Transcript
Operating Instructions ProMinent® DulcoBlend Series Polymer Blending Systems
Please read through all of these operating instructions first! Do not discard! The warranty shall be invalidated by damage caused by operating errors! Revision 2, June 20, 2015
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BA DST 005 05/16 EN
Table of Contents Specifications
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Technical Data.......................................................................................................................... 3 Wetted Materials ...................................................................................................................... 4 General Description
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Installation
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Unpacking ................................................................................................................................. 6 Location .................................................................................................................................... 6 Electrical Installation ............................................................................................................... 6 Water Installation ..................................................................................................................... 6 Polymer Installation ................................................................................................................. 6 General Electrical Installation ............................................................................................... 7 Calculating Your Polymer Solution Feed Rate
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Screen Overviews
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Language Option Screen (1).……………………….……………………..................................9 Main Screen (2).……………………….…………………….......................................................10 Settings Screen (3).……………………….……………………...............................................12 Configuration Screen (4).……………………….……………………......................................13 Description of Control Modes
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Commissioning / Start up
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Operation
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Manual (Continuous) Operation ..................................................................................……..16 Auto Mode Local ……………………………………….……………………...............................16 Auto Mode Remote …………………………………….……………………...............................17 Local Remote ………..………………………………….……………………...............................17 Maintenance
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Polymer dosing pump ........................................................................................................... 18 Cleaning the injection valve ................................................................................................. 19 Cleaning the mixing chamber............................................................................................... 20
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Troubleshooting
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DulcoBlend Polymer Concentration Tables
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Spare Parts List
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Electrical Schematics, BOM
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Specifications:
Technical Data Power Supply Required .............................. 120 VAC. 60 Hz, 1PH Power ........................................................... max 240 watt Remote control ............................................. Voltage free contact + 4-20 mA Volume of mixing chamber ........................... 7 litres Water inlet/outlet connection ........................ 3/4" FNPT Connection polymer solution ........................ 3/8” supplied tubing and foot valve Polymer dosing pump type…………….. ....... Peristaltic (Tube) pump (Do Not operate below 10% of Pump Rated Capacity) Sound level .................................................. < 70dB (A) Max. Backpressure, polymer solution ......... 60 psi Max. Viscosity of polymer solution in chamber…2000cP Recommended running temperature ........... +10 to 37 deg. C Weight (empty chamber) .............................. 91kg. mA input impedance………………………. ... 10 ohms.
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Wetted Materials Neat Polymer Solution: ‐ Tygothane ‐ PVC ‐ EPDM ‐ Polypropylene ‐ 316 Stainless Steel ‐ Viton Dilution Water Line: ‐ PVC ‐ EPDM ‐ Brass ‐ Polyamide ‐ 316 Stainless Steel Process / Solution Outlet: ‐ PVC ‐ 316 Stainless Steel ‐ EPDM Mixing Chamber Top and Bottom Plate ‐
POM – C (PolyOxyMenthylene - Copolymer)
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General Description
General description The ProMinent DulcoBlend polymer system provides a complete activation and dosing system for concentrated polymers. The true Multi-Zone mixing chamber provides proper shear and mixing energy required for efficient activation of emulsion and dispersion polymers. The system comes complete with mixing chamber, mixer, neat polymer pump, rotameters, solenoid valve, flow switch, static mixer, and control panel all assembled on a stainless steel skid suitable for floor mounting.
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Installation
Unpacking
Unpack your DulcoBlend. Make sure that your DulcoBlend hasn’t been damaged during transport. If it has, please report to the shipping company immediately. ProMinent is not responsible for damaged goods once they have left the factory.
Location
The DulcoBlend should be installed in a dry location that is protected from the elements and be easily accessible for service and maintenance.
The DulcoBlend is configured for floor mounting. Make certain that the polymer unit is located near the neat polymer container and near the point of injection.
Electrical Installation
The DulcoBlend is electrically connected according to the enclosed electrical diagram (see General Electrical Installation on next page). Make sure that the system is well grounded to prevent electrical shock.
Water Installation
Connect a clean potable water supply to the water inlet piping.
