Grundfos SMART Digital DDA Bedienungsanleitung

GRUNDFOS INSTRUCTIONS

SMART Digital - DDA

Installation and operating instructions

Declaration of conformity

GB Declaration of Conformity

We, Grundfos Alldos, declare under our sole responsibility that the products

DDA, DDC and DDE, to which this declaration relates, are in conformity with

these Council directives on the approximation of the laws of the EC member

states:

– Machinery Directive (2006/42/EC).

Standards used: EN 809: 1998, EN ISO 12100-1+A1: 2009,

EN ISO 12100-2+A1: 2009.

– Low Voltage Directive (2006/95/EC) *.

Standard used: EN 60204-1+A1: 2009.

– EMC Directive (2004/108/EC).

Standards used: EN 61000-6-2: 2005, EN 61000-6-4: 2007.

* Only for products with operating voltage > 50 VAC or >75 VDC.

Pfinztal, 1 November 2010

Ulrich Stemick

Technical Director

Grundfos Water Treatment GmbH

Reetzstr. 85, D-76327 Pfinztal, Germany

Person authorised to compile technical file and

empowered to sign the EC declaration of conformity.

English (GB)

English (GB) Installation and operating instructions

Original installation and operating instructions.

CONTENTS Page

1. Safety instructions 4

1.1 Identification of safety instructions in

these instructions 4

1.2 Qualification and training of personnel 4

1.3 Safety instructions for the operator/

user 4

1.4 Safety of the system in the event of a

failure in the dosing pump 4

1.5 Dosing chemicals 5

2. General 5

2.1 Applications 5

2.2 Improper operating methods 5

2.3 Warranty 6

2.4 Nameplate 6

2.5 Type key 7

2.6 Device overview 8

3. Technical data / dimensions 9

3.1 Technical data 9

3.2 Dimensions 11

4. Assembly and installation 12

4.1 Pump assembly 12

4.1.1 Requirements 12

4.1.2 Align and install mounting plate 12

4.1.3 Engage pump in mounting plate 12

4.1.4 Adjusting control cube position 12

4.2 Hydraulic connection 13

4.3 Electrical connection 14

5. Commissioning 16

5.1 Setting the menu language 16

5.2 Deaerating the pump 17

5.3 Calibrating the pump 17

6. Operation 19

6.1 Control elements 19

6.2 Display and symbols 19

6.2.1 Navigation 19

6.2.2 Operating states 19

6.2.3 Sleep mode (energy-saving mode) 19

6.2.4 Overview of display symbols 20

6.3 Main menus 21

6.3.1 Operation 21

6.3.2 Info 21

6.3.3 Alarm 21

6.3.4 Setup 21

6.4 Operation modes 22

6.4.1 Manual 22

6.4.2 Pulse 22

6.4.3 Analog 0/4-20 mA 23

6.4.4 Batch (pulse-based) 24

6.4.5 Dosing timer, cycle 25

6.4.6 Dosing timer, week 25

6.5 Analog output 26

6.6 SlowMode 26

6.7 FlowControl 27

6.8 Pressure monitoring 28

6.8.1 Pressure setting ranges 28

6.8.2 Calibration of pressure sensor 28

6.9 Flow measurement 29

6.10 AutoFlowAdapt 29

6.11 Auto deaeration 29

6.12 Key lock 30

6.13 Display Setup 30

6.13.1 Units 30

6.13.2 Additional display 30

6.14 Time/date 31

6.15 Bus communication 31

6.16 Inputs/outputs 31

6.16.1 Relay outputs 31

6.16.2 External stop 32

6.16.3 Empty and low-level signals 32

6.17 Basic settings 32

7. Service 33

7.1 Service system 33

7.2 Perform service 33

7.2.1 Dosing head overview 34

7.2.2 Dismantling the diaphragm and valves 34

7.2.3 Reassembling the diaphragm and

valves 34

7.3 Resetting the service system 34

7.4 Repairs 34

8. Faults 35

8.1 List of faults 36

8.1.1 Faults with error message 36

8.1.2 General faults 38

9. Disposal 38

Warning

Prior to installation, read these

installation and operating instructions.

Installation and operation must comply

with local regulations and accepted

codes of good practice.

