualisation of the operating status via LED
display:
- Voltage on, unit operational
- Door open (only if door limit switch installed)
- Warning of overtemperature
3 4 - High-pressure-operated switch has switched

----J J - Switching hysteresis: 5 K


- Floating system message contact in case
of overtemperature
- Temperature setting
(setting range 30 - 55°C) via potentiometer
- Test function

The cooling unit operates automatically i.e. after


Fig. 26: Basic controller
switching on the power supply, the evaporator fan
Legend (see Fig. 2, page 5) will run continuously and perma-
1 Controller trim panel nently circulate the internal enclosure air. The built-in
2 Temperature setting Basic controller ensures automatic normal shut-
3 LED green ("line")
down operation of the cooling unit by the value of
4 LED red ("alarm")
5 -Reset button the fixed preset.switching difference of 5 K.

20 RITIAL cooling unit assembly and operating instructions


6 Operation
6.1.2 Operating and error display
The Basic controller monitors and controls the cool-
ing unit. It indicates the operating and error status via
the green and red LEOs (Fig. 26, nos. 3 and 4):

LED Status Cause Solution

Green 'liuminated Voltage present, -


(line) unit operational

F'ashing Only with door limit switch installed : 'n order to avoid condensation, close the
Enclosure door open enclosure door as quickly as possible.

Only with door limit switch installed: Check the position of the door limit switch.
Enclosure door closed

Red A'arm/error/warning Number of F'ash interval


(alarm) flash intervals
for the
red LED

Implement
a reset
Device reset (12) '_'_'_'-'_'-'_U_'_'_'*****U_'_'_'_'_'_'_'_'_'_'
( High pressure alarm (0) '_'_'_'_'_'_'_'_'_'_'_'_'_'_U_'_'_'_'_'_U_'_'_'
(3)
Sensors Potentiometer
defective
'_'_'''***U-'*****'_U''***'_'_'*****U-'*****
or display error
(4)
Interior temperature
sensor defective
'_'_'_'*****'-'-'-'*****U-'-'*****'_'_'_'*****
Anti-icing sensor
defective
(5)
'_'_'_'_'* ****'_'_'-'_'*****'-'-'-'-'*****I_'_U_'
Overload Compressor
overloaded
(6)
'_'_'_'_'_'*****'_U_'-'_'*****'-'-'-'-'-'*****
Interior fan overloaded (7)
'_U_'_'_'_'*****'_'_'_'_'_'_'*****'_'_'_'_'_'_'
Exterior fan (8)
overloaded .'
'-'-'-'-'-'-'-'*****'-'-'-'-'-'-'-'*****
Device
status/
Overload mode
(heat loss)
(9)
'_'_'_'_'_'_'_'_'*****'_'-'_'_'-'_U_'*****
condition
Low load mode (11 )
(heat loss) '-'-'-'-'-'-'-'-'-'-'*****'-'-'-'-'-'-'-'-'-'-'
Warning Anti-icing alarm (2)
( (ambient U*****'-'*****'-'*****'-'*****'-'*****'-'*****'-'
Overtemperature (1 ) I*****1***** I* **** I*****1 * **** 1*** **1 *** ** I*****1 ** ***1
conditions)
warning

Off No No power - Check power supply


display
Rotary current phase - Swap phases
monitoring :
"LED off" = Incorrect
phase connection
Tab. 3: Operating and error display of the Basic controller

Key to flash intervals


, 500 ms (red LED on)
500 ms (red LED off)
3 s pause (red LED off)

