EWS UFS8000 Manual de usuario

Controller for ultra filtration plants

Operating manual

Software version 1.06

UFS8000

Contents

1. System description ........................................................................................................................... 1

1.1. General........................................................................................................................................ 1

1.2. Functionality overview ................................................................................................................. 1

1.3. Diagram of the unit ...................................................................................................................... 2

1.4. Unit configuration ........................................................................................................................ 2

1.5. Description of the unit.................................................................................................................. 2

2. Picture of front side........................................................................................................................... 4

3. Measurement and function display ................................................................................................. 5

3.1. LCD display ................................................................................................................................. 5

4. General operation.............................................................................................................................. 8

4.1. Main screen................................................................................................................................. 8

4.2. Menu............................................................................................................................................ 8

4.3. Window........................................................................................................................................ 9

4.3.1. Set value or text .................................................................................................................. 9

4.3.2. On / off option...................................................................................................................... 9

4.3.3. Set dropdown list................................................................................................................. 9

4.3.4. Confirmation ...................................................................................................................... 10

4.4. Alarm window ............................................................................................................................ 10

5. Unit Configuration ........................................................................................................................... 11

5.1. Inventory.................................................................................................................................... 12

5.1.1. Security switch .................................................................................................................. 13

5.1.2. Analogue control ............................................................................................................... 14

5.2. Programming............................................................................................................................. 15

5.2.1. Components ...................................................................................................................... 15

5.2.2. Units (phases) ................................................................................................................... 16

6. Components..................................................................................................................................... 17

6.1. Valves........................................................................................................................................ 17

6.1.1. Air valve............................................................................................................................. 17

6.1.2. Inlet valves ........................................................................................................................ 17

6.1.3. Concentrate valves ........................................................................................................... 18

6.1.4. Permeate valves................................................................................................................ 18

6.1.5. Backwash valve................................................................................................................. 18

6.1.6. Permeate dump valve ....................................................................................................... 19

6.2. Pumps ....................................................................................................................................... 19

6.2.1. Feed pump ........................................................................................................................ 19

6.2.2. Backwash pump ................................................................................................................ 20

6.2.3. Dosing pumps ................................................................................................................... 20

6.3. Alarm ......................................................................................................................................... 22

6.4. Switches .................................................................................................................................... 23

6.4.1. Exceeded pressure ........................................................................................................... 23

6.4.2. Stop ................................................................................................................................... 24

6.4.3. Filtration start..................................................................................................................... 24

6.4.4. Start backwash.................................................................................................................. 25

6.4.5. Alarm reset ........................................................................................................................ 25

6.5. Tanks......................................................................................................................................... 26

6.5.1. Clean water tank ............................................................................................................... 26

6.5.2. Raw water tank.................................................................................................................. 27

6.5.3. Dosing tank ....................................................................................................................... 28

6.6. Recorder outputs....................................................................................................................... 30

6.7. Flow meter................................................................................................................................. 31

6.7.1. Flow Feed.......................................................................................................................... 31

6.7.2. Flow Permeate 1 ............................................................................................................... 31

6.7.3. Flow Permeate 2 ............................................................................................................... 31

6.7.4. Flow Backwash ................................................................................................................. 31

6.7.5. Flow meter settings ........................................................................................................... 32

6.7.6. Properties flow meter ........................................................................................................ 32

6.7.7. Monitoring minimum flow .................................................................................................. 33

6.7.8. Monitoring maximum flow ................................................................................................. 33

6.8. Pressure meter.......................................................................................................................... 34

6.8.1. Pressure Feed 1................................................................................................................ 34

6.8.2. Pressure Feed 2................................................................................................................ 34

6.8.3. Pressure Backwash .......................................................................................................... 34

6.8.4. Pressure Air....................................................................................................................... 34

6.8.5. Pressure Concentrate ....................................................................................................... 34

6.8.6. Pressure Permeate ........................................................................................................... 34

6.8.7. Pressure meter settings .................................................................................................... 35

6.8.8. Properties pressure meter................................................................................................. 35

6.8.9. Monitoring minimum pressure........................................................................................... 36

6.8.10. Monitoring maximum pressure........................................................................................ 36

6.9. Turbidity meter .......................................................................................................................... 37