English (GB)

1. Safety instructions

These installation and operating instructions contain

general instructions that must be observed during

installation, operation and maintenance of the pump.

It must therefore be read by the installation engineer

and the relevant qualified operator prior to

installation and start-up, and must be available at the

installation location at all times.

1.1 Identification of safety instructions in

these instructions

The safety instructions are identified by the following

symbols:

1.2 Qualification and training of personnel

The personnel responsible for the installation,

operation and service must be appropriately

qualified for these tasks. Areas of responsibility,

levels of authority and the supervision of the

personnel must be precisely defined by the operator.

If necessary, the personnel must be trained

appropriately.

Risks of not observing the safety instructions

Non-observance of the safety instructions may have

dangerous consequences for the personnel, the

environment and the pump and may result in the loss

of any claims for damages.

It may lead to the following hazards:

• Personal injury from exposure to electrical,

mechanical and chemical influences.

• Damage to the environment and personal injury

from leakage of harmful substances.

1.3 Safety instructions for the

operator/user

The safety instructions described in these

instructions, existing national regulations on health

protection, environmental protection and for accident

prevention and any internal working, operating and

safety regulations of the operator must be observed.

Information attached to the pump must be observed.

Leakages of dangerous substances must be

disposed of in a way that is not harmful to the

personnel or the environment.

Damage caused by electrical energy must be

prevented, see the regulations of the local electricity

supply company.

Only orginal accessories and original spare parts

should be used. Using other parts can result in

exemption from liability for any resulting

consequences.

1.4 Safety of the system in the event of a

failure in the dosing pump

The dosing pump was designed according to the

latest technologies and is carefully manufactured

and tested.

If it fails regardless of this, the safety of the overall

system must be ensured. Use the relevant

monitoring and control functions for this.

Warning

If these safety instructions are not

observed, it may result in personal

injury!

Caution

If these safety instructions are not

observed, it may result in malfunction

or damage to the equipment!

Note

Notes or instructions that make the job

easier and ensure safe operation.

Caution

Before any work to the pump, the pump

must be in the ’Stop’ operational state

or be disconnected from the mains.

The system must be pressureless!

Caution

Make sure that any chemicals that are

released from the pump or any

damaged lines do not cause damage to

system parts and buildings.

The installation of leak monitoring

solutions and drip trays is

recommended.

English (GB)

1.5 Dosing chemicals 2. General

The DDA dosing pump is a self-priming

diaphragm pump. It consists of a housing

with stepper motor and electronics, a

dosing head with diaphragm and valves and the

control cube.

Excellent dosing features of the pump:

• Optimal intake even with degassing media, as

the pump always works at full suction stroke

volume.

• Continuous dosing, as the medium is sucked up

with a short suction stroke, regardless of the

current dosing flow, and dosed with the longest

possible dosing stroke.

2.1 Applications

The pump is suitable for liquid, non-abrasive, non-

flammable and non-combustible media strictly in

accordance with the instructions in these installation

and operating instructions.

Areas of application

• Drinking water treatment

• Wastewater treatment

• Swimming pool water treatment

• Boiler water treatment

• CIP (Clean-In-Place)

• Cooling water treatment

• Process water treatment

• Wash plants

• Chemical industry

• Ultrafiltration processes and reverse osmosis

•Irrigation

• Paper and pulp industry

• Food and beverage industries

2.2 Improper operating methods

The operational safety of the pump is only

guaranteed if it is used in accordance with section

2.1 Applications.

Warning

Before switching the supply voltage

back on, the dosing lines must be

connected in such a way that any

chemicals in the dosing head cannot

spray out and put people at risk.

The dosing medium is pressurised and

can be harmful to health and the

environment.

Warning

When working with chemicals, the

accident prevention regulations

applicable at the installation site

should be applied (e. g. wearing

protective clothing).

Observe the chemical manufacturer's

safety data sheets and safety

instructions when handling chemicals!

Warning

If the diaphragm leaks or is broken,

dosing liquid will escape from the

discharge opening on the dosing head

(see fig. 3).

Take suitable precautions to prevent

harm to health and damage to property

from escaping dosing liquid!

Check daily whether liquid is escaping

from the discharge opening!

