Grundfos DDA 7.5-16, DDA 12-10, DDA 12-17-7, DDA 30-4 Installation And Operating Instructions Manual
GRUNDFOS INSTRUCTIONS
SMART Digital - DDA
Installation and operating instructions
2
English (GB) Installation and operating instructions
Original installation and operating instructions.
CONTENTS
Page
1. Safety instructions
1.1 Symbols used in this document
1.2 Qualification and training of personnel
1.3 Safety instructions for the operator/user
1.4 Safety of the system in the event of a
failure in the dosing pump
1.5 Dosing chemicals
1.6 Diaphragm breakage
2. General information
2.1 Applications
2.2 Improper operating methods
2.3 Symbols on the pump
2.4 Warranty
2.5 Nameplate
2.6 Type key
2.7 Product overview
3. Technical data / Dimensions
3.1 Technical data
3.2 Dimensions
4. Assembly and installation
4.1 Pump assembly
4.1.1 Requirements 13
4.1.2 Align and install mounting plate 13
4.1.3 Engage pump in mounting plate 13
4.1.4 Adjusting control cube position 13
4.2 Hydraulic connection
4.3 Electrical connection
5. Startup
5.1 Setting the menu language
5.2 Deaerating the pump
5.3 Calibrating the pump
6. Operation
6.1 Control elements
6.2 Display and symbols
6.2.1 Navigation 20
6.2.2 Operating states 20
6.2.3 Sleep mode (energy-saving mode) 20
6.2.4 Overview of display symbols 21
6.3 Main menus
6.3.1 Operation 22
6.3.2 Info 22
6.3.3 Alarm 22
6.3.4 Setup 22
6.4 Operation modes
6.4.1 Manual 23
6.4.2 Pulse 23
6.4.3 Analog 0/4-20 mA 24
6.4.4 Batch (pulse-based) 25
6.4.5 Dosing timer cycle 26
6.4.6 Dosing timer week 26
6.5 Analog output
6.6 SlowMode
6.7 FlowControl
Pressure monitoring
6.8
6.8.1 Pressure setting ranges 30
4
6.8.2 Calibration of pressure sensor 30
4
6.9 Flow measurement
4
6.10 AutoFlowAdapt
4
6.11 Auto deaeration
6.12 Key lock
4
6.12.1 Temporary deactivation 31
5
6.12.2 Deactivation 31
5
6.13 Display Setup
6
6.13.1 Units 32
6
6.13.2 Additional display 32
6
6.14 Time+date
7
6.15 Bus communication
7
6.15.1 GENIbus communication 33
7
6.15.2 Possible industrial bus types 33
8
6.15.3 Activate communication 33
9
6.15.4 Setting the bus address 33
10
6.15.5 Characteristics of bus communication 34
10
6.15.6 Deactivate communication 34
12
6.15.7 Communication faults 34
6.16 Inputs/Outputs
13
6.16.1 Relay outputs 35
13
6.16.2 External stop 36
6.16.3 Empty and Low level signals 36
6.17 Basic settings
7. Service
14
7.1 Regular maintenance
15
7.2 Cleaning
7.3 Service system
17
7.4 Perform service
17
7.4.1 Dosing head overview 38
18
7.4.2 Dismantling the diaphragm and valves 38
18
7.4.3 Reassembling the diaphragm and valves 39
20
7.5 Resetting the service system
20
7.6 Diaphragm breakage
20
7.6.1 Dismantling in case of diaphragm
breakage
7.6.2 Dosing liquid in the pump housing 40
7.7 Repairs
8. Faults
22
8.1 List of faults
8.1.1 Faults with error message 42
8.1.2 General faults 43
9. Disposal
23
Warning
Prior to installation, read these
installation and operating instructions.
Installation and operation must comply
with local regulations and accepted
codes of good practice.
27
28
29
30
English (GB)
31
31
31
31
32
32
33
35
36
37
37
37
37
38
39
39
40
40
41
42
44
3
1. Safety instructions
Caution
Note
Caution
Note
Caution
English (GB)
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 Symbols used in this document
Warning
If these safety instructions are not
observed, it may result in personal
injury.
If these safety instructions are not
observed, it may result in malfunction
or damage to the equipment.
Notes or instructions that make the job
easier and ensure safe operation.
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.
Before any work to the pump, the pump
must be in the "Stop" operating state
or be disconnected from the power
supply. The system must be
pressureless!
The mains plug is the separator
separating the pump from the mains.
Only original 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.
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.
4
1.5 Dosing chemicals 1.6 Diaphragm breakage
Caution
Caution
Caution
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!
A deaeration hose, which is routed into
a container, e.g. a drip tray, must be
connected to the deaeration valve.