6.9.1. Turbidity meter settings..................................................................................................... 37

6.9.2. Properties turbidity meter .................................................................................................. 37

6.9.3. Monitoring minimum turbidity ............................................................................................ 38

6.9.4. Monitoring maximum turbidity ........................................................................................... 38

6.10. Temperature............................................................................................................................ 39

6.10.1. Temperature meter settings ............................................................................................ 39

6.10.2. Properties temperature meter ......................................................................................... 39

6.10.3. Monitoring minimum temperature ................................................................................... 40

6.10.4. Monitoring maximum temperature .................................................................................. 40

6.11. Transmembrane pressure ....................................................................................................... 41

6.11.1. Properties transmembrane pressure .............................................................................. 41

6.11.2. Monitoring minimum transmembrane pressure .............................................................. 42

6.11.3. Monitoring maximum transmembrane pressure ............................................................. 42

6.12. pH meter.................................................................................................................................. 43

6.12.1. pH meter settings ............................................................................................................ 43

6.12.2. Properties pH meter ........................................................................................................ 43

6.12.3. Monitoring minimum pH .................................................................................................. 44

6.12.4. Monitoring maximum pH ................................................................................................. 44

7. UF Unit .............................................................................................................................................. 45

7.1. Properties .................................................................................................................................. 45

7.2. Filtration..................................................................................................................................... 46

7.3. Filtration 2.................................................................................................................................. 46

7.4. Pre Flush ................................................................................................................................... 47

7.5. Backwash 1 ............................................................................................................................... 47

7.6. Backwash 2 ............................................................................................................................... 48

7.7. CEB 1 ........................................................................................................................................ 49

7.8. CEB 2 ........................................................................................................................................ 50

7.9. CEB 3 ........................................................................................................................................ 50

7.10. Integrity test............................................................................................................................. 51

7.11. Standby ................................................................................................................................... 52

7.12. Standby Stop........................................................................................................................... 53

7.13. Alarm ....................................................................................................................................... 53

8. Alarms............................................................................................................................................... 54

8.1. General overview ...................................................................................................................... 54

8.2. Alarm window ............................................................................................................................ 54

8.3. Overview alarms........................................................................................................................ 56

9. Manual operation of the unit .......................................................................................................... 57

9.1. Standby stop ............................................................................................................................. 57

9.2. Integrity test............................................................................................................................... 57

9.3. Standby ..................................................................................................................................... 57

9.4. Pre Flush ................................................................................................................................... 58

9.5. Filtration..................................................................................................................................... 58

9.6. Backwash .................................................................................................................................. 59

9.7. CEB ........................................................................................................................................... 59

10. Retrieve information...................................................................................................................... 60

10.1. General.................................................................................................................................... 60

10.2. Service number ....................................................................................................................... 60

10.3. Inputs....................................................................................................................................... 60

10.4. Outputs .................................................................................................................................... 61

10.5. Counters .................................................................................................................................. 61

10.6. CEB 1 ...................................................................................................................................... 61

10.7. CEB 2 ...................................................................................................................................... 62

10.8. CEB 3 ...................................................................................................................................... 62

10.9. Alarm history ........................................................................................................................... 62

10.10. Ethernet ................................................................................................................................. 62

10.11. E-mail .................................................................................................................................... 63

10.12. RS485.................................................................................................................................... 63

10.13. RS232.................................................................................................................................... 63

10.14. Outputs 0-20mA .................................................................................................................... 64

10.15. Inputs 0-20mA ....................................................................................................................... 64

10.16. Print composition in the controller ......................................................................................... 65

11. User settings.................................................................................................................................. 66

11.1. LCD Display ............................................................................................................................ 66

12. Clock ............................................................................................................................................... 67

12.1. General.................................................................................................................................... 67

12.2. Time setting............................................................................................................................. 67

12.3. Date setting ............................................................................................................................. 67

13. Language setting........................................................................................................................... 68

13.1. Change language setting ........................................................................................................ 68

14. Ethernet .......................................................................................................................................... 69

14.1. Configuration ........................................................................................................................... 69

14.1.1. DHCP function................................................................................................................. 69

14.1.2. IP address ....................................................................................................................... 69

