Grundfos DDA 12-10 Installation And Operating Instructions Manual Download

Page: 44 / 52

En
gl

h (
G

9. Disposal

This product or parts of it must be disposed
of in an environmentally sound way.
Use appropriate waste collection services.
If this is not possible, contact the nearest Grundfos
company or service workshop.

Subject to alterations.

Irregular dosing

Valves leaking or blocked

Tighten up valves, replace valves if necessary
(see section

7.4 Perform service

Backpressure fluctuations

Keep backpressure constant.

Activate "

AutoFlowAdapt

" (only DDA-FCM).

Liquid escaping from
the drain opening on
the flange

Faulty diaphragm

Immediately separate the pump from the power
supply!
Observe section

7. Service

and especially section

7.6 Diaphragm breakage

Liquid escaping

Dosing head screws not
tightened

Tighten up screws (see section

4.2 Hydraulic

connection

Valves not tightened

Tighten up valves/union nuts (see section

4.2 Hydraulic connection

Pump not sucking in

Suction lift too high

Reduce suction lift; if necessary, provide positive
inlet pressure.

Backpressure too high

Open the deaeration valve.

Soiled valves

Flush system, replace valves if necessary (see
section

7.4 Perform service

Fault

Possible cause

Possible remedy

Summary of Contents for DDA 12-10

Page 1: ...SMART Digital DDA Installation and operating instructions GRUNDFOS INSTRUCTIONS ...

Page 2: ...2 ...

Page 3: ...4 Batch pulse based 25 6 4 5 Dosing timer cycle 26 6 4 6 Dosing timer week 26 6 5 Analog output 27 6 6 SlowMode 28 6 7 FlowControl 29 6 8 Pressure monitoring 30 6 8 1 Pressure setting ranges 30 6 8 2 Calibration of pressure sensor 30 6 9 Flow measurement 31 6 10 AutoFlowAdapt 31 6 11 Auto deaeration 31 6 12 Key lock 31 6 12 1 Temporary deactivation 31 6 12 2 Deactivation 31 6 13 Display Setup 32 6...

Page 4: ...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 original acc...

Page 5: ...llation site should be applied e g wearing protective clothing Observe the chemical manufacturer s safety data sheets and safety instructions when handling chemicals 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 med...

Page 6: ...g 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 Other applications or the operation of pumps in ambient and operati...

Page 7: ...ngerous spot In case of emergency and prior to all maintenance work and repairs take the mains plug out of the mains supply The device complies with electrical safety class II Connection for deaeration hose at dosing head If the deaeration hose is not correctly connected danger will arise due to possible leakage of dosing liquid TM04 8144 4313 P Q U Type Model f Pmax Imax 97694877 Made in France N...

Page 8: ... 1 4401 E V T Gasket material EPDM FKM PTFE C SS Valve ball material Ceramic Stainless steel DIN 1 4401 F Control cube position Front mounted can be changed to the right or left 3 Voltage 1 x 100 240 V 50 60 Hz 1 2 Valve type Standard Spring loaded HV version U2U2 U7U7 AA VV XX I001 I002 I003 I004 Suction discharge side connection Hose 4 6 mm 6 9 mm 6 12 mm 9 12 mm Hose 0 17 x 1 4 1 4 x 3 8 3 8 x ...

Page 9: ...ube Graphic LC display section 6 2 2 Click wheel section 6 1 100 key section 6 1 Signal inputs outputs section 4 3 Mounting plate 100 100 TM04 1133 0110 FlowControl connection only DDA 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 ...

Page 10: ... suction lift during operation2 m 6 Max suction lift when priming with wet valves2 m 2 3 3 2 Min pressure difference between suction and discharge side bar 1 FC and FCM 2 Max inlet pressure suction side bar 2 Max viscosity in SlowMode 25 with spring loaded valves3 mPas cP 2500 2500 2000 1500 Max viscosity in SlowMode 50 with spring loaded valves3 mPas cP 1800 1300 1300 600 Max viscosity without Sl...