The dosing medium must be in liquid
aggregate state!
Observe the freezing and boiling points
of the dosing medium!
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.
If the diaphragm leaks or is broken, dosing liquid
escapes from the drain opening (fig. 41, pos. 11) on
the dosing head. Observe section 7.6 Diaphragm
breakage.
Warning
Danger of explosion, if dosing liquid
has entered the pump housing!
Operation with damaged diaphragm
can lead to dosing liquid entering the
pump housing.
In case of diaphragm breakage,
immediately separate the pump from
the power supply!
Make sure the pump cannot be put
back into operation by accident!
Dismantle the dosing head without
connecting the pump to the power
supply and make sure no dosing liquid
has entered the pump housing.
Proceed as described in section
7.6.1 Dismantling in case of diaphragm
breakage.
To avoid any danger resulting from diaphragm
breakage, observe the following:
• Perform regular maintenance. See section
7.1 Regular maintenance.
• Never operate the pump with blocked or soiled
drain opening.
– If the drain opening is blocked or soiled,
proceed as described in section
7.6.1 Dismantling in case of diaphragm
breakage.
• Never attach a hose to the drain opening. If a
hose is attached to the drain opening, it is
impossible to recognise escaping dosing liquid.
• Take suitable precautions to prevent harm to
health and damage to property from escaping
dosing liquid.
• Never operate the pump with damaged or loose
dosing head screws.
English (GB)
5
2. General information
Caution
English (GB)
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
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!
Frequent disengagement from the
mains voltage, e.g. via a relay, can
result in damage to the pump
electronics and in the breakdown of the
pump. The dosing accuracy is also
reduced as a result of internal start
procedures.
Do not control the pump via the mains
voltage for dosing purposes!
Only use the "
start and stop the pump!
External stop
" function to
6
2.3 Symbols on the pump
P
QU
Type
Model
f
P
max
Imax
97694877
Made in France
N20683
NEMA 4X
psi
gphA l/h
Bar
W IP 65
Symbol Description
Indication of universally dangerous 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!
2.4 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.
2.5 Nameplate
English (GB)
Fig. 1 Nameplate
Pos. Description Pos. Description
1 Type designation 6 Enclosure class
2 Voltage 7 Mark of approval, CE mark, etc.
3 Frequency 8 Country of origin
4 Power consumption 9 Max. operating pressure
5 Max. dosing flow 10 Model
TM04 8144 4313
7
2.6 Type key
English (GB)
The type key is used to identify the precise pump and is not used for configuration purposes.
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]
Control variant
AR
Standard
FC
AR with FlowControl
FCM
FC with integrated flow measurement
Dosing head material
PP
Polypropylene
PVC
PVC (polyvinyl chloride, only up to 10 bar)
PV
PVDF (polyvinylidene fluoride)
SS
Stainless steel DIN 1.4401
Gasket material
E
EPDM
V
FKM
T
PTFE
Valve ball material
C
Ceramic
SS
Stainless steel DIN 1.4401
Control cube position
F
Front-mounted (can be changed to the right or left)
Voltage
3
1 x 100-240 V, 50/60 Hz
Valve type
1
Standard
2
Spring-loaded (HV version)
Suction/discharge side connection
Hose, 4/6 mm, 6/9 mm, 6/12 mm, 9/12 mm
U2U2
Hose 0.17" x 1/4"; 1/4" x 3/8"; 3/8" x 1/2"
U7U7
Threaded Rp 1/4", female (stainless steel)
AA
Threaded 1/4" NPT, female (stainless steel)
VV
No connection
XX
Installation set*
Hose, 4/6 mm (up to 7.5 l/h, 13 bar)
I001
Hose, 9/12 mm (up to 60 l/h, 9 bar)
I002
Hose, 0.17" x 1/4" (up to 7.5 l/h, 13 bar)
I003
Hose, 3/8" x 1/2" (up to 60 l/h, 10 bar)
I004
Mains plug
EU
F
USA, Canada
B
UK
G
Australia, New Zealand, Taiwan
I
Switzerland
E
Japan
J
Argentina
L
Design
G
Grundfos
* 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)
8
2.7 Product overview
[Start/stop] key (section 6.1)
Mains connection
Control cube
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%
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
Fig. 2 Front view of the pump
English (GB)
