Grundfos DDI 222 Series, DDI 222 60-10, DDI 222 150-4, DDI 150-4, DDI 60-10 Installation And Operating Instructions Manual

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DDI 222

Dosing pump

Installation and operating instructions

GRUNDFOS INSTRUCTIONS

English (GB) Installation and operating instructions

Note

English (GB)

Original installation and operating instructions.

CONTENTS

1. General information

1.1 Introduction

1.2 Service documentation

1.3 Information about the product

1.4 Applications

1.5 Warranty

2. Safety

2.1 Identification of safety instructions in this manual

2.2 Qualification and training of personnel

2.3 Risks when safety instructions are not observed

2.4 Safety-conscious working

2.5 Safety instructions for the operator/user

2.6 Safety instructions for maintenance, inspection and installation work

2.7 Unauthorised modification and manufacture of spare parts

2.8 Improper operating methods

2.9 Safety of the system in the event of a failure in the dosing system

2.10 Dosing chemicals

2.11 Diaphragm breakage

3. Transport and intermediate storage

3.1 Transport

3.2 Delivery

3.3 Unpacking

3.4 Intermediate storage

3.5 Return

4. Technical data

4.1 Identification

4.2 Type key

4.3 General description

4.4 Safety functions

4.5 Dimensional sketches

4.6 Weight

4.7 Materials

4.8 Control unit

5. Installation

5.1 General information on installation

5.2 Installation location

5.3 Mounting

5.4 Installation examples

5.5 Tube / pipe lines

6. Electrical connections

6.1 Connecting the signal lines for DDI 222

6.2 Connecting the power supply cable

7. Start-up/shutdown

7.1 Initial start-up / subsequent start-up

7.2 Operating the pump

7.3 Shutdown

8. Operation

8.1 Control and display elements

8.2 Switching on/off

9. How to use the control unit

9.1 Menu levels

9.2 General functions of the control unit

9.3 Signal outputs

9.4 First function level

9.5 Second function level

9.6 Calibration

9.7 Service level

9.8 Resetting to default settings

9.9 Current signal control 0-20 mA / 4-20 mA

9.10 Flow Monitor

9.11 Batch menu / batch mode

9.12 Timer menu / timer mode

9.13 Creating a master/slave application

9.14 Hotkeys / info keys

Page

10 11 11 11

12 12 12 12 14

15 17

17 18 18

18 18

19 19 21 22 23 27 29 32 32 36 41 42 43 44

9.15 Pump safety functions

10. Maintenance

10.1 General notes

10.2 Maintenance intervals

2 2 2 4 4

5 5 5 5 5

5 5

10.3 Cleaning suction and discharge valves

10.5 Diaphragm breakage

10.6 Replacing the diaphragm

10.7 Repair

11. Fault finding chart

12. Disposal

Warning

Prior to installation, read these installation and operating instructions. Installation and operation must comply with local regulations and accepted codes of good practice.

These complete installation and operating instructions are also available on www.grundfos.com.

1. General information

1.1 Introduction

6 6

These installation and operating instructions contain all the information required for starting up and handling the DDI 222

diaphragm dosing pump.

6 6

If you require further information or if any problems arise, which

are not described in detail in this manual, please contact the

nearest Grundfos company.

1.2 Service documentation

If you have any questions, please contact the nearest Grundfos

company or service workshop.

8 9

1.3 Information about the product

1.3.1 Pump types

The DDI 222 dosing pump is available for a variety of performance ranges in various sizes:

Pump types

DDI 60-10 DDI 150-4

The following is indicated on the pump nameplate (see section 4.1 Identification):

• The pump type which specifies the stroke volume, connection size and performance data (see below).

• The pump serial number which is used to identify the pump.

• The most important characteristics of the pump configuration, e.g. dosing head and valve materials. They are described in section 4.2 Type key.

• Maximum flow rate and maximum counter-pressure.

• Supply voltage or mains voltage and mains frequency.

The pump for viscous liquids is called HV variant in the following.

1.3.2 Connection size

Pump type Connection size HV variant

DDI 60-10 DN 8 DN 20 DDI 150-4 DN 20 DN 20

46 46 46 47 47 48

1.3.3 Pump performance

Note

Caution

Note

Performance data at maximum pump counter-pressure

Normal operation Slow-mode operation Slow-mode-2 operation

Pump type

Q** p max.* Max. stroke rate Q** p max.* Max. stroke rate Q** p max.* Max. stroke rate

[l/h] [bar] [n/min] [l/h] [bar] [n/min] [l/h] [bar] [n/min]

DDI 60-10 60 10 180 40 10 120 24.7 10 74 DDI 150-4 150 4 180 100 4 120 62 4 74

* Observe the maximum permissible temperatures and that the friction loss increases with the viscosity of the dosing medium. ** The maximum dosing flow of HV-variant pumps is up to 10 % lower.

The pump can be operated in the range between

0.125 % and 100 % of the maximum dosing capacity.

The maximum display indication is higher than the nominal capacity of the pump because it refers to the default setting.

1.3.4 Accuracy

• Applies to: – water as dosing medium – fully deaerated dosing head – standard pump version.

• Dosing flow fluctuation and linearity deviation: ± 1.5 % of the

full-scale value.

• Construction tolerance: according to VDMA 24284.

1.3.5 Inlet pressure and counter-pressure / suction lift during

operation

Maximum inlet pressure

Operating conditions / version

Pump type

All*

Maximum suction lift* (start-up) for media with a viscosity similar to water

Operating conditions / version

Pump type

Continuous operation

[m]

DDI 60-10 - DDI 150-4 1

* Deaeration valve open.

Maximum suction lift* (continuous operation) for non-degassing media with a viscosity similar to water

Operating conditions / version

Pump type

Normal operation

[m]

DDI 60-10 6 DDI 150-4 3

* Dosing head and valves filled with dosing medium.

1.3.6 Sound pressure level

65 dB(A), testing according to DIN 45635-01-KL3.

[bar]

1.3.7 Enclosure class

DDI 60-10 - DDI 150-4 2

* For pumps with pressure sensor (Flow Monitor pump option),

the inlet pressure on the suction side must not exceed 1 bar.

Minimum counter-pressure at the pump discharge valve

Operating conditions / version

Pump type

All*

[bar]

DDI 60-10 - DDI 150-4 1

* For pumps with pressure sensor (Flow Monitor pump option),

the minimum system pressure is 2 bar and the minimum pressure difference between the suction and discharge sides is 2 bar. If the volume flow is not constant (as, for example, in the case of contact or analog control), even small volume flows should not fall below the minimum pressure or the minimum pressure difference.

• Pump with mains plug: IP65.

• Pump without mains plug: IP65 can only be ensured if the power supply cable is connected with IP65 protection.

1.3.8 Required energy

Power supply for AC voltage

• Rated voltage range: 110-240 V. Deviation from the rated value: ± 10 %.

• Mains frequency: 50/60 Hz.

• Maximum power consumption: 70 W including all sensors (reduced input power according to pump type and connected sensors).

The enclosure class is only met if the sockets are protected! The data regarding the enclosure class applies to pumps with correctly inserted plugs or screwed-on caps.

The power supply must be electrically isolated from the signal inputs and outputs.

English (GB)

1.3.9 Ambient and operating conditions

Caution

English (GB)

• Permissible ambient temperature: 0 °C to +40 °C.

• Permissible storage temperature: -10 °C to +50 °C.

• Permissible air humidity: max. relative humidity: 92 % (non-condensing).

Warning

The DDI 222 is NOT approved for operation in potentially explosive areas!

The installation site must be under cover! Ensure that the enclosure class of motor and pump is not affected by the atmospheric conditions.

Pumps with electronics are only suitable for indoor use! Do not install outdoors!

1.3.10 Dosing medium

Warning

The pump must be equipped with a diaphragm leakage detection when used for crystallising media.

In the event of questions regarding the material resistance and suitability of the pump for specific dosing media, please contact Grundfos Water Treatment.

The dosing medium must have the following basic characteristics:

• liquid

• non-abrasive

• non-inflammable.

Maximum permissible viscosity at operating temperature*

Maximum viscosity*

Pump type

DDI 60-10 100 200 500 DDI 150-4 100 200 500

DDI 60-10 70 100 200 DDI 150-4 50 100 200

DDI 60-10 1200 2000 3000 DDI 150-4 700 1200 1800

* The stated values are approximate values and apply to

Newtonian liquids. Note that the viscosity increases with decreasing temperature!

Normal

operation

[mPa s] [mPa s] [mPa s]

Standard with Flow Monitor

HV variant with/without Flow Monitor

Slow-mode-1

operation

Standard

Slow-mode-2

operation

Permissible media temperature

Dosing head material

PVC 0 40 Stainless steel,

DIN 1.4571* PP 0 40 PVDF** -10 60*

* A temperature of 120 °C at a counter-pressure of max. 2 bar is

permitted for a short period (15 minutes).

** At 70 °C, the maximum counter-pressure is 3 bar.

Warning

Observe the chemical manufacturer's safety instructions when handling chemicals!

The dosing medium must be in liquid form!

Observe the freezing and boiling points of the dosing medium!

The resistance of the parts that come into contact with the media depends on the media, media temperature and operating pressure. Ensure that parts in contact with the media are chemically resistant to the dosing medium under operating conditions!

Make sure that the pump is suitable for the actual dosing medium!

Min. media

temperature

[°C] [°C]

-10 70

Max. media

temperature

p < 10 bar

1.4 Applications

1.4.1 Appropriate, acceptable and correct usage

The DDI 222 pump is suitable for liquid, non-abrasive and non-inflammable media strictly in accordance with the instructions in this manual.

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 accepts no liability for any damage resulting from incorrect use.

1.5 Warranty

Warranty in accordance with our general terms of sale and delivery is only valid

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

• if the pump is not dismantled or incorrectly handled.

• if repairs are carried out by authorised and qualified personnel.

2. Safety

Caution

Note

This manual contains general instructions that must be observed during installation, operation and maintenance of the pump. This manual must therefore be read by the installation engineer and the relevant qualified personnel/operators prior to installation and start-up, and must be available at the installation location of the pump at all times.

It is not only the general safety instructions given in this "Safety" section that must be observed, but also all the specific safety instructions given in other sections.

2.1 Identification of safety instructions in this manual

If the safety instructions or other advice in this manual are not observed, it may result in personal injury or malfunction and damage to the pump. The safety instructions and other advice are identified by the following symbols:

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.

Information provided directly on the pump, e.g. labelling of fluid connections, must be observed and must be maintained in a readable condition at all times.

2.2 Qualification and training of personnel

The personnel responsible for the operation, maintenance, inspection and installation 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 the personnel do not have the necessary knowledge, the necessary training and instruction must be given. If necessary, training can be performed by the manufacturer/supplier at the request of the operator of the pump. It is the responsibility of the operator to make sure that the contents of this manual are understood by the personnel.

2.3 Risks when safety instructions are not observed

Non-observance of the safety instructions may have dangerous consequences for the personnel, the environment and the pump. If the safety instructions are not observed, all rights to claims for damages may be lost.

Non-observance of the safety instructions may lead to the following hazards:

• failure of important functions of the pump/system

• failure of specified methods for maintenance

• harm to humans from exposure to electrical, mechanical and chemical influences

• damage to the environment from leakage of harmful substances.

2.5 Safety instructions for the operator/user

Hazardous hot or cold parts on the pump must be protected to prevent accidental contact.