Operating pressure should not exceed 60 psi. If supply source is higher, use of a pressure reducing valve is recommended.
Polymer Installation
Connect the supplied flexible tubing to the polymer pump fitting and the other end to the polymer supply source (drum, tote bin, bulk tank, etc.).
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General Electrical Installation
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Calculating Your Polymer Solution Feed Rate
Concentration tables have been added at the back of this manual as examples to help calculate polymer concentrations and feed rates.
GPH Neat Polymer / Desired Solution Concentration = Dilution Water Requirement Example: 2.5GPH / 0.005 = 500GPH Dilution Water (This comes out to a 0.5% solution strength)
Total Solution Requirement x Desired Solution Concentration = Neat Polymer Requirement Example: 1200GPH x 0.001 = 1.2GPH Neat Polymer Requirement (This comes out to a 0.1% solution strength)
LPH Neat Polymer / Desired Solution Concentration = Dilution Water Requirement Example: 5.0LPH / 0.005 = 1000LPH Dilution Water (This comes out to a 0.5% solution strength)
Total Solution Requirement x Desired Solution Concentration = Neat Polymer Requirement Example: 10,000LPH x 0.001 = 10LPH Neat Polymer Requirement (This comes out to a 0.1% solution strength) NOTE: (Do Not operate Polymer Pump below 10% Speed)
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Screen Overviews LANGUAGE OPTION SCREEN (1)
Language Option Screen: When the DulcoBlend system is powered up, one of the first screens to be displayed on the Human Machine Interface (HMI) is the Language Option Screen. The system is configured for both English and French. Press the appropriate button and the system will operate in that language.
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MAIN SCREEN (2) This is the main overview screen. All modes use this screen for the main view.
Window Features 1. Alarm Button: Press this button to view all active alarms. This button will flash when there is an alarm. 2. System Flush: Press this button to initiate a system flush. The Solenoid and the Mixer will be enabled for a preset amount of time. After which the system will be off. 3. I/O Status: Press this button to enter ‘I/O Status’ screen. This screen displays the status of each digital input on the PLC. See below for more information on this screen. 4. Language: Press the ‘Language’ button to enter the ‘Language Option’ screen. 5. Settings: Press this button to enter the ‘Settings’ screen. Here is where default settings can be changed. See below for more information on this screen. 6. Mode Selection: Press this button to open the Mode ‘Configuration’ screen and select which operating mode to run the system in. 7. Start/Stop: Press this button to enable or disable the run sequence while in ‘Auto Mode, Local’. 8. Pump Status On/Off: The status of the pump is displayed above the Pump graphic. In Manual Mode, press the Pump graphic to start and stop the pump. In Auto Mode, the Pump is turned on and off by the PLC program logic. 9. Pump Speed (10 – 100%): The Pump Speed is displayed on the screen beside the pump. In Manual mode or Local Remote mode, the speed of the pump can be adjusted
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by pressing the Pump Speed graphic and then entering a new speed on the keypad. NOTE: Do Not operate below 10% 10. Mixer Status On/Off: The status of the Mixer is displayed above the Mixer graphic. In Manual Mode, press the Mixer graphic to start and stop the mixer. In Auto Mode, the Mixer is turned on and off by the PLC program logic. 11. Solenoid Valve Status Open/Closed: The status of the Solenoid Valve is displayed above the Valve graphic. In Manual Mode, press the Valve graphic to open and close the valve. In Auto Mode, the Valve is controlled by the PLC program logic. 12. System Status: This text box displays the status of the system when it is running in Auto Mode, Remote.
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SETTINGS SCREEN (3) This screen is used to adjust several basic system parameters.
Each one of these setpoints is operator adjustable. Just push on the setpoint and a keypad window will open. Type in the new setpoint and press the ‘Enter’ key.