Page 11: ...12 V 5 mA Max load for pulse input 12 V 5 mA Max load for External stop input 12 V 5 mA Min pulse length ms 5 Max pulse frequency Hz 100 Impedance at 0 4 20 mA analog input Ω 15 Accuracy of analog input full scale value 1 5 Min resolution of analog input mA 0 05 Max resistance in level pulse circuit Ω 1000 Signal output Max ohmic load on relay output A 0 5 Max voltage on relay analog output V 30 V...

Page 12: ...4 Dimensional sketch TM04 1103 0110 161 17 D B C A1 G 5 8 A 200 8 100 110 4 x Ø6 105 120 17 5 168 Pump type A mm A1 mm B mm C mm D mm DDA 7 5 16 280 251 196 46 5 24 DDA 12 10 17 7 280 251 200 5 39 5 24 DDA 30 4 295 267 204 5 35 5 38 5 ...

Page 13: ...Fig 6 Engaging the pump 4 1 4 Adjusting control cube position The control cube is fitted to the front of the pump on delivery It can be turned by 90 so that the user can select to operate the pump from the right or left side 1 Carefully remove both protective caps on the control cube using a thin screwdriver 2 Loosen screws 3 Carefully lift off control cube only so far from the pump housing that n...

Page 14: ...ponding connection see fig 3 and run into a container or a collecting tray Fig 8 Hydraulic connection Installation example The pump offers various installation options In the picture below the pump is installed in conjunction with a suction line level switch and multifunction valve on a Grundfos tank Fig 9 Installation example Warning Risk of chemical burns Wear protective clothing gloves and gogg...

Page 15: ...tage is switched on Do not manipulate mains plug or cable Note The mains plug is the separator separating the pump from the mains The rated voltage of the pump see section 2 5 Nameplate must conform to local conditions Warning Electric circuits of external devices connected to the pump inputs must be separated from dangerous voltage by means of double or reinforced insulation TM04 1121 0110 2 1 3 ...

Page 16: ...lse Pulse GND X Pulse Function Pins Plug type 1 2 3 4 Low level signal X GND Pulse Empty signal X GND Pulse Caution Danger of damage to the product due to short circuit Pin 1 supplies 30 VDC Never short circuit pin 1 with any of the other pins Function Pins Plug type 1 brown 2 white 3 blue 4 black 5 yellow green GENIbus 30 V GENI bus TXD GENI bus RXD GND Bus Analog output mA GND mA mA signal Funct...

Page 17: ...anguage 6 Press the click wheel to select the highlighted language 7 Press the click wheel again to confirm the Confirm settings prompt and apply the setting Fig 12 Set menu language Operation English Manual Actual flow Off Language Operation mode Analog output SlowMode FlowControl active Operation Setup Setup Language Language Language l h Manual 7 50 l h Manual English Manual Actual flow Off Lan...

Page 18: ...th FCM control variant it is not necessary to calibrate the pump if there is deviating or fluctuating backpressure as long as the AutoFlowAdapt function has been enabled see section 6 10 AutoFlowAdapt Requirements The hydraulics and electrics of the pump are connected see section 4 Assembly and installation The pump is integrated into the dosing process under operating conditions The dosing head a...

Page 19: ...nu 5 The pump executes 200 dosing strokes and displays the factory calibration value e g 125 ml 6 Remove the suction hose from the measuring beaker and check the remaining volume V2 e g 170 ml 7 From V1 and V2 calculate the actual dosed volume Vd V1 V2 e g 300 ml 170 ml 130 ml 8 Set and apply Vd in the calibration menu The pump is calibrated V2 170 ml Vd V1 V2 130 ml V1 300 ml Calibration Calibrat...

Page 20: ...lighted in black in the sub menus When you position the cursor on a value and press the click wheel a value is selected Turning the click wheel clockwise increases the value turning the click wheel counter clockwise reduces the value When you now press the click wheel the cursor will be released again 6 2 2 Operating states The operating state of the pump is indicated by a symbol and display colou...

Page 21: ...ual Sect 6 4 1 Pulse Sect 6 4 2 Analog 0 4 20 mA Sect 6 4 3 Batch Sect 6 4 4 Timer Sect 6 4 5 6 4 6 Running Standby Stop Deaerating Diaphragm position out Sect 7 Additional display Sect 6 13 2 AR FC variant Target flow FCM variant Actual flow Remaining batch volume Batch Timer Time until next dosing process Timer Input current Analog Blocked drive flashing symbol Run display Running rotates when p...