Changing the diaphragm, see section

7. Service.

Caution

A deaeration hose, which is routed into

a container, e. g. a drip tray, must be

connected to the deaeration valve.

Caution

The dosing medium must be in liquid

aggregate state!

Observe the freezing and boiling points

of the dosing medium!

Caution

The resistance of the parts that come

into contact with the dosing medium,

such as the dosing head, valve ball,

gaskets and lines, depends on the

medium, media temperature and

operating pressure.

Ensure that parts in contact with the

dosing media are resistant to the

dosing medium under operating

conditions, see data booklet!

Should you have any questions

regarding the material resistance and

suitability of the pump for specific

dosing media, please contact

Grundfos.

Warning

Other applications or the operation of

pumps in ambient and operating

conditions, which are not approved,

are considered improper and are not

permitted. Grundfos cannot be held

liable for any damage resulting from

incorrect use.

Warning

The pump is NOT approved for

operation in potentially explosive

areas!

Warning

A sunscreen is required for outdoor

installation!

English (GB)

2.3 Warranty

A guarantee claim in accordance with our general terms of sale and delivery is only valid if the following

requirements are fulfilled:

• The pump is used in accordance with the information within this manual.

• The pump is not dismantled or incorrectly handled.

• The maintenance is carried out by authorised and qualified personnel.

• Original spare parts are used for repairs during maintenance.

2.4 Nameplate

Fig. 1 Nameplate

TM04 1116 1110

psi

gphl/h

Type designationVoltage Frequency Max. dosing flow

Power consumption

Enclosure class

Mark of approval, CE mark, etc.

Model Current consumption Country of production

Max. operating pressure

English (GB)

2.5 Type key

The type key is used to identify the precise pump and is not used for configuration purposes.

*) including: 2 pump connections, foot valve, injection unit, 6 m PE discharge hose, 2 m PVC suction hose,

2 m PVC deaeration hose (4/6 mm)

Code Example DDA 7.5- 16 AR- PP/ V/ C- F- 3 1 U2U2 F G

Pump type

Max. flow [l/h]

Max. pressure [bar]

FCM

Control variant

Standard

AR with FlowControl

FC with integrated flow measurement

PVC

PVC-P3

Dosing head material

Polypropylene

PVC (polyvinyl chloride) (PVC dosing heads only up to 10 bar)

PVDF (polyvinylidene fluoride)

Stainless steel DIN 1.4401

PVC with Plus3

Gasket material

EPDM

FKM

PTFE

Valve ball material

Ceramic

Stainless steel DIN 1.4401

FControl cube position

Front-mounted (can be changed to the right or left)

3Voltage

1 x 100-240 V, 50/60 Hz

Valve type

Standard

Spring-loaded (HV version)

U2U2

U7U7

I001

I002

I003

I004

Suction/discharge side connection

Hose, 4/6 mm, 6/9 mm, 6/12 mm, 9/12 mm

Hose 1/8" x 1/4"; 0.17" x 1/4"; 1/4" x 3/8"; 3/8" x 1/2"

Threaded Rp 1/4", female (stainless steel)

Threaded 1/4" NPT, female (stainless steel)

No connection

Installation set*

Hose, 4/6 mm (up to 7.5 l/h, 16 bar)

Hose, 9/12 mm (up to 60 l/h, 13 bar)

Hose 0.17" x 1/4" (up to 7.5 l/h, 16 bar)

Hose, 3/8" x 1/2" (up to 60 l/h, 10 bar)

Power plug

EU (Schuko)

USA, Canada

Australia, New Zealand, Taiwan

Switzerland

Japan

Argentina

GDesign

Grundfos Alldos

English (GB)

2.6 Device overview

Fig. 2 Front view of the pump

Fig. 3 Rear view of the pump

TM04 1129 0110

Start/stop key

(Sect. 6.1)

Mains connection

Control cube Graphic LC display

(Sect. 6.2.2)

Click wheel (Sect. 6.1)

100 % key (Sect. 6.1)

Signal inputs, outputs

(Sect. 4.3)