Window Features 1. Fill Time: This is the amount of time the PLC program allows for the tank to fill before the polymer pump begins dosing. (Range 1-60 sec.) 2. Flush Time: A system flush is the act of pumping clean water through the chamber and the entire system without adding any polymer. The Flush Time setpoint is the length of time for a system flush once the ‘System Flush’ button is pressed. (Range 1- 130 sec.) 3. Wait for Flow: This setpoint is the time the PLC program will wait before anouncing a No Fow alarm after it has been detected. (Range 1-30 sec.) 4. Run Time: (Option) *When an external tank mixer is used, this is the preset amount of time the mixer will run before automatically stopping. 5. Elapsed Time: (Option) When an external tank mixer is used, this is the elapsed time the mixer has run. 6. Overview: Pressing this button will return you to the main ‘Overview’ screen. 7. Start: Pressing the ‘Start’ button will start the mixer and which will run until the Run Time has elapsed. The mixer then stops automatically.
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8. Stop: Pressing the ‘Stop’ button will stop the external tank mixer if needed before the predetermined amount of time has elapsed. *Neat polymers tend to stratify. By mixing the neat polymer (eg. daily for 5 minutes), stratification can be avoided, giving you a constant active neat polymer concentration until the tank is empty.
CONFIGURATION SCREEN (4) By pressing the ‘Mode Selection’ button from the main screen the following screen appears. From here any of the 4 operating modes can be selected by pressing the appropriate button.
Once the mode has been selected, press the ‘Overview’ button to return to the main screen and notice on the top center of the main screen, the current mode is displayed as selected.
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Description of Control Modes
The DulcoBlend system offers four different control modes as follows: Manual Mode When the system is in Manual Mode, each piece of equipment on the system has to be controlled individually, one at a time. First open the Solenoid Valve by pressing the valve graphic. Then start the Mixer by pressing the mixer graphic. Then start the Polymer Pump by pressing the pump graphic. Note: The Polymer Pump will only run if both the mixer and solenoid are on, and there is adequate flow through the Primary rotameter. If there is a No Flow Alarm, the Polymer Pump will not start. To adjust the speed of the Polymer Pump, press the current pump speed text box and enter a new speed (10-100%) on the keypad. To shut the system down, press the polymer pump graphic to stop the pump, press the mixer graphic to stop the mixer, and press the valve graphic to close the solenoid valve.
Auto Mode, Local When the system is in Auto Mode, Local, the system is started by pressing the ‘Start’ button in the top right corner of the Main overview screen. An external 4-20 mA signal from the Plant control system then controls the speed of the Polymer Pump. The Solenoid Valve, Mixer and Polymer Pump are all controlled automatically by the PLC program logic. To stop the system, press the ‘Stop’ button in the top right corner of the Main overview screen. If there is not enough flow through the Primary rotameter, a Low Flow Alarm occurs and the Polymer Pump stops running.
Auto Mode, Remote When the system is in Auto Mode, Remote, the system is started and stopped from an external voltage free remote contact from the Plant control system. Also, an external 4-20 mA signal from the Plant control system controls the speed of the Polymer Pump. The Solenoid Valve, Mixer and Polymer Pump are all controlled automatically by the PLC program logic. If there is not enough flow through the Primary rotameter, a Low Flow Alarm occurs and the Polymer Pump stops running.
Local, Remote When the system is in Local, Remote mode, it works exactly the same as when it is in Auto Mode, Remote, except for one difference; the speed of the Polymer Pump is controlled Locally from the HMI, just like when the system was in Manual Mode. So when the system is in Local,
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Remote, the system is started and stopped from an external voltage free remote contact from the Plant control system. The speed of the Polymer Pump is controlled locally by the operator on the HMI. The Solenoid Valve, Mixer and Polymer Pump are all controlled automatically by the PLC program logic. If there is not enough flow through the Primary rotameter, a Low Flow Alarm occurs and the Polymer Pump stops running.
Commissioning / Start Up
The polymer pump should not be running during the following procedure. Make sure that the pump indicates ‘OFF’.
Ensure inlet water supply, neat polymer supply, and polymer solution discharge are connected to the DulcoBlend.
Ensure that correct power is supplied to the DulcoBlend.
Open the incoming water valve on the primary rotameter 100%. (Fully counter clockwise).