Leakages of dangerous substances (e.g. hot, toxic) must be disposed of in a way that is not harmful to the personnel or the environment. Legal regulations must be observed.

Damage caused by electrical energy must be prevented (for more details, see for example the regulations of the VDE and the local electricity supply company).

2.6 Safety instructions for maintenance, inspection and installation work

The operator must ensure that all maintenance, inspection and installation work is carried out by authorised and qualified personnel, who have been adequately trained by reading this manual.

All work on the pump should only be carried out when the pump is stopped. The procedure described in this manual for stopping the pump must be observed.

Pumps or pump units which are used for media that are harmful to health must be decontaminated.

All safety and protective equipment must be immediately restarted or put into operation once work is complete.

Observe the points described in the initial start-up section prior to subsequent start-up.

Warning

Electrical connections must only be carried out by qualified personnel!

The pump housing must only be opened by personnel authorised by Grundfos!

2.7 Unauthorised modification and manufacture of spare parts

Modification or changes to the pump are only permitted following agreement with the manufacturer. Original spare parts and accessories authorised by the manufacturer are safe to use. Using other parts can result in liability for any resulting consequences.

2.8 Improper operating methods

The operational safety of the supplied pump is only ensured if it is used in accordance with section 1. General information. The specified limit values must under no circumstances be exceeded.

2.9 Safety of the system in the event of a failure in the dosing system

DDI 222 dosing pumps are designed according to the latest technologies and are carefully manufactured and tested. However, a failure may occur in the dosing system. Systems in which dosing pumps are installed must be designed in such a way that the safety of the entire system is still ensured following a failure of the dosing pump. Provide the relevant monitoring and control functions for this.

English (GB)

2.4 Safety-conscious working

The safety instructions in this manual, applicable national health and safety regulations and any operator internal working, operating and safety regulations must be observed.

2.10 Dosing chemicals

Caution

English (GB)

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

The pump must be equipped with a diaphragm leakage detection when used for crystallising media.

2.11 Diaphragm breakage

If the diaphragm leaks or is broken, dosing liquid escapes from the drain opening (H) (fig. 2) on the dosing head. Observe section

10.6 Replacing the diaphragm.

Warning

Danger of explosion, if dosing liquid has entered the pump housing!

When operating the pump with a damaged diaphragm, dosing liquid can enter the pump housing.

In case of diaphragm breakage, immediately separate the pump from the power supply!

Make sure that the pump cannot be put back into operation by accident!

Dismantle the dosing head without connecting the pump to the power supply. Make sure that no dosing liquid has entered the pump housing. Proceed as described in section 10.6 Replacing the diaphragm.

To avoid any danger resulting from diaphragm breakage, observe the following:

• Perform regular maintenance. See section 10.2 Maintenance intervals.

• Never operate the pump with blocked or soiled drain opening.

– If the drain opening is blocked or soiled, proceed as

described in section 10.6 Replacing the diaphragm.

• 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.

3. Transport and intermediate storage

3.1 Transport

Do not throw or drop the pump.

3.2 Delivery

The DDI 222 dosing pump is delivered in a cardboard box. Place the pump in the packaging during transport and intermediate storage.

3.3 Unpacking

Retain the packaging for future storage or return, or dispose of the packaging in accordance with local regulations.

3.4 Intermediate storage

• Permissible storage temperature: -10 °C to +50 °C.

• Permissible air humidity: max. relative humidity: 92 % (non-condensing).

3.5 Return

Return the pump in its original packaging or equivalent. The pump must be thoroughly cleaned before it is returned or

stored. It is essential that there are no traces of toxic or hazardous media remaining on the pump.

Grundfos accepts no liability for damage caused by incorrect transportation or missing or unsuitable packaging of the pump!

Before returning the pump to Grundfos Water Treatment for service, the safety declaration at the end of these instructions must be filled in by authorised personnel and attached to the pump in a visible position.

If a pump has been used for a medium which is injurious to health or toxic, the pump will be classified as contaminated.

If Grundfos Water Treatment is requested to service the pump, it must be ensured that the pump is free from substances that can be injurious to health or toxic. If the pump has been used for such substances, the pump must be cleaned before it is returned.

If proper cleaning is not possible, all relevant information about the chemical must be provided.

If the above is not fulfilled, Grundfos Water Treatment can refuse to accept the pump for service. Possible costs of returning the pump are paid by the customer.

The safety declaration can be found at the end of these instructions.

The replacement of the power supply cable must be carried out by an authorised Grundfos service workshop.

4. Technical data

Made in Germany

DDI 60-10 AF-PVC/T/C-S-31C5C5B 91836593 Type: DDI 222 S/N:07/22288 60 l/h, 10 bar, 0,070 kW, IP 65 100-240 V, 50/60 Hz 91836593P1107120722288

4.1 Identification

Fig. 1 DDI 222 nameplate

Pos. Description

1 Type designation 2 Model 3 Maximum capacity [l/h] 4 Voltage [V] 5 Frequency [Hz] 6 Product number 7 Country of origin 8 Year and week code

9 Marks of approval, CE mark, etc. 10 Maximum pressure [bar] 11 Serial number

English (GB)

TM03 8687 5112

4.2 Type key

English (GB)

Example: DDI 150 - 4 AR -PP /E /G -S -3 1 B2 B2 F

Type range Mains plug

DDI X No plug

Maximum flow [l/h] F EU (Schuko)

Maximum counter-pressure [bar] B USA, Canada

Control variant I Australia, New Zealand

AR Standard E Switzerland AF AR with Flow Monitor Connection, suction/discharge AP AR with PROFIBUS 4 Tube, 6/9 mm

APF AR with Flow Monitor and PROFIBUS

Dosing head variant Q Tube, 19/27 mm PP Polypropylene

PV PVDF (polyvinylidene fluoride) PVC Polyvinyl chloride SS Stainless steel, DIN 1.4401

PP-L PP + integrated diaphragm leakage detection

PV-L PV + integrated diaphragm leakage detection

PVC-L PVC + integrated diaphragm leakage detection

SS-L SS + integrated diaphragm leakage detection

Gasket material 1 Standard

E EPDM (ethylene propylene diene monomer)

VFKM

TPTFE

Valve ball material

CCeramics GGlass

TPTFE

SS Stainless steel, DIN 1.4401 Supply voltage

Control panel position 3 1 x 100-240 V, 50/60 Hz F Front-mounted

SSide-mounted

6 Tube, 9/12 mm S Tube, 0.375"/0.5"

Tube 6/12 mm/

cementing diameter 12 mm Tube 13/20 mm/

cementing diameter 25 mm

A Threaded, Rp 1/4, female A1 Threaded, Rp 3/4, female A3 Threaded, 3/4" NPT, female V Threaded, 1/4" NPT, female A9 Threaded, 1/2" NPT, male B3 Welding diameter 16 mm B4 Welding diameter 25 mm

Valve type

Spring-loaded

0.05 bar suction opening

pressure; 0.05 bar discharge opening pressure

For abrasive media

(stainless steel only)

Spring-loaded (DN 20, stainless-steel balls)

0.8 bar discharge opening pressure

Note

Caution

Q1 Q2 Q3

4.3 General description

The DDI 222 is a dosing pump with an EC motor (brushless DC motor) as the drive and electronic power control. The pump is operated via the diagonal display in a user-friendly menu structure.

The pump incorporates an overpressure safety feature. When an adjustable cut-off pressure is exceeded, the pump can be switched off automatically.

The DDI 222 is available in various versions. See also section 1. General information.

Option: The pump can also be equipped with the following:

• diaphragm leakage sensor (MBS)

• interface for PROFIBUS. The functions are described, but only apply to the relevant pump

version.

Fig. 2 DDI 222

Pos. Components

3a Suction valve 3b Discharge valve

2 Dosing head D MBS pressure switch (optional) H Drain opening

4.3.1 HV variant for liquids which are more viscous than water

All HV-variant pumps are equipped with spring-loaded DN 20 valves with an opening pressure of 0.1 bar (or 0.8 bar for the pressure side) and connection for PVC tube 19 x 27. DDI 60-10 has a special dosing head.

Note that the HV-variant pump has other dimensions than the standard pump and that other connection line dimensions might be required!

4.4 Safety functions

4.4.1 Diaphragm leakage detection (optional)

Pumps with diaphragm leakage signal have a special dosing head with a diaphragm set and pressure switch. The pressure switch (socket 1) is fitted and connected to the pump on delivery.

Fig. 3 Dosing head with diaphragm set and pressure switch

for diaphragm leakage detection

Pos. Components

2 Dosing head

D Pressure switch Q1 Working diaphragm Q2 Signal diaphragm (intermediate layer made from fabric) Q3 Protection diaphragm

In the event of a leak in the diaphragm:

• Dosing medium penetrates between the working diaphragm and the protection diaphragm and is transferred to the pressure switch via the signal diaphragm.

• On the next pressure stroke, pressure is applied to the pressure switch, which is activated. The pump indicates an

TM03 6661 4506

error but continues operating.

• The electronics operates two contacts, which can be used, for example, to trigger an alarm signal or to switch off the pump.

• In emergency mode, the pump can continue operating for a short time.

Warning

Danger of explosion, if dosing liquid has entered the pump housing!

If the diaphragm is possibly damaged, don’t connect the pump to the power supply! Proceed as described in section 10.5 Diaphragm breakage!

After a diaphragm leakage detection, the pressure switch has to be checked. In case the diaphragm of the pressure switch is broken or affected by the dosing liquid, the pressure switch must be replaced.

4.4.2 Pressure control

The DDI 222 pump incorporates a pressure control function. The pressure is calculated from the motor current consumption or is measured directly in the dosing head if a pressure sensor is present (Flow Monitor pump option). At a user-defined pressure, the pump is switched off automatically.

English (GB)

TM03 6611 4506

To protect the pump and system against excessive pressure build-up, install an overflow valve in the discharge line.

This function protects the pump, but not the system. It is recommended that the system is protected by an overflow valve.

This function can be enabled and disabled in the second function level of the electronics.

4.4.3 Dosing control (Flow Monitor)

Note

A4 A3

207

172.5

16.5

Ø7

61.5 105

123

B3 B4

230

175

(159)

MLS

MBS: Diaphragm leakage sensor (optional) DS: Pressure sensor (Flow Monitor pump option)

English (GB)

The pressure sensor (Flow Monitor pump option) is used as a dosing controller and to monitor the pressure for the whole power ranges.

The Flow Monitor for dosing control consists of a pressure sensor integrated in the dosing head.

The pressure sensor is available as Flow Monitor pump option. The pressure sensor is fitted to the pump on delivery. Upgrades are not possible.

Pressure control is primarily used to protect the pump. This function is not a substitute for the overflow valve.

4.5 Dimensional sketches

4.4.4 Flow compensation

The flow compensation is a function to keep the dosing flow constant with changing system pressure. Pressure changes are detected by the pressure sensor and the motor speed is adjusted accordingly.

To use this function, pressure control or dosing control (Flow Monitor) has to be activated in the electronics.

When dosing media with a viscosity similar to water, the pump needs not to be calibrated, as the pump already responds to the possible change of the system pressure.

When dosing media with a viscosity different from water or after a software update, the pump has to be calibrated.