RITIAL cooling unit assembly and operating instructions 21


6 Operation
The overtemperature message (red LED illuminated) The cooling unit will commence operation and the
(,"''''Ir'tlrr,,'] may also be polled via an integral floating contact on green LED will flash (U'-'_II_ . . .). Test mode is
L:;;;I..A.J',"d the connection clamp of the cooling unit (system completed after approximately 5 minutes. The unit
"'"""'1ioOi............ message relay with changeover contact, see con- switches off and changes to normal operation.
nection diagrams under "4.6.3 Installing the power
supply", page 13): Key
- Terminal 3: NC (normally closed) I = LED 500 ms on
- Terminal 4: C (connection of the supply voltage = LED 500 ms off
to the system message relay)
- Terminal 5: NO (normally open) In normal operation, the green LED is permanently
The NC and NO definitions refer to the de-energised illuminated.
state. As soon as power is applied to the cooling unit, • Next, rotate the potentiometer back to the required
the system message relay picks up, so that the relay setpoint.
contacts change status (contact 3 - 4 open; contact
4 - 5 closed) . This is the normal operating state of the 6.1.4 Setting the temperature
cooling unit. As soon as an error message occurs or
the power supply is interrupted, the relay drops out Note:
and contact 3 - 4 is closed. With the Basic controller, the temperature
is preset at the factory to +35°C.
6.1.3 Test mode for the Basic controller In order to save energy, do not set the
The Basic controller is equipped with a test function temperature any lower than is actually
whereby the cooling unit commences cooling oper- necessary.
ation independently of the set temperature or door
limit switch function . To change the temperature setting:
First you must dismantle the trim panel of the con- • Dismantle the trim panel of the controller as
troller. described in "6.1 .3 Test mode for the Basic
• Switch off the mains voltage. controller", page 22.
• Remove the louvred grille in which the controller • Set the required temperature on the temperature
is installed . setting device (Fig. 26, page 20).
• Release the display lock from behind and pull it o Carefully push the trim panel onto the display until
forwards slightly. you hear it snap into place.
• Push the display back into the louvred grille.
• Re-attach the louvred grille to the cooling unit.

6.1.5 Resetting the Basic controller


Following a high-pressure alarm in the cooling cycle,
and once the cause has been rectified, you will need
to manually reset the Basic controller:
• Dismantle the trim panel of the Basic controller as
( described in "6.1.3 Test mode for the Basic
( controller", page 22.
• Press the reset button (Fig. 26, no. 5) for at least
3 sec.
The red LED is extinguished.
• Re-install the Basic controller.
Fig. 27: Loosen the trim panel of the Basic controller

• Carefully raise the trim panel, e.g. using your


thumb or a flat screwdriver, and remove it.
You can now start test mode.
• Rotate the potentiometer to the left-hand stop, then
hold the rubberised potentiometer display down
while you re-connect the mains voltage .

22 RIDAL cooling unit assembly and operating instruc tions


(
6 Operation
6.2 Control using the Comfort controller The Comfort controller has a 7-segment display
For unit types SK xxxx.500/.51 0/.540 and (Fig. 28, no. 4). After switching on the power supply,
SK xxxx.600/.61 0/.640. the current software version is initially displayed for
approximately 2 sec., followed by a preset option
1 2 (e.g. t10) or the temperature.

~L ~7
In regular operation, the display shows both the tem-
perature (in degrees Celsius or Fahrenheit - users

,'-
--
_, _,
i'0~~1
~~
[] s~;'
may switch between the two) and any error messages.
The current enclosure internal temperature is usually
displayed permanently. In the event of an error mes-
sage, this will alternate with the temperature display.

-----;3 4 3
-RITTAL
The unit is programmed using buttons 1 - 3 (Fig. 28).
The relevant parameters also appear in the display.

6.2.2 Launching test mode


Fig. 28: Comfort controller The Comfort controller is equipped with a test func-
tion whereby the cooling unit commences cooling
Legend
operation independently of the set temperature or
1 Programming button, also display of the
set temperature unit (degrees Celsius)
door limit switch function.
( 2 Set button • Simultaneously press buttons 1 and 2 (Fig. 28)
3 Programming button, also display of the for at least 5 sec.
set temperature unit (degrees Fahrenheit) The cooling unit will commence operation.
4 7-segment display After approximately 5 minutes, test mode will end .
The unit switches off and changes to normal oper-
6.2.1 Properties
ation.
- Four voltage variants are supported:
- 115 V 6.2.3 General programming information
- 230 V Using buttons 1, 2 and 3 (Fig. 28) you can change
- 400 V, 2-phase 24 parameters within the preset ranges (min. value-
- 400/460 V, 3-phase max. value).
- Integral start-up delay and door limit switch Tables 4 and 5 show the parameters which can be
function altered. Fig. 29 on page 25 shows which buttons
- Protective function to prevent icing must be pressed.
- Monitoring of all motors (compressor,
condenser fan, evaporator fan) Note on switching hysteresis:
- Phase monitoring for three-phase units ccJ With a low hysteresis and short switching
- Master-slave function with a maximum of ten units. cycles, there is a risk that cooling may not
One device functions as a master unit. Once the be adequate or that only partial sections
set temperature is reached by one of the connect- of the enclosure are cooled .
ed slave devices or in the event of the door limit
Note on temperature settings:
switch function, the affected slave unit will report
With the Comfort controller, the temperature
to the master unit, which will switch all the other
is preset at the factory to +35°C.
cooling units on or off as required.
In order to save energy, and due to the
- Switching hysteresis: Adjustable within the range
risk of increased condensation, do not set
2 -10 K, preset to 5 K.
the temperature lower than that actually
- Visualisation of the current enclosure internal tem- necessary.
perature and all error messages in the 7-segment
display. Note on useful cooling output:
- Using an interface card (Model No. SK 3124.100), Interactive performance diagrams for
the unit may be incorporated into higher-level calculating the useful cooling output
remote monitoring systems such as the RITTAL may be found at www.rittal.com .
Computer Multi Control CMC.