Ensure that the secondary rotameter is closed (if one is supplied). (Fully clockwise).
Operating pressure should not exceed 60 psi. If supply source is higher, use of a pressure reducing valve is recommended.
Turn on main breaker located inside control panel.
Start the system by pressing ‘Mode Selection’ from the (Main Screen) then ‘Manual Mode’ from the (Mode Selection screen).
Press the ‘Off/On’ button for the inlet solenoid on the (Main Screen) to initiate water flow.
Press the ‘Off/On’ button for the mixer on the (Main Screen) to initiate mixing.
When the water starts to flow at the discharge outlet, the system is primed.
Reduce the flow by turning the primary rotameter valve until the mixer stops. (The flow switch inactivates during reduced water flow).
Close solenoid by pressing the ‘Off/On’ button on the inlet solenoid on the (Main Screen).
The DulcoBlend is now ready for service.
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Operation
Manual (Continuous) Operation
Start your DulcoBlend by selecting ‘Manual Mode’ in the Mode Selection screen.
The mixer, solenoid and polymer pump are all manually enabled. The polymer pump will not start until the flow switch located on the primary rotameter is triggered from sufficient flow. Note: The Polymer Pump will only run if the solenoid valve is open. (Adequate flow must be achieved past the rotameter flow switch).
Adjust the pump capacity and the amount of preparation water by using the Polymer Concentration tables at the back of this manual. The concentration of the diluted polymer should never exceed 0.5%. The table is designed around a product that contains 50% active polymer. This is valid for most emulsion and dispersion polymers.
Change the amount of dilution water by adjusting the flow through the primary and/or secondary rotameter.
Adjust the polymer dosage according to your above result by adjusting the pump speed to a higher or lower value.
To adjust the polymer pump capacity, press the pump speed text box and set the % speed. Then press enter.
Auto Mode Local
Start the polymer dosage by selecting ‘Auto Mode, Local’ in Mode Selection screen.
An external 4-20mA source is required to operate the unit in Auto Mode Local.
Push the START button on the Main screen.
Increase or decrease the polymer dosage by changing the 4-20 mA external signal to a higher or lower value (4-20 mA = 0 – 100% pump speed). Change the amount of dilution water correspondingly. Use the Polymer Concentration tables at the back of this manual to determine water and polymer flow rates. The concentration of the diluted polymer should never exceed 0.5%.
Stop the polymer dosage by pushing the STOP button on the Main screen.
Note: Do not run the Polymer Pump below 10%
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Operation
Auto Mode Remote
Start the polymer dosage by selecting ‘Auto Mode, Remote’ in the Mode Selection screen.
An external 4-20mA source and a voltage free contact are required to operate the unit in Auto Mode Remote.
Enable the unit via the voltage free remote contact.
Increase or decrease the polymer dosage by changing the 4-20 mA external signal to a higher or lower value (4-20 mA = 0 – 100% pump speed). Change the amount of dilution water correspondingly. Use the Polymer Concentration tables at the back of this manual to determine water and polymer flow rates. The concentration of the diluted polymer should never exceed 0.5%.
Stop the polymer by opening the external enable contact.
Contact Logic:
Closed contact = Run. Open contact = Stop.
Local, Remote
Start the polymer dosage by selecting ‘Local, Remote’ mode in the Mode Selection screen.
A voltage free contact is required to operate the unit in Local, Remote mode.
Enable the unit via the voltage free remote contact.
Increase or decrease the polymer dosage by changing the Polymer Pump Speed manually (locally) on the Main overview screen. (10 to 100%). Change the amount of dilution water correspondingly. Use the Polymer Concentration tables at the back of this manual to determine water and polymer flow rates. The concentration of the diluted polymer should never exceed 0.5%.
Stop the polymer by opening the external enable contact.
Contact Logic:
Closed contact = Run. Open contact = Stop.
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Maintenance
Polymer Pump
The polymer pump is a peristaltic pump for continuous duty. It’s equipped with flexible tubing with good mechanical and chemical qualities.
The flexible tubing is assembled with the suction side tubing connection on the bottom of the pump. The polymer discharge tubing is on the top of the pump.