Fig. 4 DDI 222

Dimensions for DDI 222

DDI 60-10 283 338 306 137 - 58 37 R 5/8 252 153 DDI 150-4 315 372 350 137 139 90 39 R 1 1/4 265 179

[mm]A4[mm]A5[mm]B3[mm]B4[mm]

[mm]

DDI 60-10 / HV 295 350 328 137 - 68 38 R 1 1/4 246 143 DDI 150-4 / HV 315 372 350 137 139 90 39 R 1 1/4 265 179

TM03 6663 4506

[mm]

4.6 Weight

Caution

Note

Pump type Dosing head material Weight [kg]

DDI 60-10 PVC, PP, PVDF 5 DDI 60-10 Stainless steel, DIN 1.4571 7 DDI 150-4 PVC, PP, PVDF 6.5 DDI 150-4 Stainless steel, DIN 1.4571 12

4.7 Materials

Pump housing material

Pump and control unit housing: PPE-SB (fibre-reinforced Lurranyl).

Pressure sensor (Flow Monitor)

Sensor: Aluminium oxide Al O-rings: FKM, EPDM or PTFE.

Pressure switch (MBS)

Pressure switch: Stainless steel, DIN 1.4305. Diaphragm of the pressure switch: EPDM.

Warning

Observe the manufacturer's safety instructions when handling chemicals!

Further information on resistance with regard to the media, media temperature and operating pressure is available on request.

2O3

(96 %).

4.8 Control unit

Functions of pumps with control unit

• "continuous operation" button for function test and suction

• memory function (stores a maximum of 65,000 pulses)

• two-stage tank-empty signal (e.g. via Grundfos tank-empty sensor)

• stroke / pulse signal / pre-empty signal (adjustable)

• dosing controller or Flow Monitor function (only with sensor optional)

• diaphragm leakage detection (only with sensor - optional)

• access-code-protected settings

• remote on/off

• calibration (adjust the pump to local operating conditions)

• pressure control function / counter-pressure display

• dosing capacity display (can be reset)

• operating hours counter (cannot be reset)

• interface: PROFIBUS (optional).

Operating modes:

• manual input/display of the dosing flow in l/h or gal/h. quasi continuous dosing (short suction stroke, dosing stroke as long as possible).

• contact signal control input/display in ml/contact, most constant dosing

• current signal control 0-20 mA / 4-20 mA adjustment of volumetric flow proportional to the current signal (displayed in l/h). weighting of current input/output.

• batch dosing Setting the dosing capacity and dosing flow per batch triggered manually or by an external contact signal.

• batch dosing with timer functions

– setting the dosing capacity and dosing flow per batch – setting the start time for first batch – setting the repeat time for subsequent batches.

• slow mode (for viscous media) two-stage reduction of the maximum dosing flow to 66 % (slow mode 1) or 41 % (slow mode 2).

Inputs and outputs

Inputs

Contact signal

Current 0-20 mA Maximum load: 22 Ω Remote on/off Maximum load: 12 V, 5 mA Tank-empty signal Maximum load: 12 V, 5 mA Dosing controller and diaphragm leakage sensor

Outputs

Current 0-20 mA Maximum load: 350 Ω

Error signal

Stroke signal Contact time/stroke: 200 ms

Pre-empty signal

4.8.1 Interface (optional)

•PROFIBUS.

Maximum load: 12 V, 5 mA Minimum pulse length: 10 ms Minimum pause time: 25 ms

Maximum ohmic load: 50 VDC / 75 VAC, 0.5 A

English (GB)

5. Installation

Note

Caution

7

9.95

(159)

172.5

16.5

105

10i

15i

11i

12i

English (GB)

5.1 General information on installation

Warning Observe the specifications for the range of

applications and installation location described in sections 1. General information and

5.2 Installation location.

Warning Faults, incorrect operation or faults on the pump or

system can, for example, lead to excessive or insufficient dosing, or the permissible pressure may be exceeded. Consequential faults or damage must be evaluated by the operator and appropriate precautions must be taken to avoid them!

5.2 Installation location

Warning Danger to life due to non-tripping of the residual

current device (RCD)! If the pump is connected to an electric

installation where a residual current device (RCD) is used as an additional protection, this RCD must trip when earth fault currents with DC content (pulsating DC) and smooth DC earth fault currents occur. This means that a RCD type B, sensitive to universal current, must be used.

5.2.1 Space required for operation and maintenance

5.2.2 Permissible ambient influences

Permissible ambient temperature: 0 °C to +40 °C. Permissible air humidity: max. relative humidity:

92 % (non-condensing).

The installation site must be under cover! Ensure that the enclosure class of motor and pump is not affected by the atmospheric conditions.

Pumps with electronics are only suitable for indoor use! Do not install outdoors!

5.2.3 Mounting surface

The pump must be mounted on a flat surface.

5.3 Mounting

Carefully tighten the screws, otherwise the plastic housing may be damaged.

The pump must be installed in a position where it is easily accessible during operation and maintenance work.

The control elements must be easily accessible during operation. Maintenance work on the dosing head and the valves must be

carried out regularly. Provide sufficient space for removing the dosing head and the valves.

5.4 Installation examples

TM03 6664 4506

Fig. 5 Drilling scheme

• Use four M6 screws to mount the pump on the tank or on a console so that the suction valve is at the bottom and the discharge valve is at the top (dosing always flows upwards).

Fig. 6 Installation example of pump with manual deaeration

Pos. Components

1i Dosing tank 2i Electric agitator 3i Extraction device 4i Suction pulsation damper 5i Dosing pump 6i Relief valve 7i Pressure-loading valve 8i Pulsation damper 9i Calibration tube

TM03 6665 4506

Pos. Components

10i Injection unit 11i Deaeration and evacuation valve 12i Check-back valve 15i Filter

5.4.1 Installation tips

13i

10i

15i

p _ 1bar

p  1 bar

14i

p -p _ 1bar

p2 - p1  1 bar

15i

10i

• For non-degassing media with a viscosity similar to water, the pump can be mounted on the tank (observe the permissible suction lift).

• Flooded suction preferred.

• For media with a tendency to sedimentation, install the suction line with filter (15i) so that the suction valve remains a few millimetres above the possible level of sedimentation.

Fig. 7 Tank installation

With open outflow of the dosing medium or low counter-pressure

A positive pressure difference of at least 1 bar must be ensured between the counter-pressure at the injection point and the pressure of the dosing medium at the pump suction valve.

• If this cannot be ensured, install a pressure-loading valve (7i) immediately before the outlet or the injection unit.

• To protect the dosing pump against excessive pressure build-up, install a relief valve (6i) in the discharge line.

• For degassing media:

– Flooded suction. – Install a filter (15i) in the suction line to prevent the valves

being contaminated.

Fig. 10 Installation with relief valve and filter

• For line lengths above 1 metre a suction pulsation damper (4i)

TM03 6666 4506TM03 6667 4506TM03 6668 4506

may be required, depending on the flow rate.

Fig. 11 Installation with suction pulsation damper

• For damper and line lengths above 3 metres and for flexible pipework and line lengths above 5 metres, a pulsation damper (8i) must be used to protect the system.

English (GB)

TM03 6669 4506TM03 6670 4506TM03 6671 4506

Fig. 8 Installation with pressure-loading valve

• To avoid the siphon effect, install a pressure-loading valve (7i) in the discharge line and, if necessary, a solenoid valve (14i) in the suction line.

Fig. 9 Installation to avoid the siphon effect

Fig. 12 Installation with pulsation damper

• When installing the suction line, observe the following:

Caution

12i

11i

Caution

English (GB)

– Keep the suction line as short as possible. Prevent it from

becoming tangled. – If necessary, use swept bends instead of elbows. – Always route the suction line up towards the suction valve. – Avoid loops as they may cause air bubbles.

5.5.2 Sizing of tube / pipe lines

Warning

Observe the pressure stage of the used lines. The maximum permissible inlet pressure and the pressure stage of the discharge lines must not be exceeded!

Minimum internal diameter

Pump version

Fig. 13 Installation of suction line

• In the case of long discharge lines, install a non-return valve (12i) in the discharge line.

Fig. 14 Installation with non-return valve

5.5 Tube / pipe lines

5.5.1 General

Warning

To protect the dosing pump against excessive pressure build-up, install a relief valve in the discharge line.

All lines must be free from strain! Avoid loops and buckles in the tubes! Keep the suction line as short as possible!

The flow must run in the opposite direction to gravity!

Observe the manufacturer's safety instructions when handling chemicals!

Only use the specified line types!

Maximum suction line length

• 5 m for standard pumps when dosing media with a viscosity similar to water and using a pulsation damper.

• 1.2 m when dosing media with a higher viscosity than water.

• 1.2 m for pumps with Flow Monitor (2 m for standard DDI 60-10) when dosing media with a viscosity similar to water and not using a pulsation damper.

Pump type

Standard HV variant

[mm] [mm]

DDI 60-10

Suction side: 9

Discharge side: 6

DDI 150-4 13

TM03 6672 4506TM03 6673 4506

5.5.3 Connecting the suction and discharge lines

• Connect the suction line to the suction valve (3a). – Install the suction line in the tank so that the foot valve

remains approximately 5 to 10 mm above the bottom of the tank or the possible level of sedimentation.

• Connect the discharge line to the discharge valve (3b).

Fig. 15 Connecting the suction and discharge lines

Pos. Components

3a Suction valve 3b Discharge valve

C Pipe connection D Tube connection

Observe the pressure limits specified in section

1. General information!

Suction side: 19

Discharge side: 13

Suction side: 19

Discharge side: 13

TM03 6235 4506

6. Electrical connections

Caution

optional

Optional

Note

Make sure that the pump is suitable for the electricity supply on which it will be used.

Warning

Electrical connections must only be carried out by qualified personnel!

Disconnect the power supply before connecting the power supply cable and the relay contacts!

Observe the local safety regulations!

6.1 Connecting the signal lines for DDI 222

Warning

The pump housing must only be opened by personnel authorised by Grundfos!

Warning

Protect the cable connections and plugs against corrosion and humidity.

Only remove the protective caps from the sockets that are being used.

The power supply must be electrically isolated from the signal inputs and outputs.

English (GB)

Fig. 16 DDI 222 connection diagram

6.1.1 Diaphragm leakage signal / (pressure sensor - Flow Monitor)

Socket 1

For diaphragm leakage signal (MBS) and/or pressure sensor (Flow Monitor pump option). The diaphragm leakage signal and pressure sensor are pre-assembled with an M12 plug for socket 1.

• Connect the cables according to the table below.

Socket 1 Used for / wire colours

Pin Assignment Diaphragm leakage signal (MBS) Pressure sensor

1+ 5 V x 3 Pressure sensor input x 4 MBS input Black 5 GND Green/yellow x

6.1.2 Current output / Flow Monitor (pressure sensor)

Socket 2

For pressure sensor for Flow Monitor option. The pressure sensor is supplied ready-made with M12 plug for socket 2 or socket 1. The current output indicates the current dosing flow and can be weighted independently of the selected operating mode.

See section

9.6.4 Weighting of current input/output.

Pressure sensor (Flow Monitor): If socket 2 is also used for current output, the pressure sensor can be either connected to socket 1 or preferably together with the current output to socket 2 using the plug set (product number 96645265 (321-327)).