14.1.3. Subnetmask .................................................................................................................... 70

14.1.4. Default gate-way ............................................................................................................. 70

14.1.5. HTTP port number .......................................................................................................... 70

14.1.1. Modbus............................................................................................................................ 70

14.2. Access via internet (WAN) ...................................................................................................... 70

14.2.1. IP address of the modem (WAN) .................................................................................... 72

14.2.2. IP address of the modem (LAN)...................................................................................... 72

14.2.3. NAPT............................................................................................................................... 72

14.2.4. DHCP Lease ................................................................................................................... 73

15. SD card ........................................................................................................................................... 74

15.1. Arrangement of the cards........................................................................................................ 74

15.2. Directories ............................................................................................................................... 74

15.3. Software files........................................................................................................................... 75

15.4. Log functions ........................................................................................................................... 75

15.4.1. Alarm log function ........................................................................................................... 76

15.4.2. Data log function ............................................................................................................. 76

15.4.3. Process log function........................................................................................................ 77

16. E-mail .............................................................................................................................................. 78

16.1. Configuration ........................................................................................................................... 78

16.1.1. Switch on / off e-mail function ......................................................................................... 78

16.1.2. IP address of SMTP server ............................................................................................. 78

16.1.3. E-mail sender .................................................................................................................. 78

16.1.4. E-mail address of the recipient........................................................................................ 79

16.2. Log functions ........................................................................................................................... 79

16.2.1. Alarm log function ........................................................................................................... 79

17. RS485.............................................................................................................................................. 80

17.1. Configuration ........................................................................................................................... 80

17.1.1. Configuration in the controller ......................................................................................... 80

17.1.2. Configuration of the “Hyperterminal”............................................................................... 80

17.2. Log functions ........................................................................................................................... 80

17.2.1. Alarm log function ........................................................................................................... 81

17.2.2. Data log function ............................................................................................................. 81

17.2.3. Process log function........................................................................................................ 82

17.1. Modbus.................................................................................................................................... 82

18. RS232.............................................................................................................................................. 82

19. Hard disk ........................................................................................................................................ 83

19.1. Back-up via the fitting contractor............................................................................................. 83

19.2. Back-up by the end user ......................................................................................................... 83

20. Logging .......................................................................................................................................... 84

20.1. Alarm data ............................................................................................................................... 84

20.1.1. CSV format...................................................................................................................... 84

20.1.2. XML format...................................................................................................................... 85

20.2. Data information ...................................................................................................................... 85

20.2.1. CSV format...................................................................................................................... 86

20.2.2. XML format...................................................................................................................... 86

20.3. Process data ........................................................................................................................... 87

21. Modbus........................................................................................................................................... 88

21.1. Registers ................................................................................................................................. 88

21.1.1. Register : values ............................................................................................................. 88

21.1.2. Register : unities / decimals ............................................................................................ 89

21.1.3. Register : others .............................................................................................................. 90

22. Internet ........................................................................................................................................... 91

22.1. Access via the local network (LAN)......................................................................................... 91

22.2. Access via internet (WAN) ...................................................................................................... 91

22.3. Security.................................................................................................................................... 91

22.4. Head page ............................................................................................................................... 92

22.5. Unit display.............................................................................................................................. 93

22.6. Controller display / operation................................................................................................... 93

22.6.1. Protection ........................................................................................................................ 94

22.6.2. Terminal mode ................................................................................................................ 94

22.7. Getting log files........................................................................................................................ 94

22.8. “Internet key” ........................................................................................................................... 94

23. Service ............................................................................................................................................ 95

23.1. Service number ....................................................................................................................... 95

23.2. Maintenance............................................................................................................................ 95

23.3. Names ..................................................................................................................................... 96

23.4. Resets ..................................................................................................................................... 96

23.5. Hard disk ................................................................................................................................. 96

23.6. Hardware test .......................................................................................................................... 97

23.6.1. Inputs............................................................................................................................... 97

23.6.2. Relay outputs .................................................................................................................. 97

23.6.3. Outputs 0-20mA .............................................................................................................. 98

23.6.4. Inputs 0-20mA ................................................................................................................. 98

23.6.5. Back light......................................................................................................................... 98