Page 22: ...gs and control variants The contents of the Setup menu also vary depending on the operation mode TM04 1157 2011 TM04 1106 1010 Counters Resettable Volume Total dosed volume l or US gallons Yes Operating hours Accumulated operating hours pump switched on h No Motor runtime Accumulated motor runtime h No Strokes Accumulated number of dosing strokes No Power on off Accumulated frequency of switching ...

Page 23: ...sed on the frequency of external pulses the set dosing volume pulse Fig 16 Pulse mode The dosing volume per pulse is set in ml pulse in the Operation menu using the click wheel The setting range for the dosing volume depends on the pump type The frequency of incoming pulses is multiplied by the set dosing volume If the pump receives more pulses than it can process at the maximum dosing flow it run...

Page 24: ...positive gradient Fig 19 Analog scaling with pos gradient In example 1 the reference points I1 6 mA Q1 1 5 l h and I2 16 mA Q2 7 5 l h have been set From 0 to 6 mA analog scaling is described by a line that passes through Q 0 l h between 6 mA and 16 mA it rises proportionally from 1 5 l h to 7 5 l h and from 16 mA onwards it passes through Q 7 5 l h Example 2 DDA 7 5 16 Analog scaling with negativ...

Page 25: ... displayed and can be increased Fig 23 Batch mode Signals received during a batch process or an interruption e g alarm External stop will be ignored If the pump is restarted following an interruption the next batch volume is dosed on the next incoming pulse Fig 24 Batch mode In the Operation menu the total batch volume e g 75 ml and the remaining batch volume still to be dosed e g 43 ml are shown ...

Page 26: ...k These dosing procedures may take place regularly on one or several week days The setting range for the batch volume corresponds to the values in section 6 4 4 Batch pulse based Fig 28 Example for Dosing timer week function In the event of an interruption e g disconnection of the mains voltage External stop the dosing is stopped while the time continues running After suspending the interruption t...

Page 27: ...as the current analog input signal See 6 4 3 Analog 0 4 20 mA Wiring diagram see section 4 3 Electrical connection TM04 1138 1110 TM04 1136 1110 Timer Procedure Batch volume Dosing time s Start time hh mm 1 80 5ml 39 0 05 00 M T T W F S S Operation 80 5 ml Timer 43 32 TM04 1153 1110 Setting Description of output signal Variant FCM FC AR Output Input The analog input signal is mapped 1 1 to the ana...

Page 28: ...owing cases for dosing media with a high viscosity for degassing dosing media for long suction lines for large suction lift In the Setup SlowMode menu the speed of the suction stroke can be reduced to 50 or 25 Fig 32 SlowMode menu Caution Enabling the SlowMode function reduces the maximum dosing flow of the pump to the set percentage value TM04 1153 1110 Off SlowMode 50 max SlowMode 25 max SlowMod...

Page 29: ...ion stroke length Causes for deviations can be identified immediately by aligning the current indicator diagram with a calculated optimum indicator diagram Air bubbles in the dosing head reduce e g the discharge phase and consequently the stroke volume see fig 33 Requirements for a correct indicator diagram are FlowControl function is active pressure difference between suction and discharge side i...

Page 30: ...ed in the factory As a rule it does not need to be re calibrated If specific circumstances e g pressure sensor exchange extreme air pressure values at the location of the pump necessitate a calibration the sensor can be calibrated as follows 1 Set pump to Stop operating state 2 Make system pressureless and flush 3 Dismantle suction line and suction valve 4 Proceed as described below to calibrate I...

Page 31: ...The AutoFlowAdapt function identifies pressure fluctuations and responds by adjusting the stroke frequency The actual flow is thus maintained at a constant level 6 11 Auto deaeration Dosing degassing media can result in air pockets in the dosing head during breaks in dosing This can result in no medium being dosed when restarting the pump The Setup Auto deaeration function performs pump deaeration...