TM03 6583 4506

Socket 2 Cable Used for

Pin Assignment Wire colour +/- current output Pressure sensor

1+ 5 V Brown x 3 Pressure sensor input Blue x 4 Current output Black + 5 GND Green/yellow - x

6.1.3 Stroke/pulse signal / pre-empty signal / error signal

Caution

English (GB)

Socket 3

Electrically isolated output for stroke/pulse signal or pre-empty signal and error signal.

Socket 3 Cable Used for

Pin Assignment Wire colour

1 Error signal contact Brown x 2 Stroke/pulse signal or pre-empty signal contact White x 3 Stroke/pulse signal or pre-empty signal contact Blue x 4 Error signal contact Black x

6.1.4 Remote on/off / contact input / current input

Socket 4

For the remote on/off input and contact input or current input. If the remote on/off and contact inputs are to be used at the same time, wire 1 is assigned twice.

For the connection of one cable, use a plug adapter with simple cable entry, for the connection of two cables, use a plug adapter with double cable entry, otherwise the protection will be lost!

Socket 4 Cable Used for

Pin Assignment Wire colour

1GND Brown x x 2 Current input White + 3 Remote on/off input Blue x 4 Contact input Black x

6.1.5 Empty signal only / pre-empty and empty signal

Socket 5

For the empty signal only or pre-empty and empty signal input. The suction lines with empty signal or pre-empty and empty signal are pre-assembled with a plug for socket 5.

Remote on/off

input

Stroke/pulse signal /

pre-empty signal

Contact input +/- current input

Error signal

Socket 5 Used for

Pin Assignment Empty signal Pre-empty signal

1 Pre-empty signal x 2 Empty signal x 3GND x x

6.1.6 PROFIBUS (optional)

Socket 6

Socket 6 for PROFIBUS is only used when the PROFIBUS option is selected. For pumps with PROFIBUS option, please refer to the separate "PROFIBUS-DP" manual provided.

6.2 Connecting the power supply cable

Caution

7. Start-up/shutdown

Warning

Disconnect the power supply before connecting the power supply cable!

Before connecting the power supply cable, check that the rated voltage stated on the pump nameplate corresponds to the local conditions!

Do not make any changes to the power supply cable or plug!

The pump can be automatically started by connecting the power supply!

The assignment between the plug-and-socket connection and the pump must be labelled clearly (e.g. by labelling the socket outlet).

• Do not switch on the power supply until you are ready to start the pump.

6.2.1 Versions without mains plug

Warning

The pump must be connected to an external clearly labelled mains switch with a minimum contact gap of 3 mm in all poles.

• Connect the pump to the mains in accordance with local electrical installation regulations.

Warning

IP65 can only be ensured if the power supply cable is connected with IP65 protection.

6.2.2 Version with mains plug

• Insert the mains plug in the mains socket.

Warning

The electronic printed circuit board may be live even if the mains voltage is not connected! The printed circuit board may only be replaced by service personnel authorised by Grundfos.

Warning

Risk of chemical burns!

Wear protective clothing (gloves and goggles) when working on the dosing head, connections or lines!

Before each start-up, check the dosing head screws.

After initial start-up and after each time the diaphragm is changed, tighten the dosing head screws.

After approximately 6-10 operating hours or two days, cross-tighten the dosing head screws using a torque wrench.

Torque: 7 Nm (+ 1 Nm).

7.1 Initial start-up / subsequent start-up

7.1.1 Checks before start-up

• Check that the rated voltage stated on the pump nameplate corresponds to the local conditions!

• Check that all connections are secure and tighten, if necessary.

• Check that the dosing head screws are tightened with the specified torque and tighten, if necessary.

• Check that all electrical connections are correct.

7.1.2 Assisting suction for systems without flooded suction

At the dry suction/discharge valves:

1. Remove the suction line.

2. Hold a small container of water directly next to the suction

valve and draw water until the dosing head is full.

3. Reinsert the suction line.

7.1.3 Starting the pump

1. Open the suction and discharge isolating valves, if installed.

2. Depressurise the system on the discharge side of the pump:

– Open the system deaeration and evacuation valve.

3. Let the pump run in continuous operation:

– Switch on the power supply. – Press the "Start/Stop" button and keep it pressed. – The pump switches to continuous operation at maximum

stroke frequency.

4. Leave the pump running until the dosing head and the valves

are filled with medium and dosing medium flows from the deaeration line on the discharge side.

5. Close the system deaeration and evacuation valve.

The pump is now ready for operation.

7.1.4 Tightening dosing head screws

English (GB)

After initial start-up and after each time the diaphragm is changed, tighten the dosing head screws.

After approximately 6-10 operating hours or two days, cross-tighten the dosing head screws using a torque wrench.

Torque: 7 Nm (+ 1 Nm).

7.2 Operating the pump

Note

Caution

Stop

Start

Down

Mode

Stop Start

Info

Down

English (GB)

To operate the pump, see sections 8. Operation,

9. How to use the control unit and

10. Maintenance and, if necessary, section

11. Fault finding chart.

7.3 Shutdown

Warning

Risk of chemical burns!

Wear protective clothing (gloves and goggles) when working on the dosing head, connections or lines!

Do not allow any chemicals to leak from the pump. Collect and dispose of all chemicals correctly!

If possible, rinse the dosing head before shutting down the pump, e.g. by flushing it with water.

7.3.1 Switching off / uninstalling

1. Switch off the pump and disconnect it from the power supply.

2. Depressurise the system.

3. Take suitable steps to ensure that the returning dosing medium is safely collected.

4. Carefully remove all lines.

5. Uninstall the pump.

7.3.2 Cleaning

1. Rinse all parts that have come into contact with the medium very carefully:

– lines – valves – dosing head – diaphragm.

2. Remove any trace of chemicals from the pump housing.

7.3.3 Storage

Storage of the pump:

1. After cleaning (see above), carefully dry all parts and reinstall the dosing head and valves, or

2. change the valves and diaphragm.

See section

7.3.4 Disposal

Disposal of the pump:

• After cleaning (see above), dispose of the pump in accordance

with the relevant regulations.

10. Maintenance.

8. Operation

In the event of a diaphragm leakage, the dosing liquid may leak out of the hole in the intermediate flange between the pump and the dosing head. The parts inside the housing are protected from the dosing liquid for a short time (depending on the type of liquid) by the housing sealing. It is necessary to check regularly (daily) if liquid is leaking out of the intermediate flange.

Observe section 10.5 Diaphragm breakage

For maximum safety, we recommend the pump version with diaphragm leakage detection.

8.1 Control and display elements

TM03 6257 4506

Fig. 17 Display of DDI 222

Element Description

Light-emitting diode (LED)

• Lights up red when the pump is stopped.

• Lights up green when the pump is started and briefly goes out during a suction stroke.

• Lights up yellow when the pump is switched off remotely.

• Flashes red if an error signal is present.

• Flashes red/green when an error message is present and the pump is running, or restarts automatically after the error has been corrected.

• Goes out when the pump is in menu mode.

"Start/Stop"

• Use this button to start or stop the pump.

• Error signals can be acknowledged by pressing the "Start/Stop" button.

Use the "Menu/Info" button to switch between the operating modes.

Use the "Down" and "Up" buttons to change values in the display.

8.1.1 Display test

A display test is automatically performed when the pump is switched on. All the segments of the LCD are switched on for 3 seconds and the software version number is then displayed for 2 seconds.

8.1.2 Display indicator

When switched on (if the pump was stopped) and during pump operation, the dosing flow setpoint is displayed. With contact control the set ml/contact value is displayed.

8.2 Switching on/off

Before switching on the pump, check that it is installed correctly. See sections 5. Installation and 7.1 Initial start-up / subsequent start-up.

• To start the pump, switch on the power supply.

• To stop the pump, switch off the power supply.

9. How to use the control unit

Note

Manual

l/h

Stop

1.20

Manual

l/h

Stop

1.20

First see sections 5. Installation,

7. Start-up/shutdown and 7.2 Operating the pump. Only the additional functions are described in this section.

9.1 Menu levels

Menu levels used in the control unit

• First function level: for selecting and setting the operating modes of the pump (Manual, Contact, Analog), performing the batch and timer functions and starting the pump.

•

Second function level: for setting and viewing additional

functions, selecting and setting the batch and timer functions and setting the access code to protect the pump against unintentional or unauthorised access to pump settings.

•

Service level: for setting the pump type and the unit of display

for the dosing flow (l/h or gal/h) and setting the inputs and outputs.

Saving user settings

The pump settings are automatically saved approximately every 10 minutes and remain as they are even after the power supply has been switched off.

9.2 General functions of the control unit

9.2.1 Suction

If the "Start/Stop" button is pressed for longer than 1 second, the pump switches to continuous operation for as long as the button is held down (e.g. for suction).

This happens regardless of the selected operating mode. (In batch or timer mode, the pump has to be stopped first.)

9.2.2 Locking "run"

The pump can be locked to avoid manual stopping. When activating this function (service level), the pump starts

running with the present settings and cannot be stopped using the "Start/Stop" button.

It is still possible to acknowledge error messages using the "Start/Stop" button.

Stopping the pump when the locking "run" is activated

• If remote on/off is connected, use remote off.

• Disconnect the pump from the power supply.

For "Batch manual", the "Run" button should not be locked as the pump then runs in continuous operation.

9.2.3 Two-stage tank-empty signal

This function is used to provide a warning when the tank is almost empty and to switch off the pump when the tank is empty. To use the pre-empty signal, ensure that the suction line is equipped with two float switches.

Pre-empty signal

The pre-empty signal can be an error signal or a pre-empty signal at socket 3. For a pre-empty signal, relay 1 must be set to "Pre-empty signal". See sections

9.7.1 Modifying the switch assignment.

When the contact of the corresponding float switch closes,

• the error signal relay or pre-empty signal relay switches on, but the pump is not switched off.

• The LED flashes red.

• The empty-signal symbol flashes in the display.

Fig. 18 Display: pre-empty signal

Once the error has been corrected,

• the error signal relay or pre-empty relay switches off.

• The pump returns to the state it was in before the error occurred.

Empty signal

When the contact of the corresponding float switch closes,

• the pump is switched off.

• The error signal relay switches on.

• The LED flashes red.

• The empty-signal symbol lights up in the display.

Fig. 19 Display: empty-signal symbol

Once the error has been corrected,

• the pump starts running again (if it was running before).

• The error signal relay switches off.

• The pump returns to the state it was in before the error occurred.

6. Electrical connections and

English (GB)

TM03 6596 4506TM03 6597 4506

9.2.4 Diaphragm leakage sensor (MBS)

Note

Manual

l/h

1.20

MBS

Manual

l/h

Stop

1.20

ERROR

MBS

Analog

Run

ERROR

1/min

bar

Analog

Stop

ERROR

1/min

bar

Note

Analog

Run

ERROR

1/min

bar

English (GB)

As an option, the pump can be equipped with a sensor for diaphragm leakage detection.

The electronics automatically detects whether a sensor is connected. The following appears in the display.

Fig. 20 Display: MBS sensor is connected

When a diaphragm leakage is detected by the sensor,

• the pump is switched off.

• The error signal relay switches on.

• The LED flashes red.

• "MBS" and "ERROR" flash in the display.

Fig. 21 Display: diaphragm leakage detected

Once the error has been corrected (the contact is no longer closed),

• press the "Start/Stop" button to acknowledge the error.

• The pump starts running again (if it was running before).

• The error signal relay switches off.

• The pump returns to the state it was in before the error occurred.