23.6.6. Media............................................................................................................................... 99

24. Security ........................................................................................................................................ 100

24.1. Controller ............................................................................................................................... 100

24.1.1. Pass word...................................................................................................................... 100

24.1.2. Menu ............................................................................................................................. 101

24.1.3. Process ......................................................................................................................... 101

24.2. Internet .................................................................................................................................. 101

25. Power failure ................................................................................................................................ 102

25.1. Clock...................................................................................................................................... 102

25.2. Alarms ................................................................................................................................... 102

25.3. Programming......................................................................................................................... 102

26. Messages ..................................................................................................................................... 103

26.1. Hardware changed ................................................................................................................ 103

27. Boot software............................................................................................................................... 104

27.1. General.................................................................................................................................. 104

27.2. Changing application software .............................................................................................. 104

28. Frequently asked questions....................................................................................................... 105

28.1. General.................................................................................................................................. 105

28.2. Relay outputs ........................................................................................................................ 105

28.3. Digital inputs.......................................................................................................................... 105

28.4. E-mail .................................................................................................................................... 105

28.5. Internet .................................................................................................................................. 106

28.6. RS485.................................................................................................................................... 106

28.7. RS232.................................................................................................................................... 106

29. Terminology ................................................................................................................................. 107

30. Overview menu ............................................................................................................................ 108

31. Opening casing............................................................................................................................ 109

32. Terminal block connection......................................................................................................... 110

32.1. Schematics............................................................................................................................ 110

32.2. Remarks ................................................................................................................................ 112

33. Electrical connection examples................................................................................................. 112

34. Installation and Start up.............................................................................................................. 114

34.1. General.................................................................................................................................. 114

34.2. Installation ............................................................................................................................. 115

34.3. Ethernet connector ................................................................................................................ 115

35. Maintenance................................................................................................................................. 116

36. Spare parts................................................................................................................................... 116

36.1. Order codes........................................................................................................................... 116

36.2. Pictures.................................................................................................................................. 116

37. Technical specifications............................................................................................................. 117

37.1. Casing dimensions ................................................................................................................ 118

38. Index ............................................................................................................................................. 119

39. Declaration of conformity........................................................................................................... 121

40. Warranty conditions.................................................................................................................... 122

UFS8000 System description 1

1. System description

1.1. General

The UFS8000 is applicable for the automatic control and monitoring of ultra filtration units. Thanks to

the flexible programmable software this controller is suitable for a large number of various water

treatment applications.

1.2. Functionality overview

•Menu-driven operating and programming of controller graphic colour TFT display (800x480).

•Operates via touch panel.

•Choice of languages.

•Universally applicable to ultra filtration plants.

•Flexibly programmable for specific user requirements.

•Water production via manual controls or level switches

•Free programmable service telephone number.

•Programming locally and via web browser

•Schematic diagram via web browser

•Modbus compatible protocol through RS485 and Ethernet.

•Measurement data logging via RS232, RS485 and SD card.

•Alarm logging via RS232, RS485, SD card and E-mail.

•8 free programmable inputs for potential free switches.

Available input functions: High-level switch, Low-level switch,

Overpressure, Start Backwash, Start Filtration, Alarm reset, Security switches for valves /

pumpes and Level switch for dosing tank

•7 free programmable relay outputs

Available relay functions: Feed pump, Air valve, Inlet valve, Concentrate valve,

Permeate valve, Permeatedump valve, Dosing pump, Backwash valve, Backwash pump

and Alarm.

•Optional: 2 x print with 3 outputs 0(4)-20mA for writer or control frequency regulator.

•Optional: 4 prints with 3 programmable inputs 0-20mA.

Available measuring functions: Level of the clean water tank, Level of the raw water tank,

level of dosage tank, flow measurements, pressure measurements, temperature and pH

meter.

measurement and turbidity measurements.

•Alarm history: last 20 alarms are stored with date and time

•Update of software via SD card

•Date and time with battery

•Securing program information in the event of a loss of voltage, the program information is

stored without battery.

•Manufactured according to EMC guidelines.

•Casing suitable for wall mount, mounting and panel mounting.