TM04 1129 0110
Fig. 3 Rear view of the pump
TM04 1133 0110
9
3. Technical data / Dimensions
English (GB)
3.1 Technical data
Data 7.5-16 12-10 17-7 30-4
Turndown ratio (setting range) [1:X] 3000 1000 1000 1000
[l/h] 7.5 12.0 17.0 30.0
[gph] 2.0 3.1 4.5 8.0
[l/h] 3.75 6.00 8.50 15.00
[gph] 1.00 1.55 2.25 4.00
[l/h] 1.88 3.00 4.25 7.50
[gph] 0.50 0.78 1.13 2.00
[l/h] 0.0025 0.0120 0.0170 0.0300
[gph] 0.0007 0.0031 0.0045 0.0080
[bar] 16 10 7 4
[psi] 230 150 100 60
[strokes/
min]
190 155 205 180
[m] 6
[m] 2 3 3 2
[bar] 1 (FC and FCM: 2)
[mPas]
(= cP)
[mPas]
(= cP)
[mPas]
(= cP)
[mPas]
3)
(= cP)
2500 2500 2000 1500
1800 1300 1300 600
600 500 500 200
50 300 300 150
[mm]4669
[mm] 9
Mechanical
data
Max. dosing capacity
Max. dosing capacity with SlowMode 50 %
Max. dosing capacity with SlowMode 25 %
Min. dosing capacity
Max. operating pressure
Max. stroke frequency
1)
Stroke volume [ml] 0.74 1.45 1.55 3.10
Accuracy of repeatability [%] ± 1
Max. suction lift during operation
Max. suction lift when priming with wet
2)
valves
Min. pressure difference between suction and
discharge side
2)
Max. inlet pressure, suction side [bar] 2
Max. viscosity in SlowMode 25 % with
spring-loaded valves
Max. viscosity in SlowMode 50 % with
spring-loaded valves
Max. viscosity without SlowMode with
spring-loaded valves
3)
3)
3)
Max. viscosity without spring-loaded valves
Min. internal hose/pipe diameter
suction/discharge side
Min. internal hose/pipe diameter
suction/discharge side (high viscosity)
2), 4)
4)
Min./Max. liquid temperature [°C] -10/45
Min./Max. ambient temperature [°C] 0/45
Min./Max. storage temperature [°C] -20/70
Max. relative humidity (non-condensing) [%] 96
Max. altitude above sea level [m] 2000
10
Data 7.5-16 12-10 17-7 30-4
Voltage [V]
100-240 V, - 10 %/+ 10 %,
50/60 Hz
Length of mains cable [m] 1.5
Max. inrush current for 2 ms (100 V) [A] 8
Electrical
data
Max. inrush current for 2 ms (230 V) [A] 25
Max. power consumption P
1
[W] 24
5)
Enclosure class IP65, Nema 4X
Electrical safety class II
Pollution degree 2
Max. load for level input 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
Signal input
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
Max. ohmic load on relay output [A] 0.5
Signal
output
Max. voltage on relay/analog output [V] 30 VDC/30 VAC
Impedance at 0/4-20 mA analog output [Ω] 500
Accuracy of analog output (full-scale value) [%] ± 1.5
Min. resolution of analog output [mA] 0.02
Weight (PVC, PP, PVDF) [kg] 2.4 2.4 2.6
Weight/size
Weight (stainless steel) [kg] 3.2 3.2 4.0
Diaphragm diameter [mm] 44 50 74
Sound
pressure
Max. sound pressure level [dB(A)] 60
Approvals CE, CB, CSA-US, NSF61, GOST/TR, C-Tick
1)
The maximum stroke frequency varies depending on calibration
2)
Data is based on measurements with water
3)
Maximum suction lift: 1 m, dosing capacity reduced (approx. 30 %)
4)
Length of suction line: 1.5 m, length of discharge line: 10 m (at max. viscosity)
5)
With E-Box
English (GB)
11
3.2 Dimensions
161
17
D
B
C
A1
G 5/8"
A
200.8
100%
110
4 x Ø6
105
120
17.5
168
English (GB)
Fig. 4 Dimensional sketch
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
TM04 1103 0110
12
4. Assembly and installation
Note
Caution
Caution
IP65, Nema 4X
For use in Australia:
Installation of this product must
comply with AS/NZS3500!
Certificate of suitability number:
CS9431
C-tick number: N20683
4.1 Pump assembly
Warning
Install the pump in such a way that the
plug can easily be reached by the
operator during operation! This will
enable the operator to separate the
pump from the mains quickly in case of
emergency!
The pump is delivered with a mounting plate.
The mounting plate can be mounted vertically e.g.
on a wall or horizontally e.g. on a tank. It takes just a
few quick steps to firmly secure the pump to the
mounting plate by means of a slot mechanism.
The pump can easily be released from the mounting
plate for maintenance.
4.1.1 Requirements
• The mounting surface must be stable and must
not vibrate.
• Dosing must flow upwards vertically.
4.1.2 Align and install mounting plate
• Vertical installation: Mounting plate slot
mechanism must be above.