Page 32: ...e can be set in the Setup Time date menu Operation mode function Metric units US units Manual control ml h or l h gph Pulse control ml ml 0 4 20 mA Analog control ml h or l h gph Batch pulse or timer controlled ml or l gal Calibration ml ml Volume counter l gal Pressure monitoring bar psi TM04 1151 2011 Operation 1 30 l h Manual 1 28l h Additional display Setting Description Default display Depend...

Page 33: ... off the power supply of the pump 3 Install and connect the E Box CIU as described in the respective separate installation and operating instructions 4 Switch on the power supply of the pump The Activate communication prompt is displayed After confirmation the Bus symbol appears in the Activated functions area of the Operation menu no matter if the prompt was accepted or refused If the prompt has ...

Page 34: ...vate communication Bus control function can be deactivated in the Setup Bus menu After deactivation all submenus in Setup menu are available The Bus symbol in the display disappears at next restart of the pump after the E Box CIU plug was disconnected 6 15 7 Communication faults Faults are only detected if the respective BusWatchDog see functional profile on E Box CIU product CD is activated In ca...

Page 35: ...anged in Time date menu timer dosing and timer relay output functions Relay 2 are stopped Timer dosing and timer relay output functions must be restarted manually Changing time or date can cause increase or decrease in concentration In Output Relay 1 Relay 2 External stop Empty signal Low level signal NO NO NO Relay 1 signal Relay 2 signal Description Alarm Alarm Display red pump stopped e g empty...

Page 36: ...cted to the pump The pump responds to the signals as follows Both signal inputs are allocated to the normally open contact NO in the factory They can be re allocated in the Setup Inputs Outputs menu to normally closed contact NC 6 17 Basic settings All settings can be reset to the settings default upon delivery in the Setup Basic settings menu Selecting Save customer settings saves the current con...

Page 37: ...diately The symbol appears in the Operation menu The number of the service kit required is also displayed in the Info menu Interval Task Daily Check if liquid leaks from the drain opening fig 41 pos 11 and if the drain opening is blocked or soiled If so follow the instructions given in section 7 6 Diaphragm breakage Check if liquid leaks from the dosing head or valves If necessary tighten dosing h...

Page 38: ...kwise and remove with flange 2 12 Make sure the drain opening 11 is not blocked or soiled Clean if necessary 13 Check the safety diaphragm 1 for wear and damage Replace if necessary If nothing indicates that dosing liquid has entered the pump housing go on as described in section 7 4 3 Reassembling the diaphragm and valves Otherwise proceed as described in section 7 6 2 Dosing liquid in the pump h...

Page 39: ...n immediately a pressure can build up between the diaphragm fig 41 pos 4 and the safety diaphragm in the flange fig 41 pos 2 The pressure can press dosing liquid through the safety diaphragm into the pump housing Most dosing liquids don t cause any danger when entering the pump housing However a view liquids can cause a chemical reaction with inner parts of the pump In the worst case this reaction...

Page 40: ... Repairs If a repair isn t economically reasonable dispose of the pump observing the information in section 9 Disposal 7 7 Repairs After consulting Grundfos please send the pump together with the safety declaration completed by a specialist to Grundfos The safety declaration can be found at the end of these instructions It must be copied completed and attached to the pump If the above requirements...

Page 41: ...ed display indicates an alarm and the pump is stopped The last 10 faults are stored in the Alarm main menu When a new fault occurs the oldest fault is deleted The two most recent faults are shown in the display you can scroll through all the other faults The time and cause of the fault are displayed The list of faults can be deleted at the end of the list If there is a service requirement this app...

Page 42: ...g Broken leaky suction line Strongly degassing medium Tank dosing medium empty Check suction line and repair if necessary Provide positive inlet pressure place dosing medium tank above the pump Enable SlowMode see section 6 6 SlowMode Fill tank Cavitation Warning Blocked constricted squeezed suction line Blocked constricted suction valve Suction lift too high Viscosity too high Enable SlowMode see...

Page 43: ... Display in the Alarm menu Possible cause Possible remedy Fault Possible cause Possible remedy Dosing flow too high Inlet pressure greater than backpressure Install additional spring loaded valve approx 3 bar on the discharge side Increase pressure differential Incorrect calibration Calibrate the pump see section 5 3 Calibrating the pump No dosing flow or dosing flow too low Air in dosing head Dea...