Mounting plate

100%100%

TM04 1133 0110

FlowControl connection

FC/FCM

Deaeration valve

Dosing head

Valve, suction side

Connection, deaeration

hose

Valve, discharge side

Control cube assembly

screws

Drain opening in case of

diaphragm breakage

English (GB)

3. Technical data / dimensions

3.1 Technical data

Data DDA pump type

7.5 - 16 12-10 17-7 30-4

Mechanical

data

Turndown ration (setting range) [1:X] 3000 1000 1000 1000

Max. dosing flow [l/h] 7.5 12.0 17.0 30.0

[gph] 2.0 3.1 4.5 8.0

Max. dosing flow with SlowMode 50 % [l/h] 3.75 6.00 8.50 15.00

[gph] 1.00 1.55 2.25 4.00

Max. dosing flow with SlowMode 25 % [l/h] 1.88 3.00 4.25 7.50

[gph] 0.50 0.78 1.13 2.00

Min. dosing flow [l/h] 0.0025 0.0120 0.0170 0.0300

[gph] 0.0007 0.0031 0.0045 0.0080

Max. operating pressure [bar] 16 10 7 4

[psi] 230 150 100 60

Max. stroke frequency 1) [Strokes/

min] 190 155 205 180

Stroke volume [ml] 0.74 1.45 1.55 3.10

Accuracy of repeatability [%] ±1

Max. suction lift during operation2) [m] 6

Max. suction lift when priming with wet

valves 2) [m] 2 3 3 2

Min. pressure difference between suction

and discharge side [bar] 1 (FC and FCM: 2)

Max. pressure, suction side [bar] 2

Max. viscosity in SlowMode 25 % with

spring-loaded valves 3) [mPa s]

(= cP) 2500 2500 2000 1500

Max. viscosity in SlowMode 50 % with

spring-loaded valves 3) [mPa s]

(= cP) 1800 1300 1300 600

Max. viscosity without SlowMode with

spring-loaded valves 3) [mPa s]

(= cP) 600 500 500 200

Max. viscosity without spring-loaded

valves 3) [mPa s]

(= cP) 50 300 300 150

Min. diameter of hose/pipe on suction/

discharge side 2) 4) [mm] 4 6 6 9

Min. diameter of hose/pipe on suction

side for highly viscous media (HV) 4) [mm] 9

Min. diameter of hose/pipe on discharge

side for highly viscous media (HV) 4) [mm] 9

Max. media temperature [°C] 45

Min. media temperature [°C] -10

Max. ambient temperature [°C] 45

Min. ambient temperature [°C] 0

Max. storage temperature [°C] 70

Min. storage temperature [°C] -20

English (GB)

1) The maximum stroke frequency varies depending on calibration

2) Data is based on measurements with water

3) Maximum suction lift: 1 m, dosing flow reduced (approx. 30 %)

4) Length of suction line: 1.5 m / length of discharge line: 10 m (at max. viscosity)

5) With E-Box.

Electrical

data

Voltage [V] 100-240 V, 50-60 Hz

Length of mains cable [m] 1.5

Max. current consumption (100 V) [A] 8

Max. current consumption (230 V) [A] 25

Max. power consumption P1[W] 18 / 245)

Enclosure class IP 65, Nema 4X

Electrical safety class II

Signal input

Max. load for level input 12 V, 5 mA

Max. load for pulse input 12 V, 5 mA

Max. load for external stop 12 V, 5 mA

Min. pulse length [ms] 5

Max. pulse frequency [Hz] 100

Impedance at 0/4-20 mA analog input [Ω]15

Max. resistance in level circuit [Ω]1000

Max. resistance in pulse circuit [Ω]1000

Signal

output

Max. ohmic load on relay output [A] 0.5

Max. voltage on relay output [V] 30 VDC / 30 VAC

Impedance at 0/4-20 mA analog output [Ω]500

Weight/ size

Weight (PVC, PP, PVDF) [kg] 2.4 2.4 2.6

Weight (stainless steel) [kg] 3.2 3.2 4.0

Diaphragm diameter [mm] 44 50 74

Sound

pressure

level Max. sound pressure level [dB(A)] 60

Approvals CE, CSA-US, NSF61, GHOST, C-Tick

Data DDA pump type

7.5 - 16 12-10 17-7 30-4

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