A cable break of the pressure switch is also indicated as a diaphragm leakage signal (MBS error). After acknowledging the MBS error, the pump continues to operate without error indication!

9.2.5 Blocking safety

If the pump has existing strokes to process, a check is carried out to determine whether the drive is turning. If the drive motor is blocked, e.g. due to excess counter-pressure in the dosing system, this is detected and indicated by the integrated motor monitoring function.

• The error signal relay switches on.

• "1/min", "bar" and "ERROR" flash in the display.

Fig. 22 Display: motor monitoring

9.2.6 Power off

If the power consumption of the drive motor is too high, e.g. due to excess counter-pressure in the dosing system, this is detected and indicated by the power monitoring function.

• The error signal relay switches on.

• "1/min", "bar" and "ERROR" flash in the display.

• The pump is stopped. Every 10 minutes, an attempt is made to automatically restart the pump.

• The LED flashes red/green.

TM03 6598 4506TM03 6599 4506

Fig. 23 Display: power off

For possible errors and their correction, see section

Once the error has been corrected,

• the pump restarts automatically, or

• press the "Start/Stop" button to acknowledge the error.

9.2.7 Remote on/off

The pump can be switched off remotely (e.g. from a control room).

• If switched off remotely, the pump does not respond to any input signals or to operator input.

Exception: The pump can still be stopped manually (press the

"Start/Stop" button) and run in continuous operation (press and hold down the "Start/Stop" button).

• "Stop" lights up in the display.

• The yellow LED lights up.

• When switched on remotely, the pump returns to the state it was in before it was switched off. If, for example, the pump was previously in "Stop" mode, it returns to this mode once it is switched on.

9.2.8 Memory function

Contact signals, which cannot be processed immediately, can be stored and subsequently made available to the pump for processing. A maximum of 65,000 contact signals can be stored.

•

Without memory: If the pump is running when a contact

signal is received, the signal is ignored. The pump performs the current dosing, then it is again ready to receive new contact signals, i.e. it rejects excess contacts.

•

With memory: If the pump is running when a contact signal is

received, the signal is stored in the memory. First, the pump performs the current dosing, then it processes the contact signals from the memory.

The contents of the memory are deleted:

• by switching off the power supply

• by switching the operating mode.

The contents of the memory are not deleted:

• by actuating the remote on/off contact

TM03 6763 4506

• by pressing the "Start/Stop" button

• by continuous operation.

11. Fault finding chart.

TM03 6360 4506

• The pump is stopped.

• The red LED flashes. For possible errors and their correction,

see section Once the error has been corrected,

• press the "Start/Stop" button to acknowledge the error.

11. Fault finding chart.

The memory function can be enabled and disabled in the second function level.

9.2.9 Flow Monitor

Caution

Note

The pump can be equipped with a pressure sensor (Flow Monitor pump option).

Based on the pressure measured by the sensor and on the motor position, an indicator diagram is created. Possible dosing faults or the exceeding of the permissible counter-pressure are detected reliably and indicated by the display or the error message output.

The following errors are recognised:

• Pressure exceeded (the pump is stopped and restarts automatically when the pressure decreases).

• Dosing error (the pump doses 30 % to 100 % less due to a leaking discharge valve or suction valve, a clogged suction line or an air bubble in the dosing head).

Depending on the operating conditions, it may be impossible to detect dosing errors due to several faults occurring simultaneously (e.g. leaking suction and discharge valves)!

The dosing controller and dosing control functions can be switched on and off independently of each other. It is always possibly to display the pressure that has been measured during operation whenever the pressure sensor is connected.

For information about operating the pump with the Flow Monitor, see section 9.10 Flow Monitor.

9.3 Signal outputs

The control unit has the following signal outputs, e.g. in order to return a signal to the control room.

9.3.1 Current signal output

English (GB)

To use the control signal output, see section

9.9 Current signal control 0-20 mA / 4-20 mA.

The current flow rate of the pump is output as a current signal.

• Current output 0-20 mA in the following mode:

– Current control 0-20 mA.

• Current output 4-20 mA in the following modes:

– Current control 4-20 mA – Manual – Contact – Batch dosing with manual/contact start – Timer with manual/contact start.

The current output is linear between 4 (0) mA at flow rate = 0 and 20 mA at maximum flow rate Q

(default setting) or the corresponding

max.

weighting value pair.

9.3.2 Error signal

Used to return various error states to the control room.

9.3.3 Stroke signal / pre-empty signal / pulse input

Depending on the relay setting, the contact output receives a signal in these cases:

• for each complete stroke of the pump, or

• a pre-empty signal input, or

• each pulse input at the pump.

To set the relay, see section

assignment

9.7.1 Modifying the switch

9.4 First function level

Stop Start

Down

Analog

0.000

4-20 mA

l/h

Analog

0.000

0-20 mA

l/h

Contact ml

1.75

l/h

Manual

1.20

Run

Info

Down

Pump not running (LED lights up red)

Pump running (LED lights up green)

Manual control

Contact signal

control

Current signal

control

0-20 mA

Current signal

control

4-20 mA

Set the dosing rate to approx.

0.125 % to 100 % of max. dosing rate [l/h]

Set the dosing quantity/signal to

0.111 - 22.2 ml (DDI 60-10)

0.278 - 55.5 ml (DDI 150-4)

Dosing rate proportional to current signal*

 20 mA: Continuous operation, max. dosing rate

< 0.2 mA: Pump stops

0.2 - 20 mA: Dosing rate proportional to current signal

Dosing rate proportional to current signal*

 20 mA: Continuous operation, max. dosing rate

< 4.2 mA: Pump stops

4.2 - 20 mA: Dosing rate proportional to current signal

< 2 mA: Fault signal switches on > Display: "ERROR", LED flashes red

Setting the weighting (max. dosing rate)

English (GB)

Fig. 24 First function level

* You can modify the assignment between the current input and the flow rate. See section

9.9 Current signal control 0-20 mA / 4-20 mA.

TM03 6674 4506

9.4.1 Setting the operating modes

Manual

l/h

Run

1.20

Note

Contact ml

1.75

The operating modes are selected in the first function level, and settings can be made for the modes.

This function level can only be opened when the pump is stopped.

1. When the pump is stopped (LED lights up red), press the "Menu/Info" button.

– The first function level is opened.

2. Navigate in the first function level by repeatedly pressing the "Menu/Info" button.

3. Use the "Up" and "Down" buttons to modify the settings in the relevant menu as shown in fig. 24.

4. Press the "Start/Stop" button to confirm the settings and to exit the first function level.

– The pump is running (LED lights up green).

9.4.2 Manual control

Dosing with manual on/off and manually adjustable dosing flow

In this operating mode, all the settings are entered on the pump by the operator.

• Use the "Start/Stop" button to start or stop the pump.

• Use the "Up" and "Down" buttons to increase or decrease the

flow rate. This can be done when the pump is stopped or when it is running.

9.4.3 Contact signal control

The pump must be started first in this operating mode (LED lights up green and "Run" appears in the display).

• Use the "Start/Stop" button to start or stop the pump.

For continuous dosing in a process

For each signal received at the contact input of the pump (e.g. from a water meter with reed contact output), the pump doses the set dosing capacity. The dosing is continuously distributed between the incoming contacts via a controller. The maximum dosing capacity must not be exceeded.

Input range for the dosing capacity per contact

Min. dosing capacity

Pump type

DDI 60-10 0.111 22.2 DDI 150-4 0.278 55.5

Even if the pump receives more contact signals than it can process at the maximum flow rate, it only runs in continuous operation with a maximum stroke frequency of 180/min. 120/min. in slow mode).

(= 1/50 stroke/contact)

[ml] [ml]

Max. dosing capacity

(= 4 strokes/contact)

English (GB)

Fig. 25 Display: manual control

The maximum displayed/adjustable flow rate is automatically set according to the selected pump type and the calibrated stroke volume.

Input range for the flow rate

Pump type

DDI 60-10 0.075

DDI 150-4 0.188

min.

[l/h]

Resolution of flow rate

20 ml/h for Q < 10 l/h 100 ml/h for Q

20 ml/h for Q < 10 l/h 100 ml/h for Q 1 l/h for Q

 10 l/h

 100 l/h

TM03 6601 4506

Fig. 26 Display: contact signal control

Use the "Up" and "Down" buttons in the first function level to set the dosing volume for each contact signal.

1. When the pump is stopped (LED lights up red), press the "Menu/Info" button.

– The first function level is opened.

2. Use the "Up" and "Down" buttons in the "contact signal control" menu to set the dosing volume per contact signal.

3. Press the "Start/Stop" button to confirm the settings and to exit the first function level.

– The pump is running (LED lights up green).

Due to the constant dosing control, the pump can continue dosing for a short time even when no contact has been received.

9.4.4 Current signal control 0-20 mA / 4-20 mA

For current signal control, see section 9.9 Current signal control

0-20 mA / 4-20 mA

9.5 Second function level

9.5.1 Opening / exiting the second function level

Open the second function level

• to set the access code,

• to enable or disable functions such as Flow Monitor or

memory,

• to enter settings for operating modes such as batch mode,

• to display the total number of operating hours and total dosing

capacity,

• to carry out a calibration, or

• to modify the assignment between the current input/output and

dosing rate.

This function level can only be opened when the pump is stopped (LED lights up red).

TM03 6602 4506

9.5.2 Setting the access code

Note

Down

Stop

Start

Stop

Start

Stop

Start

Info

Pump running (LED lights up green)

Pump not running (LED lights up red)

Keep pressed for 3 seconds

Second function level

Setting code 111

• Calibration

• Pressure control

•Flow on/off

• Memory function on/off

• Weighting of current input/output

•Batch mode

•Timer mode

•PROFIBUS

•Slow mode

• Display or resetting of total dosing capacity

• Display of total number of operating hours

English (GB)

The access code is used to protect the pump against unintentional/unauthorised access to pump settings.

The default setting is 111. Code 111 gives access to all settings described in sections

function level

1. Press the "Start/Stop" button while the pump is running (LED lights up green).

– The pump is stopped (LED lights up red).

2. Press and hold down the "Menu/Info" button for 3 seconds. – The second function level is opened. – The input arrow appears in the display. – "C:111" (default setting is "111") or a user-defined code

3. Use the "Up" and "Down" buttons to set the code in the range between 1 and 999.

Code 111 is required to open the second function level.

The "Start/Stop" button for stopping the pump is active with any code.

appears in the display.

9.4 First function level and 9.5 Second

Fig. 27 Opening / exiting the second function level

TM03 6371 4506

1. Navigate in the second function level by repeatedly pressing

Note

Stop Start

Stop

Start

Stop

Start

Down

C:111

Code

Memory

OFF

Analog

L: 00

Down

4-20 mA

OFF

CAL

Stop

Start

Down

P:OFF

bar

Stop Start

Down

Info

Stop Start

flow

OFF

Down

Info

Keep pressed for 3 seconds

Setting code 111

Calibration

Dosing controller

Pressure control

Memory function

Weighting of current

input/output

Press "Up" to start calibration, see section

9.6 Calibration

Switch dosing controller on/off ON/OFF

Press "Up" to switch on pressure control function

For maximum counter-pressure settings, see section

9.10.2 Setting the Flow Monitor

Saving of approx. 65,000 contact signals

ON/OFF

Weighting of current input/output, see section

9.9 Current signal

control 0-20 mA / 4-20 mA

Batch Timer PROFIBUS Slow mode Dosing quantity counter Operating hours counter

See next page

the "Menu/Info" button.