The cooling unit operates automatically i.e. after


switching on the power supply, the evaporator fan
(see Fig. 2, page 5) will run continuously and per-
manently circulate the internal enclosure air. The
compressor and condenser fan are regulated by the
Comfort controller.

RITIAL cooling unit assembly and operating instructions 23


6 Operation
In principle, the programming is identical for all You can now alter the parameter within the preset
editable parameters. limits.
To enter programming mode: • Press one of the programming buttons A (0C) or
......-~ • Press button 2 ("Set") for approx. 5 sec. .... (OF) until the required value appears .
The controller is now in programming mode. While in • Press button 2 ("Set") to confirm the change.
programming mode, if you do not press any buttons You can now alter other parameters in the same way.
for approx. 30 sec., the display will first flash , then There is no need to re-enter the authorisation code
the controller will switch back to normal display "22" .
mode. The "Esc" display indicates that any made • To exit programming mode, press button 2 ("Set")
changes have not been saved . again for approximately 5 sec .
• Press the programming buttons A (0C) or .... (OF) "Acc" will appear in the display to indicate that the
to switch back and forth between the editable changes have been saved. The display will then
parameters (see tables 4 and 5). switch back to regular operation (enclosure internal
• Press button 2 ("Set") to select the displayed temperature) .
parameter for editing . You can also program the Comfort controller
The current value of this parameter is displayed . using a diagnosis software package (Model No.
• Press one of the programming buttons A (0C) or SK 3159.100), the supply of which also includes
.... (OF) . a connection cable to the PC . The cable connector
on the rear of the Comfort controller display serves
( The "Cod" display will appear. In order to be able to
as an interface.
change a value, you must enter the authorisation
code "22".
• Keep the programming button A (0C) held down
until "22" appears.
• Press button 2 ("Set") to confirm the code.

6.2.4 Variable parameters


See also Fig . 29 on page 25.

Progr. Display Parameter Min. Max. Factory Description I

,level screen value value setting


1 St Internal enclosure 20 55 35 . The setting of the enclosure internal temperature
temperature is preset at the factory to 35°C and may be altered
setpoint Ti within a range of 20 - 55°C.
2 Fi Filter mat 10 60 99 To activate filter mat monitoring, set the display to
monitoring (= off) at least 10 K above the temperature differential
displayed in programming mode "Fi". Filter mat
( monitoring is preset to "deactivated" in the factory
(99 = off).
3 Ad Master-slave 0 19 0 See "6 .2.7 Setting the master-slave identifier",
identifier page 27.
4 CF Temperature 0 1 0 The temperature display can be switched from
conversion °c (0) to OF (1). The corresponding LED displays
°CrF the current unit of temperature.
5 Hi Setting for 2 10 5 The cooling unit is preset in the factory to a
switching switching hysteresis of 5 K. This parameter should
difference only be changed in consultation with us.
(hysteresis) Please contact us for advice.
6 H2 Differential for 3 15 5 If the internal enclosure temperature exceeds the
error message A2 set value by more than 5 K, then error message
A2 (enclosure internal temperature too high)
appears on the display terminal. If necessary,
the differential may be altered here within the
range of 3 - 15 K.
Tab. 4: Editable parameters

24 RITT AL cooling unit assembly and operating instructions


r-- ,..--, ~ ~

JJ
=l ~ !"I
t\)
»c- (,..
~
o
0
Q.
...
"'C
0
,," ~
...
(Q
co
c
::>
~
ill
= 5 sec, I»
3 3
""
Pl
en 3 3
en
<T> s"
<Q
S'
(Q
3 Q
IT 0
'< (§ <:
Pl
::>
Q. ~. ...<:
(I)

0 ~ (ii'
""0
CD
~
- -- ~

--,........................................................................................i
- - t .................................................................... :E
,,"
co
,,"
~
2
Q.
0"
::>
en

0')

o
"C
CD
~

......
".,;;.

o:,j
Di
6 Operation
"'"""'~--. 6.2.6 Defining system messages for evaluation A more detailed explanation of the system messages
System messages are shown on the display screen may be found in section "6.2.8 Evaluating system
of the Comfort controller via the displays A 1 to A20 messages", page 27.
and EO. See also Fig. 29 on page 25.