•Available in 24V, 115V, 230V, 240V, 115/24V, 230/24V, 240/24V

UFS8000 System description 2

1.3. Diagram of the unit

The unit is schematically represented in the following diagram

The diagram features all the components defined in the controller. Only the components that are

connected to the available in- and outputs can be displayed.

§ 29 “Terminology” on page 107 offers an overview of the meaning of the abbreviations used..

These abbreviations may differ from the picture, because they have been modified by the user.

1.4. Unit configuration

In the controller the unit configuration can be configured via the menu option “Unit” (in the main menu).

First of all, an inventory has to be made of the components that have to be driven by the controller,

and to which pins these components are connected. The inventory is described in § 5.1 “Inventory” on

page 12.

Subsequent to the inventory any delays, limits etc. can be set for the various components under the

“Programming - Components ” option. This is described in § 6 “Component” on page 17.

Next the various phases (“Filtration”, “Pre Flush” etc.) can be programmed.

The functions that are switched on or switched off can be set for each phase. A time duration may also

be entered. This is described in § 7 “UF Unit” on page 45.

1.5. Description of the unit

The controller distinguishes different phases:

- Filtration Production of water

- Pre Flush Flushing the membrane before filtration

- Backwash 1 Rinsing the membrane (e.g. from bottom)

- Backwash 2 Rinsing the membrane (e.g. from top)

- Integrity test Checking the membrane

- CEB 1,2 and 3 Rinsing the membrane with chemicals

- Standby Installation out of service : no production of water

- Standby Stop Installation out of service : only be switched on

manually.

- Alarm Installation out of service : no production of water

UFS8000 System description 3

The controller is routinely delivered in the “Standby Stop" phase. The unit will not be automatically

started until this is switched on manually (see § 9.1 “Standby stop” on page 57. Once it is switched on,

the controller will no longer start in this phase after a power failure, unless this phase is activated via

the programming (see § 7.12 “Standby Stop” on page 53).

The production of water can be started depending on the level in the tanks, the “start filtration” switch

(if enabled) or manually.

It is possible to disable the installation manually during the “Filtration” phase (see § 9.5 “Filtration” on

page 58), regardless of the level in the tanks or the position of an eventual “start filtration” switch.

The installation will go on “Standby” after this phase (depending on the programming, eventually by a

backwash).

The lower bar in the main window will then show that unit has been manually switched off. The unit will

no longer be automatically switched on until the unit is manually turned on again.

It is further possible to activate a backwash or chemical rinse during the production (see § 7.7 “CEB 1”

on page 49, § 7.8 “CEB” on page 50 and § 7.9 “CEB” on page 50).

One backwash phase is activated as a standard. A second backwash phase, however, can be

activated (see § 7.6 “Backwash 2” on page 48). With this a distinction can be made between a

backwash via the top and bottom of the filter.

If an eventual chemical rinse is dependent on the number of executed backwashes, then, in the case

of two activated “normal” backwashes, “Backwash 2” is checked for the counter of the number of

executed backwashes. If “Backwash 2” is not activated, then “Backwash 1” is, of course, checked.

Also a second filtration phase (“Filtration 2”) can be activated (see § 7.3 “Filtration 2” on page 46) to

perform “top / bottom” filtration.

A chemical rinse will follow immediately after the respective backwash. If there are any chemical

rinses occurring simultaneously, then these will be carried out directly after one another.

For “Chemical rinse 2” (CEB 2), the interval can also be made dependent on the “Chemical rinse 1”

(CEB 1) phase. In this case, the cycle will be as follows:

Also see § 7.8 “CEB” on page 50.

For the testing of a "leak" in the membrane, the “Integrity Test” phase is present in the control unit.

This phase can only be achieved through the “Standby” phase (see § 9.3 “Standby” on page 57).

The test is not started automatically immediately, but the system is initially in a “rest” position. The

actual test can be started from this position (see § 9.2 “Integrity test” on page 57). There is more

information on the “Integrity Test” phase in § 7.10 “Integrity test” on page 51.

If a phase is interrupted because of an alarm situation the top bar will show there is an alarm situation.

Also shown is the phase when the alarm occurred, the cause of the interruption and how the

unit is switched on again.

§ 7.13 “Alarm” on page 53 In § 8 “Alarms” on page 54 there is more information about alarms.

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