2. Use the "Up" and "Down" buttons to modify the settings in the relevant menu as shown in figs 28 and 29.

3. Press the "Start/Stop" button to exit the second function level.

You can only change the parameters in the shown order. When the "Menu/Info" button is pressed again (after one run), the first function level opens automatically.

English (GB)

Fig. 28 Second function level, part 1

TM03 6609 4506

English (GB)

Stop Start

Stop

Start

Down

OFF

9999

OFF

BUS

SL : OF

Stop

Start

Stop

Start

Stop

Start

Stop

Start

Down

l /

Info

Setting code 111 Calibration Dosing controller Pressure control Memory function Weighting of current input/output

Batch on/off ON/OFF Adjustment of batch quantity and

dosing rate for batch operation, see section

9.11 Batch menu / batch mode

Timer on/off ON/OFF Adjustment of batch quantity, dosing

rate and times for timer operation, see section

9.12 Timer menu / timer mode

Slow mode on/off ON/OFF To set the slow-mode factor, see

section

9.6.8 Slow mode

Display of total dosing quantity [l] (resettable)

0.000 - 9.999

10.00 - 99.99

100.0 - 999.9 1000 - 9999

Display of operating time of drive 1 = 10 h to 9999 = 99,990 h

Batch

PROFIBUS

(only with

PROFIBUS)

Slow mode

(anti-cavitation)

Dosing quantity

counter

Operating hours

counter

See previous page

Bus address indication

Timer

Fig. 29 Second function level, part 2

TM03 6610 4506

9.6 Calibration

Note

red LED

Down

Stop

Start

Stop

Start

Stop

Start

OFF

Down

CAL

- - -

CAL

Info

OFF

CAL

Run

CAL

200

Stop

CAL

Stop CAL

1315

Stop

CAL

1295

Stop

CAL

Flashing

Green LED flashing Process 200 strokes

Manual stop at user-defined stroke number

Value of manufacturing calibration - calculated for stroke number of actual calibration

Input of actual ascertained calibration volume

Flashing

Wait until ON CAL (not flashing) is displayed

Red LED

The dosing flow display is set by default for an operating counter-pressure of 3 bar. Calibration can be used to set the pump flow to the actual operating conditions.

With activated flow compensation (see section

4.4.4 Flow compensation):

When dosing media with a viscosity different from water or after a software update the pump has to be calibrated. After a software update "cal" is flashing in the display.

Calibrate the pump under normal operating conditions with the discharge line connected and at operating counter-pressure.

The dosed volume must be gauged in litres during calibration, e.g. by drawing the dosing medium from a gauged tank.

"OFF CAL" appears in the display.

1. Press the "Up" button. – "- - -" and "CAL" (flashing) appear in the display.

2. Wait until "ON" and "CAL" (not flashing) appear in the display. – "ON CAL" appears in the display.

3. Press the "Start/Stop" button. – Calibration is started. The LED flashes green and "Run"

flashes in the display.

• 200 strokes are performed by default. The number of strokes

performed appears in the display.

• Press "Start/Stop" to stop at any stroke value. – The LED lights up red.

4. Press the "Start/Stop" button.

The current calibration value is displayed (not with replacement circuit boards!).

5. Use the "Up" and "Down" buttons to enter the calibration value (gauged volume in ml).

• Press the "Menu/Info" button (confirm the setting and move on

to the next menu item), or

• press the "Start/Stop" button (confirm the setting and close the

second function level).

The calibration process does not change the setting for the assignment/weighting of the current input and output for the flow rate.

If a current input or output is used, check after calibration to determine whether a new current weighting is required.

English (GB)

Fig. 30 Calibration

TM03 6678 4506

Adjusting the operating counter-pressure without gauging

1000

1200

1400

1600

1800

2000

2200

2400

2600

2800

3000

3200

012345678910

sys

[bar]

kal

[ml]

DDI 60 -10

DDI 150 - 4

sys.

[bar]

cal

[ml]

Note

English (GB)

the dosed volume during calibration

If you do not gauge the dosed volume, you can determine the "calibration value" from the following dosing capacity curves in order to adjust your pump to the operating counter-pressure.

The curves represent 200 strokes:

• Dosing medium with a viscosity similar to water

• 0.5 m flooded suction.

Fig. 31 Dosing capacity curves

TM03 6679 4506

Values are approximate values and do not take into consideration deviations due to construction tolerance according to VDMA 24284.

9.6.1 Flow Monitor

In order for the pressure sensor (if installed) to function as a dosing controller, the dosing controller must be switched on. See section

9.10 Flow Monitor.

9.6.2 Pressure control

In the pressure control menu, the pressure control function is switched on or off and the stop counter-pressure is set. See section

9.10 Flow Monitor.

9.6.3 Memory function

The memory function is used to store excess contact signals for processing later. See section

9.6.3 Memory function.

• Switch the memory function on/off with "Up" / "Down".

• Press the "Menu/Info" button (confirm the setting and move on to the next menu item), or

• press the "Start/Stop" button (confirm the setting and close the second function level).

9.6.4 Weighting of current input/output

In current input/output operation, the dosing capacity is controlled via the current signal. The pump emits a current signal as a feedback for control rooms or master/slave applications.

For weighting of current input/output, see also

9.9 Current signal control 0-20 mA / 4-20 mA.

9.6.5 Batch menu / batch mode

In batch mode, a defined batch quantity is dosed with a defined dosing flow. The batch can be dosed manually or by a contact. See section

9.6.6 Timer menu / timer mode

In timer mode, a defined batch quantity is dosed with a defined dosing flow and a defined start time. See section

menu / timer mode

9.11 Batch menu / batch mode.

9.12 Timer

9.6.7 PROFIBUS menu

Note

The "PROFIBUS" menu item is only displayed for pumps with PROFIBUS interfaces. The PROFIBUS interface is activated/deactivated in this menu and the bus address is specified.

9.6.8 Slow mode

Slow mode reduces the maximum dosing flow of the pump in two stages to 66 % (slow mode 1) or 41 % (slow mode 2).

By increasing the minimum suction time, cavitation is, for example, reduced with viscous media.

Slow mode can be activated in any operating mode. In the slow-mode menu, the slow mode function is set and the slow-mode factor is selected.

Setting slow mode

In the second function level, "SL:OF" appears in the display.

• Use the "Up" and "Down" buttons to switch between normal operation (SL:OF), slow mode 1 (SL:01) and slow mode 2 (SL:02).

– The current slow-mode factor appears in the display.

• Press the "Menu/Info" button (confirm the setting and move on to the next menu item), or

• press the "Start/Stop" button (confirm the setting and close the second function level).

The maximum flow rate of the pump decreases. The maximum stroke rate is 120 l/min. in slow mode 1 and 74 l/min. in slow mode 2. The minimum adjustable flow rate is maintained.

9.6.9 Display/resetting of total dosing capacity

The total capacity dosed since the value was last reset is displayed.

The maximum value that can be displayed is 9999 l. If this value is exceeded, the counting starts again at zero.

To reset the value,

1. press the "Up" button.

– "dEL" appears in the display.

2. Press the "Start/Stop" button.

– The total dosing capacity is deleted.

• Press the "Menu/Info" button (confirm the setting and move on to the next menu item), or

• press the "Start/Stop" button (confirm the setting and close the second function level).

Display of value during pump operation (in "Run" mode)

• Press the "Menu/Info" button.

– The total capacity dosed since the value was last reset is

displayed.

9.6.10 Display of total number of operating hours

The operating hours counter indicates the operating time of the drive, e.g. to check maintenance intervals. The maximum number of operating hours that can be displayed is 99,990 h (display = 9999).

The operating hours counter cannot be reset.

Multiply the number displayed by 10 to determine the number of operating hours.

9.7 Service level

Open the service level

• to modify the switch assignments of the electronics,

• to set the pump type, or

• to select the unit of measurement for the dosing flow (l/h or gal/h) that will be displayed.

9.7.1 Modifying the switch assignment

You are modifying the default settings of your control unit. They will therefore differ from the technical data.

The service level can only be accessed when the power supply is switched on.

1. Simultaneously press the "Menu/Info" and "Down" buttons

and hold them down.

2. Switch on the power supply.

– The LED alternately flashes red and green.

3. Release the "Menu/Info" and "Down" buttons.

4. Press the "Start/Stop" button.

5. Press the "Up" button.

– The LED lights up yellow. – "Func" appears in the display.

6. Press the "Menu/Info" button.

– The service level is opened.

English (GB)

Stop

Start

Down

Stop

Start

Info

Pump not connected to power supply

LED flashes up red and green alternating

LED lights up yellow

Service level

1. Relay function (stroke / pre-empty / pulse selection)

2. Relay output, NO/NC (stroke / pre-empty / pulse)

3. Pre-empty signal, NO/NC input

4. Empty signal, NO/NC input

5. Error signal, NO/NC output

6. Remote off, NO/NC input

7. Locking "run" on/off – dosing controller calibration – number of error strokes for the dosing controller – unit [l/h] / [gph]

Keep pressed when switching on

Fig. 32 Opening / exiting the service level

1. Navigate in the service level by repeatedly pressing the "Menu/Info" button.

2. Use the "Up" and "Down" buttons to modify the switch assignment in the relevant menu.

3. Press the "Menu/Info" button for 10 seconds to open the pump type selection.

4. Press the "Start/Stop" button – to confirm the new settings – to exit the service level – to open the first function level.

TM03 6684 4506

1. Relay function (stroke / pre-empty / pulse selection)

Note

Caution

"1:OFF", "1:ON" or "1:1:1" appears in the display.

• Use the "Up" and "Down" buttons to switch between: – "1:OFF": Relay function = stroke signal ("1/min" flashes in

display), and

– "1:ON": Relay function = pre-empty signal (empty-signal

symbol flashes in the display), and

– "1:1:1": Relay function = pulse input ("n:1" flashes in the

display).

• Press the "Menu/Info" button (confirm the setting and move on

to the next menu item), or

• press the "Start/Stop" button (confirm the setting and close the

service level).

2. Relay output, NO/NC (stroke / pre-empty / pulse)

"2:NO" or "2:NC" appears in the display ("1/min" and empty-signal symbol flash in the display).

• Use the "Up" and "Down" buttons to switch between: – "2:NO": Stroke/pre-empty signal/pulse input relay = normally

open contact, and

– "2:NC": Stroke/pre-empty signal/pulse input relay = normally

closed contact.

• Press the "Menu/Info" button (confirm the setting and move on

to the next menu item), or

• press the "Start/Stop" button (confirm the setting and close the

service level).

3. Pre-empty signal, NO/NC input

"3:NO" or "3:NC" appears in the display (empty-signal symbol flashes in display).

• Use the "Up" and "Down" buttons to switch between: – "3:NO": Pre-empty signal = normally open contact, and – "3:NC": Pre-empty signal = normally closed contact.

• Press the "Menu/Info" button (confirm the setting and move on

to the next menu item), or

• press the "Start/Stop" button (confirm the setting and close the

service level).

4. Empty signal, NO/NC input

"4:NO" or "4:NC" appears in the display (empty-signal symbol lights up in the display).

• Use the "Up" and "Down" buttons to switch between: – "4:NO": Empty signal = normally open contact, and – "4:NC": Empty signal = normally closed contact.