Page 44: ...Liquid escaping from the drain opening on the flange Faulty diaphragm Immediately separate the pump from the power supply Observe section 7 Service and especially section 7 6 Diaphragm breakage Liquid escaping Dosing head screws not tightened Tighten up screws see section 4 2 Hydraulic connection Valves not tightened Tighten up valves union nuts see section 4 2 Hydraulic connection Pump not suckin...

Page 45: ...rror in brief We hereby declare that the pump has been cleaned and is completely free from chemical biological and radioactive substances _____________________________________ Date and signature _____________________________________ Company stamp Note Fill in this document using English or German language Product type nameplate Model number nameplate Dosing medium TM04 1185 1110 100 Dosing liquid ...

Page 46: ...apětím 50 VAC nebo 75 VDC Toto ES prohlášení o shodě je platné pouze tehdy pokud je zveřejněno jako součást instalačních a provozních návodů Grundfos DK EF overensstemmelseserklæring Vi Grundfos erklærer under ansvar at produkterne DDA DDC og DDE som denne erklæring omhandler er i overensstemmelse med disse af Rådets direktiver om indbyrdes tilnærmelse til EF medlemsstaternes lovgivning Maskindire...

Page 47: ...izvode s radnim naponom 50 VAC ili 75 VDC Ova EZ izjava o suklađnosti važeća je jedino kada je izdana kao dio Grundfos montažnih i pogonskih uputa IT Dichiarazione di conformità CE Grundfos dichiara sotto la sua esclusiva responsabilità che i prodotti DDA DDC e DDE ai quali si riferisce questa dichiarazione sono conformi alle seguenti direttive del Consiglio riguardanti il riavvicinamento delle le...

Page 48: ...ão de conformidade CE é apenas válida quando publicada como parte das instruções de instalação e funcionamento Grundfos RU Декларация о соответствии ЕС Мы компания Grundfos со всей ответственностью заявляем что изделия DDA DDC и DDE к которым относится настоящая декларация соответствуют следующим Директивам Совета Евросоюза об унификации законодательных предписаний стран членов ЕС Механические уст...

Page 49: ...n om överensstämmelse är endast giltig när den publiceras som en del av Grundfos monterings och driftsinstruktion TR EC uygunluk bildirgesi Grundfos olarak bu beyannameye konu olan DDA DDC ve DDE ürünlerinin AB Üyesi Ülkelerin kanunlarını birbirine yaklaştırma üzerine Konsey Direktifleriyle uyumlu olduğunun yalnızca bizim sorumluluğumuz altında olduğunu beyan ederiz Makineler Yönetmeliği 2006 42 E...

Page 50: ...S s r o Čapkovského 21 779 00 Olomouc Phone 420 585 716 111 Telefax 420 585 716 299 Denmark GRUNDFOS DK A S Martin Bachs Vej 3 DK 8850 Bjerringbro Tlf 45 87 50 50 50 Telefax 45 87 50 51 51 E mail info_GDK grundfos com www grundfos com DK Estonia GRUNDFOS Pumps Eesti OÜ Peterburi tee 92G 11415 Tallinn Tel 372 606 1690 Fax 372 606 1691 Finland OY GRUNDFOS Pumput AB Mestarintie 11 FIN 01730 Vantaa Ph...

Page 51: ...NDFOS Singapore Pte Ltd 25 Jalan Tukang Singapore 619264 Phone 65 6681 9688 Telefax 65 6681 9689 Slovenia GRUNDFOS d o o Šlandrova 8b SI 1231 Ljubljana Črnuče Phone 386 1 568 0610 Telefax 386 1 568 0619 E mail slovenia grundfos si South Africa Grundfos PTY Ltd Corner Mountjoy and George Allen Roads Wilbart Ext 2 Bedfordview 2008 Phone 27 11 579 4800 Fax 27 11 455 6066 E mail lsmart grundfos com Sp...

Page 52: ...24708 1213 ECM 1125152 The name Grundfos the Grundfos logo and be think innovate are registered trademarks owned by Grundfos Holding A S or Grundfos A S Denmark All rights reserved worldwide Copyright Grundfos Holding A S ...

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