Progr. Display Min. Max. Factory Type or location of fault


level screen value value setting j
7 Ai 0 2 0 Enclosure door open
8 A2 0 2 0 Internal temperature of enclosure too high
9 A3 0 2 0 Filter monitoring
10 A4 0 2 0 Ambient temperature too high/too low
11 A5 0 2 0 Icing hazard
12 A6 0 2 1 PSAH pressure-operated switch
13 A7 0 2 2 Evaporator coil
14 A8 0 2 1 Condensate warning
15 A9 0 2 1 Condenser fan blocked or defective
16 A10 0 2 1 Evaporator fan blocked or defective
17 A11 0 2 2 Compressor
18 A12 0 2 1 Condenser
19 A13 0 2 1 Ambient temperature sensor
20 A14 0 2 1 Icing temperature sensor
21 A15 0 2 1 Condensate warning temperature sensor
22 A16 0 2 1 Internal temperature sensor
23 A17 0 2 1 Phase monitoring
24 A18 0 2 0 EPROM
25 A19 0 2 0 LAN/Master-Slave
Tab. 5: System messages which may be evaluated via relays

The system messages A 1 - A 19 may additionally be This is the normal operating state of the cooling unit.
evaluated via two floating system message relays. In As soon as a system message occurs or the power
this way, one of the two system message relays may supply is interrupted, the corresponding relay will
be allocated to each system message. drop out and open the contact.
System alarm relay with normally open contact:
see connection diagrams under "4.6.3 Installing the Program system messages with the value
power supply", page 13: 0: System message is not sent to the system
- Terminal 3: NO (normally open, relay 2) messag e relay, but merely appears in the
- Terminal 4: C (connection of the supply voltage display
to the system message relay) 1: System message is evaluated by relay 1
- Terminal 5: NO (normally open, relay 1) 2: System message is evaluated by relay 2

The definition NO refers to the de-energised state.


As soon as power is applied to the cooling unit, both
system message relays (relay 1 and 2) energise.

26 RIDAL cooling unit assembly and operating instructions


(
6 Operation
6.2.7 Setting the master-slave identifier On the slave cooling unit (00 = factory setting),
When several cooling units are connected together set its own address:
(maximum ten), one of the cooling units must be 11: Slave cooling unit no. 1
defined as the "master" and the others as "slaves". 12: Slave cooling unit no. 2
For this purpose, assign a corresponding identifier 13: Slave cooling unit no. 3
(address) to each cooling unit which will enable the 14: Slave cooling unit no. 4
cooling unit to be identified in the network. 15: Slave cooling unit no. 5
If one of the slave units reaches the set temperature 16: Slave cooling unit no. 6
or if the door limit switch function is activated, the 17: Slave cooling unit no. 7
affected slave unit will report to the master unit, 18: Slave cooling unit no. 8
which then deactivates all the other cooling units. 19: Slave cooling unit no. 9

cc::r Notes:
- Only one unit may be configured as
master, and its identifier must match
the number of slave units connected.
~ 02 Gj 11
~
12

- The slave units must have different Fig. 30: Master-slave connection (example)
identifiers.
For further connection examples, see "4.6.1 Bus
- The identifiers must be numbered in
connection (only in conjunction with several units
ascending order without any gaps.
with a Comfort controller)", page 11 .
For details of how to set the identifier, see "6.2.4
On the master cooling unit (00 = factory setting), Variable parameters", page 24 or "6.2.5 Programming
set the number of slave units present in the network: overview", page 25, parameter "Ad".
01: Master with 1 slave cooling unit
6.2.8 Evaluating system messages
02: Master with 2 slave cooling units
03: Master with 3 slave cooling units In the Comfort controller, system messages are
04: Master with 4 slave cooling units indicated by a number in the display.
05: Master with 5 slave cooling units Following the appearance of messages A03, A06
06: Master with 6 slave cooling units and A07 and after rectifying their cause, you
07: Master with 7 slave cooling units will need to reset the Comfort controller (see
08: Master with 8 slave cooling units "6.2.9 Resetting the Comfort controller", page 29).
09: Master with 9 slave cooling units