• Press the "Menu/Info" button (confirm the setting and move on

to the next menu item), or

• press the "Start/Stop" button (confirm the setting and close the

service level).

5. Error signal, NO/NC output

"5:NO" or "5:NC" appears in the display ("ERROR" flashes in the display).

• Use the "Up" and "Down" buttons to switch between: – "5:NO": Error signal relay = normally open contact, and – "5:NC": Error signal relay = normally closed contact.

• Press the "Menu/Info" button (confirm the setting and move on

to the next menu item), or

• press the "Start/Stop" button (confirm the setting and close the

service level).

6. Remote off, NO/NC input

"6:NO" or "6:NC" appears in the display ("Run" and "Stop" flash in the display).

• Use the "Up" and "Down" buttons to switch between: – "6:NO": Remote off = normally open contact, and – "6:NC": Remote off = normally closed contact.

• Press the "Menu/Info" button (confirm the setting and move on

to the next menu item), or

• press the "Start/Stop" button (confirm the setting and close the

service level).

7. Locking "run" on/off

The locking of the "Start/Stop" button to prevent manual stopping of the pump can be enabled and disabled.

The display indicates "7:ON" or "7:OFF" (the "Run" symbol is displayed).

• Use the "Up" and "Down" buttons to switch between: – "7:ON": Locking "run" on, and – "7:OFF": Locking "run" off.

• Press the "Menu/Info" button (confirm the setting and move on

to the next menu item), or

• press the "Start/Stop" button (confirm the setting and close the

service level).

P: CAL on/off (only for Flow Monitor)

"CAL:ON" or "CAL:OFF" appears in the display ("CAL" appears).

• Use the "Up" and "Down" buttons to switch between: – "CAL:ON": Calibration of the pressure sensor for the Flow

Monitor enabled, and

– "CAL:OFF": Calibration of the pressure sensor for the Flow

Monitor disabled.

For calibration, see section 9.10.7 Calibrating the sensor after the sensor has been replaced.

St: e.g. "60" (only for Flow Monitor)

• Use the "Up" and "Down" buttons to set the "number of error

strokes permitted when starting". If the number of error strokes is exceeded, the "Flow error" error message appears.

FE: e.g. "7" (only for Flow Monitor)

• Use the "Up" and "Down" buttons to set the "number of error

strokes permitted during operation". If the number of error strokes is exceeded, the "Flow error" error message appears.

Selection of unit (display)

"Unit l/h" or "Unit gph" appears in the display.

• Use the "Up" and "Down" buttons to switch between: – "Unit l/h": Unit Q = l/h, and – "Unit gph": Unit Q = gal/h.

• Press the "Start/Stop" button (confirm the setting and close the

service level), or

• press the "Menu/Info" button for a minimum of 10 seconds

(confirm the setting and open the pump selection).

Pump selection

The actual pump type must always be selected to ensure error-free operation of the electronic control function. Otherwise the displayed pump and signals differ from the actual conditions.

"-60" or "-150" appears in the display.

• Use the "Up" and "Down" buttons to switch between the pump

types DDI 60-10 and DDI 150-4.

• Select your pump type, which is indicated on the pump

nameplate.

• Press the "Start/Stop" button (confirm the setting and close the

service level).

English (GB)

9.8 Resetting to default settings

Note

Analog

0-20mA

l/h

Run

Analog

l/h

Run

2.50

4-20mA

Analog

l/h

Run

0.000

ERROR

4-20mA

English (GB)

You can reset the first and second function levels to the default settings when the power supply is being connected.

The service level settings (pump type, unit of display for the dosing flow, input and output settings) and the values for the total dosing capacity and operating hours counter remain as they are.

The pump is disconnected from the power supply.

1. Simultaneously press the "Up" and "Down" buttons and hold them down.

2. Switch on the power supply. – "boot" appears in the display.

3. Release the "Up" and "Down" buttons. – All modified settings at the first and second function levels

are reset to the default settings.

9.9 Current signal control 0-20 mA / 4-20 mA

For controlling the dosing pump via an external current signal of 0-20 mA (4-20 mA)

4-20 mA current signal control

If the current input signal falls below 2 mA, the error relay is switched, as an error has probably occurred at the signal source or on the cable.

• The error signal relay switches on. The LED flashes red.

• "4-20 mA" and "ERROR" flash in the display.

TM03 6605 4506

Fig. 35 Display: 4-20 mA current signal control

Fig. 33

Fig. 34 Display: 4-20 mA current signal control

• The flow rate is proportional to a current input signal of

• Above 19.5 mA, the pump runs in continuous operation at

• Below 0.2 (4.2) mA, the pump switches off.

• Use the "Start/Stop" button to start or stop the pump.

Display: 0-20 mA current signal control

0-20 mA (4-20 mA).

maximum dosing flow (Q

Default setting for Q 3 bar (default calibration value). Once the pump has been calibrated, the current signals must be weighted. See sections 9.9.2 With calibrated pump and 9.9.3 Setting the weighting.

The pump must be started first in this operating mode (LED lights up green and "Run" appears in the display).

max.

is the dosing flow up to

max.

TM03 6603 4506TM03 6604 4506

The assignment between the current signal and flow rate is

0 mA 4 mA 8 mA 12 mA 16 mA 20 mA

[mA]

Q [l/h]

/ I

out

0-20 mA

4-20 mA

out

4-20 mA, manual,

kontakt

1..

2..

max

default (Q

kal

)

50 l/h

20 l/h

40 l/h

10 l/h

30 l/h

max.

default (Q

cal

)

Iin / I

out

0-20 mA

4-20 mA

out

4-20 mA, manual,

contact

Iin [mA]

Note

linear.

• With 0-20 mA current signal control, the curve for current input

and current output passes through Q = 0 at 0 mA and the value pair Q

max.

) at 20 mA (curve 1a).

cal

• With 4-20 mA current signal control, the curve for current input

and current output passes through Q = 0 at 4 mA and the value pair Q

max.

) at 20 mA (curve 2a).

cal

• With manual or contact control, the curve for current output

passes through Q = 0 at 4 mA and the value pair Q at 20 mA (curve 2a).

The default setting for Q default calibration at 3 bar.

is the maximum dosing flow at

max.

cal

English (GB)

)

Fig. 36 Current input and current output with default setting

9.9.1 Direct weighting of the current signal input and output

Weighting while the pump is running can be carried out in the first function level. The currently set value increases or decreases for the maximum flow rate Q Q

select mA max.

max. (Qcal

), or with weighting set value

Setting the weighting

The parameters for 0-20 mA and for 4-20 mA are independent of one another. The weighting parameters are modified and saved according to the set operating mode.

Select the current control used (0-20 mA / 4-20 mA) before weighting.

Weighting can be set independently of the current input value that is currently set. The dosing flow value [l/h] that corresponds to the set current input value [mA] always appears in the display.

1. When the pump is running or stopped, press and hold down the "Up" button for approximately 5 seconds.

– "0-20 mA" or "4-20 mA", "Analog" and "l/h" flash in the

display.

2. Use the "Up" and "Down" buttons to increase or decrease the currently set value for the maximum flow rate.

The curve for current input / current output now passes as follows:

• With 0-20 mA (4-20 mA) current signal control, the curve for

current input and current output passes linearly through Q = 0 at 0 mA (4 mA) and the currently set value for the maximum flow rate Q

select max.

The set weighting is saved in the pump. The values are retained, e.g. when the power supply is switched off, and are also active when current weighting is called in the second function level.

at 20 mA (curves 1b and 2b).

TM03 6675 4506

Even for current input / current output assignments that are

0 mA 4 mA 8 mA 12 mA 16 mA 20 mA

[mA]

Q [l/h]

/ I

out

0-20 mA

4-20 mA

out

4-20 mA, manual,

kontakt

1..

2..

max

default (Q

kal

)

50 l/h

20 l/h

select max.

40 l/h

10 l/h

30 l/h

max.

default (Q

cal

)

Iin / I

out

0-20 mA

4-20 mA

out

4-20 mA, manual,

contact

select max.

Iin [mA]

0 mA 4 mA 8 mA 12 mA 16 mA 20 mA

[mA]

select mA max. b

max.

select mA max. a

max.

select mA min.

min.

Q [l/h]

50 l/h

20 l/h

40 l/h

10 l/h

30 l/h

select mA max. a

/ mA

max.

select mA min.

/ mA

min.

Iin [mA]

select mA max. b

/ mA

max.

Note

English (GB)

already weighted in the second function level (see curve 3a), subsequent weighting can be set or weighting can be shifted here. The value for the maximum flow rate Q mA

is shifted (curve 3b).

max.

Fig. 37 Current input and current output with direct weighting

select mA max.

TM03 6676 4506

Fig. 38 Current input and current output with subsequent weighting

9.9.2 With calibrated pump

When calibrating the pump for your application and using current signal control and/or current output, proceed as follows:

1. Calibrate the pump.

2. Determine the maximum flow rate Q the pump: Q calibration, e.g. in manual mode, or the displayed flow rate in

is the maximum adjustable flow rate after

cal

by taking a reading on

cal

continuous operation (press and hold down the "Start/Stop" button for longer than 1 second).

3. To set the current input / current output weighting, see section

9.9.3 Setting the weighting.

For unweighted assignment (curves 1a, 2a, see fig. 34) select the following reference points:

L: mA H: mA

cal

is re-calibrated. This protects the user-defined

= 0 (4) mA / Q

min.

= 20 mA / Q

max.

select mA min.

select mA max.

is not updated automatically when the pump

value pairs. After calibration, new weighting may be required!

TM03 6677 4506

= 0 l/h

= Q

cal

9.9.3 Setting the weighting

Note

Analog

L:0.0

Down

Stop Start

Analog

0.000

l / h

0-20 mA

Down

Analog

10.00

l / h

0-20 mA

Stop Start

0-20 mA

Info

0-20 mA

Analog

H:20.0

Down

Stop Start

Analog

71.00

l / h

0-20 mA

Down

Analog

40.00

l / h

0-20 mA0-20 mA

0-20 mA

Stop Start

Flashing

Select value for current input mA

min.

0-20 mA

Select value for current input mA

max.

> mA

min.

Set the flow rate Q

mA min.

0 - 0.999 l/h 1 - 9.9 l/h 10 - 99.9 l/h

100 - Q

max.

[l/h]

Set the flow rate Q

mA max.

0 - 0.999 l/h 1 - 9.9 l/h 10 - 99.9 l/h

100 - Q

max.

[l/h]

The setting options for weighting depend on the selected current signal control. The parameters for 0-20 mA and for 4-20 mA are independent of one another. The weighting parameters are modified and saved according to the set operating mode.

Select the current control operating mode used later (0-20 mA / 4-20 mA) manually or via contact signal before weighting. (Weighting of the control output for manual control mode or contact signal control is the same as current weighting 4-20 mA.)

English (GB)

Fig. 39

Setting the weighting

In the second function level, first enter the values for reference pair L:

The display shows

• the current value for mA

The default value is "L:0.0 mA" ("L:4.0 mA").

• "Analog"

• "0-20 mA" ("4-20 mA") (flashing).

Proceed as follows:

1. Use the "Up" and "Down" buttons to enter the minimum current input mA (e.g. mA

2. Press the "Start/Stop" button.

= 6 mA).

min.

– The current value for the mA

appears in the display (the default value is 0.000).

min.

between 0 mA (4 mA) and 20 mA

assigned flow rate Q

min.