After approximately 500 hours of accumulated running time, the SERVICE icon will light up on the pump. This is a reminder that the pump tube is nearing its minimum life expectancy and should be replaced. (Your actual tube life will depend on many factors such as the chemical used, back pressure, temperature, viscosity, and motor RPM).
The polymer injection valve is located on the top of the DulcoBlend. The injection valve must be cleaned when using different types of polymers such as anionic/cationic or oilbased/water-based. Failure to do this can result in clogging of the injection valve.
Before dismantling the injection valve, the fluid level in the mixing chamber MUST be lowered to prevent polymer spilling out of the injection port.
Lower the fluid level in the mixing chamber by first opening the discharge port valve and then opening the flush drain valve located at the bottom of the chamber:
Flush Drain Valve
Make sure that you connect tubing to the drain valve to prevent polymer spillage. You may need to open the ball valve above rotameter to allow air in:
Valve
Once the fluid level is below the injection valve, the valve can be disconnected for cleaning.
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Maintenance
Cleaning the injection valve
The liquid level in the mixing chamber MUST be below the injection valve. Lower tank level by opening the drain valve on base of tank.
Loosen the screws on the small oval lid on the top of the mixing chamber.
Lift the lid using a screwdriver or similar tool.
Carefully take out the injection valve.
Unscrew the injection valve
Clean the valve with a paper towel. Do not use water. A solvent can be used to clean the valve if necessary.
Check the O-Rings and replace if necessary.
Clean the injection valve seat in a similar fashion.
Reassemble the valve and check the spring for functionality before re-installing into chamber.
Warning: Do not allow water to get in the injection chamber, otherwise removal of injection hose and injection nipple will be required. Take a paper towel and insert through chamber and pull through till thoroughly cleaned.
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Maintenance
Cleaning the mixing chamber
Ensure pump is off.
Open the solenoid valve (Press solenoid ‘OPEN’ in manual mode) and let the dilution water rinse the inside of the chamber while the mixer is running.
If emptying the chamber is necessary, shut off polymer pump and discharge outlet. Open the drain valve located at bottom of chamber and flush water through.
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Troubleshooting
ALARM SCREEN (5) This screen is used to view and acknowledge alarms. To open this screen, press the ‘Alarm’ button in the top left corner of the main overview screen.
Potential list of Alarm messages and solutions: 1. ‘No Flow Main Water Line’ – Indicates incoming water is below rotameter sensor level. 2. ‘Mixer Circuit Breaker Tripped’ – Indicates mixer motor has exceeded breaker setting. Try resetting breaker and flushing the tank. 3. ‘Mixer Thermal Protection Tripped’ – Indicates mixer internal protection has tripped. Once motor cools it will reset automatically. 4. ‘Polymer Pump Fault’ – (Option) Indicates the pump tube has failed. 5. ‘No Flow Post Dilution Line’ – (Option) Indicates post dilution water is below rotameter sensor level.
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DulcoBlend Polymer Concentration Tables
DulcoBlend 60x2-0.55T @ 0.25%
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DulcoBlend 60x2-0.55T @ 0.30%
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DulcoBlend 60x2-0.55T @ 0.35%
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DulcoBlend 60x2-0.55T @ 0.40%
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DulcoBlend 60x2-0.55T @ 0.45%
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DulcoBlend 60x2-0.55T @ 0.5%
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DulcoBlend 180x2-1.19T @ 0.25%
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DulcoBlend 180x2-1.19T @ 0.30%
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DulcoBlend 180x2-1.19T @ 0.35%
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DulcoBlend 180x2-1.19T @ 0.40%
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DulcoBlend 180x2-1.19T @ 0.45%
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DulcoBlend 180x2-1.19T @ 0.50%
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DulcoBlend 300x2-2.74T @ 0.35%
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DulcoBlend 300x2-2.74T @ 0.40%
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DulcoBlend 300x2-2.74T @ 0.45%
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DulcoBlend 300x2-2.74T @ 0.50%
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Spare Parts List
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Electrical Schematics, BOM
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