RID AL cooling unit assembly and operating instructions 27


(
6 Operation
Display System message Possible cause Measures to rectify the fault I

[screen
A01 Enclosure door open Door open or door limit switch Close door, position door limit switch correctly,
incorrectly positioned check connection if necessary
A02 Internal temperature Cooling capacity inadequate/unit undersized. Check cooling capacity
of enclosure too high Error as a consequence of messages A03
toA17.
A03 Filter monitoring Filter mat soiled Clean or replace;
reset the Comfort controller
A04 Ambient temperature Ambient temperature outside of admissible Raise or lower the ambient temperature
too high/too low operating range (+ 10°C to +60°C) (e.g. heat or ventilate the room)
A05 Icing hazard Operational display in case of icing hazard. Set the enclosure interior temperature to a
Evaporator coil fan may be mechanically higher value. Check the evaporator fan;
blocked, defective, or cold air outlet release or exchange if necessary.
obstructed.
A06 PSAH pressure-operated Ambient temperature too high Lower the ambient temperature;
switch reset the Comfort controller
Condenser soiled Clean the condenser;
reset the Comfort controller
Filter mat soiled Clean or replace;
reset the Comfort controller
Condenser fan defective Replace;
reset the Comfort controller
E-valve defective Have the sensor repaired by a refrigeration
engineer; reset the Comfort controller
PSAH pressure-operated switch defective Have the switch replaced by a refrigeration
engineer; reset the Comfort controller
A07 Evaporator coil Lack of coolant; sensor in front of or behind Have the sensor repaired by a refrigeration
condenser defective. engineer; reset the Comfort controller
A08 Condensate warning Condensate discharge kinked or blocked Check condensate discharge; repair any kinks
or blockages in the hose as necessary
Only in units with optional Check the evaporation unit,
condensate evaporation exchange if necessary
A09 Condenser fan Blocked or defective Clear the blockage; replace if necessary
A10 Evaporator fan Blocked or defective Clear the blockage; replace if necessary
A11 Compressor Compressor overloaded No action required;
(internal winding protection) unit switches back on automatically
Defective Exchange by refrigeration engineer
(check by measuring the winding resistance)
A12 Condenser temperature Open or short-circuit Replace
sensor
A13 Ambient temperature Open or short-circuit Replace
sensor
A14 Icing temperature sensor Open or short-circuit Replace
A15 Condensate warning Open or short-circuit Replace
temperature sensor
A16 Internal temperature sensor Open or short-circuit Replace
A17 Phase monitoring For three-phase devices only: Exchange two phases
Incorrect rotary field/phase absent
A18 EPROM error New board obstructed Software update needed (only following board
installation with more recent software):
Enter the programming level with Code 22;
press button 1 and confirm with "Set" until
"Acc" appears. Next, disconnect the unit from
the mains and reconnect.
A19 LAN/Master-Slave Master and slave not connected Check setting and/or cable
A20 Voltage drop Error display not shown Event is stored in the log file
EO Display message Connection problem between the display Reset: Switch power supply off, then switch on
and the controller board again after approx. 2 sec.
Cable defective; connection loose Exchange the boards
OL Overload Ambient parameters or heat loss outside of the applicable limits
LH Low heat Minimal heat loss inside the enclosure
rSt Reset Manual device reset required,
see "6.2.9 Resetting the Comfort controller", page 29.
Tab. 6: Troubleshooting with the Comfort controller

28 RITIAL cooling unit assembly and operating instructions


7 nspection and maintenance
6.2.9 Resetting the Comfort controller
After the occurrence of faults A03, A06 and AO?,
you will need to reset the Comfort controller.
• Press buttons 1 (A) and 3 (T) (Fig . 28)
simultaneously for 5 sec.
The system messages will disappear and the
temperature display will be shown.

7 Inspection and maintenance

Risk of electric shock!


The unit is live.
Switch off the power supply before open-
ing, and take suitable precautions against
it being accidentally switched back on.

( 7.1 General Fig. 31: Disconnect the mains plug


The cooling circuit is designed in the form of a
maintenance-free, hermetically sealed system.
The cooling unit is filled with the required quantity