• Horizontal installation: Mounting plate slot
mechanism must be opposite the dosing head.
• The mounting plate can be used as a drill
template, please see fig. 4 for drill hole distances.
4.1.3 Engage pump in mounting plate
1. Attach the pump to the mounting plate support
clamps and slide under slight pressure until it
engages.
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.
The enclosure class (IP65/Nema 4X)
and shock protection are only
guaranteed if the control cube is
installed correctly!
Pump must be disconnected from the
power supply!
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 no tensile stress is produced
on the flat band cable.
4. Turn control cube by 90 ° and re-attach.
– Make sure the O-ring is secure.
5. Tighten screws slightly and attach protective
caps.
English (GB)
TM04 1159 0110
Fig. 5 Locate mounting plate
Warning
Make sure that you do not damage any
cables and lines during installation!
1. Indicate drill holes.
2. Drill holes.
3. Secure mounting plate using four screws,
diameter 5 mm, to the wall, on the bracket or the
tank.
TM04 1162 0110
TM04 1182 0110
Fig. 7 Adjusting control cube
13
4.2 Hydraulic connection
Caution
Caution
Caution
Note
Caution
Union nut
Tensioning ring
Cone part
Hose
Deaeration
hose
Tank
Multifunction
valve
Suction line with
empty signal
English (GB)
Warning
Risk of chemical burns!
Wear protective clothing (gloves and
goggles) when working on the dosing
head, connections or lines!
The dosing head may contain water
from the factory check!
When dosing media which should not
come into contact with water, another
medium must be dosed beforehand!
Faultless function can only be
guaranteed in conjunction with lines
supplied by Grundfos!
The lines used must comply with the
pressure limits as per section
3.1 Technical data!
Important information on installation
• Observe suction lift and line diameter, see
section 3.1 Technical data.
• Shorten hoses at right angles.
• Ensure that there are no loops or kinks in the
hoses.
• Keep suction line as short as possible.
• Route suction line up towards the suction valve.
• Installing a filter in the suction line protects the
entire installation against dirt and reduces the
risk of leakage.
• Only control variant FC/FCM: For discharge
quantities < 1 l/h we recommend the use of an
additional spring-loaded valve (approx. 3 bar) on
the discharge side for the safe generation of the
necessary differential pressure.
Hose connection procedure
1. Push union nut and tensioning ring across hose.
2. Push cone part fully into hose, see fig. 8.
3. Attach cone part with hose to corresponding
pump valve.
4. Tighten union nut manually.
– Do not use tools!
5. Tighten up union nuts after 2-5 operating hours if
using PTFE gaskets!
6. Attach deaeration hose to the corresponding
connection (see fig. 3) and run into a container or
a collecting tray.
Fig. 8 Hydraulic connection
Pressure differential between suction
and discharge side must be at least
1 bar/14.5 psi!
Tighten the dosing head screws with a
torque wrench once before
commissioning and again after
2-5 operating hours at 4 Nm.
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.
TM04 1155 0110
14
TM04 1183 0110
Fig. 9 Installation example
4.3 Electrical connection
Note
2
1
3
4
2
1
3
4
5
2
3
4
1
2
1
3
►
2
1
GND
GND
BUS
BUS
GND
12
34
12
34
12
5
34
34
12
Warning
The enclosure class (IP65/Nema 4X) is only guaranteed if plugs or protective caps are
correctly installed!
Warning
The pump can start automatically when the mains voltage is switched on!
Do not manipulate mains plug or cable!
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.
Signal connections
Warning
Electric circuits of external devices connected to the pump inputs must be separated from
dangerous voltage by means of double or reinforced insulation!
English (GB)
Fig. 10 Wiring diagram of the electrical connections
TM04 1121 0110
15
Analog, External stop and pulse input
Caution
Sensor
English (GB)
Function
1/brown 2/white 3/blue 4/black
Analog GND/(-) mA (+) mA mA signal
External stop GND X Pulse
Pulse GND X Pulse
Level signals: Empty signal and Low-level signal
Pins
Plug type
Function
1234
Pins
Plug type
Low-level signal XGND Pulse
Empty signal XGND Pulse
GENIbus, Analog output
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!
Pins
Function
1/brown 2/white 3/blue 4/black
GENIbus +30 V
GENI bus
TXD
GENI bus
RXD
5/yellow/
green
GND Bus
Plug type
Analog output (+) mA GND/(-) mA mA signal
Relay outputs
Pins
Function
1/brown 2/white 3/blue 4/black
Plug type
Relay 1 XXPulse
Relay 2 XX Pulse
FlowControl signal connection
TM04 1158 0110
Fig. 11 FlowControl signal connection
16
Loading...