3. Use the "Up" and "Down" buttons to enter the desired value for flow rate Q

mA min.

at mA

min.

(e.g. Q

mA min.

= 10 l/h).

mA min.

Now enter the values for reference pair H:

1. Press the "Start/Stop" button. – The current value for mA

appears in the display (the

max.

default value is "H:20.0 mA").

2. Use the "Up" and "Down" buttons to enter the maximum current input mA

3. Press the "Start/Stop" button. – The current value for the mA

appears in the display (the default value is Q

max.

4. Use the "Up" and "Down" buttons to enter the desired value for flow rate Q

• Press the "Menu/Info" button (confirm the setting and move on

to the next menu item), or

• press the "Start/Stop" button (confirm the setting and close the

second function level).

mA max.

max.

> mA

at mA

(e.g. mA

min.

assigned flow rate Q

max.

(e.g. Q

max.

= 16 mA).

max.

mA max.

max.

= 40 l/h).

TM03 6682 4506

Result of weighting

Note

0 mA 4 mA 8 mA 12 mA 16 mA 20 mA

[mA]

Q [l/h]

50 l/h

20 l/h

select mA max. d

40 l/h

10 l/h

30 l/h

select mA max. e

select mA min. d

select mA min. e

Iin [mA]

select mA min. d

select mA max. e

select mA max. d

select mA min. e

0 mA 4 mA 8 mA 12 mA 16 mA 20 mA

in/out

[mA]

Q [l/h]

L: Q

select mA min.

= ____ / ____mA

min.

H: Q

select mA max.

= ____ / ____mA

max.

kal

L: Q

select mA min.

____/____ mA

min.

H: Q

select mA max.

____/____ mA

max.

cal

Q [l/h]

in/out

[mA]

Note

English (GB)

In the example, the following values were entered as reference points L

L H

: mA

and Hd:

= 6 mA, Q

min.

= 16 mA, Q

max.

select mA min.

select mA max.

= 10 l/h

= 40 l/h.

The curve for current input / current output now passes through Q = 0 at < 6 mA, from Q = 10 l/h at 6 mA to Q = 40 l/h at 16 mA, and through Q = 40 l/h at > 16 mA (curve 1d).

In the same way, it is also possible to enter a current weighting with a negative gradient. In order to do this, the value pair for reference point L must first be entered with the smaller mA value followed by reference point H.

In the example, the following values were entered as reference points L

L H

: mA

and He:

= 2 mA, Q

min.

= 16 mA, Q

max.

select mA min.

select mA max.

= 60 l/h

= 10 l/h.

The curve for current input/current output now passes through Q = 0 at < 2 mA, from Q = 60 l/h at 2 mA to Q = 10 l/h at 16 mA, and through Q = 10 l/h at > 16 mA (curve 1e).

Fig. 40 Result of weighting

The maximum flow rate of the pump must not be exceeded!

Note down the set current weighting in the following diagram for current input/current output:

1. Label the Q [l/h] axis for your working area.

2. Mark your reference points with the value pairs: L: mA H: mA

min.

max.

/ Q

select mA min.

/ Q

select mA max.

and

in the diagram.

3. Draw the curve as a line from L to H, vertically from Q

select mA min.

select mA max.

to the mA axis, and horizontally from

to the edge of the diagram.

9.10 Flow Monitor

9.10.1 Application notes

Dosing of degassing media (H agents)

• For a robust operation, set the number of permissible error strokes to a value higher than 10.

Dosing of antiscalent (viscosity higher than 20 mPa s)

• Use spring-loaded valves for high-viscosity media.

• When dosing viscous media, see also section

medium

Dosing of viscous media

• For media with a viscosity higher than 20 mPa s, spring-loaded suction and discharge valves are recommended.

For batch or timer operation

• Set the number of permissible error strokes to a value lower than the number of working strokes.

• If, while the pump is stopped, the pressure in the discharge line falls below the minimum pressure of 2 bar (e.g. in the event of a leak in the pressure-loading valve), increase the number of permissible error strokes so as to prevent unnecessary error messages.

Ensuring the counter-pressure by a pressure-loading valve:

• Check the counter-pressure 2 to 3 weeks after start-up.

– If it is below 2 bar, the pressure-loading valve has to be

re-adjusted.

– If the volume flow is not constant (as, for example, in the

case of contact or analog control), even small volume flows should not fall below the minimum pressure or minimum pressure difference of 2 bar.

TM03 6683 4506

9.10.2 Setting the Flow Monitor

In order for the pressure sensor (if installed) to function as a dosing controller, the dosing controller must be switched on.

To allow the pump to switch off in the event of overpressure and to set the cut-off pressure of the pump, the pressure control function must be switched on and set.

If no pressure sensor is connected, the pump determines the pressure from the motor current.

For applications with high requirements in terms of precision, the pressure control function must be used with a pressure sensor.

Switching on dosing controller

Menu item "flow" is open.

– "flow OFF" appears in the display.

1. Press the "Up" button.

– "flow ON" appears in the display. – The dosing controller is activated.

Switching on pressure control function

, chlorine bleaching

2O2

1.3.10 Dosing

Fig. 41 Diagram for current input / current output

This menu item only appears if the pressure sensor has already been detected once.

1. Press the "Menu/Info" button.

– Menu item "P" is open. – "P:OFF" appears in the display.

2. Press the "Up" button.

– "P:ON" appears in the display.

TM03 6614 4506

– The pressure control function is activated.

Fig. 42 Set cut-off pressure

P:OFF

bar

Down

10.0

Down

P:OFF

P:on

Stop

Start

6.0

Stop

Start

Info

bar

Second function level

Note

Caution

1.210

flow

l/h

Manual

1.210

flow*ERROR*

l/h

Manual

English (GB)

TM03 6680 4506

"P:ON" in the display:

1. Press the "Start/Stop" button. – The currently defined cut-off pressure is shown in the

display. The default value is the maximum counter-pressure of the pump type + 1 bar (pumps < 10 bar) or + 2 bar (pumps from 10 bar and up).

2. Use the "Up" and "Down" buttons to enter the desired cut-off pressure.

– You can set the cut-off pressure at which the pump is to be

stopped at around 2 bar up to the default value.

• Press the "Menu/Info" button (confirm the setting and move on

to the next menu item), or

• press the "Start/Stop" button (confirm the setting and close the

second function level).

The actual cut-off pressure p the set pressure p

set

: p

cut-off

is higher than

cut-off

= p

+ 0.5 bar.

set

When you are setting the cut-off pressure, be aware that the pressure measured in the dosing head is higher than the system pressure. It is advisable to display the measured pressure first, see section Displaying the pressure that has been measured. The set cut-off pressure should be higher than the measured pressure in the dosing head.

9.10.3 Dosing controller function

The pump software monitors the dosing process and emits a pulse for each dosing stroke. For each stroke, the "flow" display is momentarily turned off.

• When switched on, the electronics detects whether the dosing

controller is activated.

– "flow" appears in the display.

Suppression of dosing control function during start-up operation

60 error strokes* are permitted during the start-up operation, before an error signal is emitted. After a further 7 error strokes*, a dosing error is signalled.

* Default values, see also section

assignment

9.7.1 Modifying the switch

The start-up operation is triggered as follows:

• By switching on the power supply.

• Deaeration operation (continuously pressing the "Start/Stop" button).

The start-up operation is completed

• after 60 strokes.

• after the first valid stroke signalled by the dosing controller.

• after short switching on and off the pump by pressing the "Start/Stop" button.

The number of permissible error strokes can be increased or decreased since, depending on pump type for example, 60 strokes may take a considerable time during the start-up operation.

Dosing error (after start-up operation)

If, after seven successive strokes or after the number of strokes which have been defined by the user, the dosing controller does not emit a signal. This is recognised as an error:

• The error signal relay switches on, but the pump is not switched off.

• The LED flashes red.

• "flow" and "ERROR" flash in the display.

Fig. 43 Display: "Dosing controller"

TM03 6576 4506

Fig. 44 Display: "Dosing error"

Once the error has been corrected and seven valid strokes have

TM03 6574 4506

been measured or the "Start/Stop" button has been pressed, the error signal relay switches off.

• The pump returns to the state it was in before the error occurred.

9.10.4 Pressure control function

Caution

1.210

bar

l/h

Manual

8.99

ERROR* bar*

Manual

RUN*

….

Pump running

Pump waiting

2 sec.

10 min.

Pressure exceeded

English (GB)

To protect the pump and system against excessive pressure build-up, install an overflow valve in the discharge line.

The pressure sensor monitors the pressure in the dosing head. If the set pressure is exceeded by 0.5 bar, the pump switches off.

When switched on, the electronics detects whether the chamber pressure control function is activated.

• "bar" appears in the display.

Fig. 45 Display: "Pressure control"

Pressure exceeded

If, after one stroke, the cut-off pressure is exceeded, this is recognised as an error:

• The pump is stopped.

• The error signal relay switches on.

• The LED alternately flashes red and green.

• The last pressure value to be measured is displayed.

• "RUN", "ERROR" and "bar" flash in the display.

TM03 6577 4506TM03 6578 4506

Fig. 46 Display: "Pressure exceeded"

Pump restart attempts:

• First the pump makes four attempts to restart, each separated by a 2-second pause, if the chamber pressure has fallen below the cut-off pressure (p

• After the pressure was exceeded, the pump restarts smoothly. If the set cut-off pressure is exceeded, the pump is stopped again immediately.

• After four attempts, the pump waits 10 minutes before attempting to automatically restart again.

• The pump continuously attempts to restart if the chamber pressure decreases in this way.

Fig. 47 Pump restart attempts

Error correction

• Press the "Start/Stop" button to stop the pump and prevent it from restarting.

• Check the discharge valve and the installation on the discharge side and correct any errors, if necessary. For maintenance work, see section

• Check and correct the pressure setting, if necessary.

Once the error has been corrected,

• press the "Start/Stop" button to restart the pump.

– The pump returns to the state it was in before the error

occurred.

< p

act

set

10. Maintenance.

TM03 6579 4506

Displaying the pressure that has been measured

The pressure that has been measured during the pump operation can be displayed at any time.

• Press the "Menu/Info" button twice. (If only pressed once, the dosed quantity is displayed.)

– The pressure is displayed for approximately 10 seconds.

9.10.5 Error message - broken cable or faulty sensor

Note

2.42

ERROR*

Manual

RUN

l/h

Stop Start

Down

Stop Start

Down

St:60

ERROR

FE: 7

ERROR

Info

Permissible error

strokes during start-up

operation

Number of error

strokes until the error

message is triggered

Use the "Up" and "Down" buttons to set the number of permissible error strokes during the start-up operation in the range between 1 and 99.

Use the "Up" and "Down" buttons to set the number of error strokes until the error message is triggered during normal dosing operation in the range between 3 and 99.

Service level

If the dosing controller and/or the pressure control function are/is switched on, the missing signal is recognised and emitted as an error.

A faulty pressure sensor (broken cable) is displayed as follows:

• The error signal relay switches on.

• The pump is not stopped!

• The LED flashes red.

• "ERROR" flashes in the display.

Fig. 48 Display: "Broken cable"

Correct error

• Press the "Start/Stop" button twice to confirm the error and to stop the pump.

• Repair the cable break.

Once the error has been corrected,

• press the "Start/Stop" button to restart the pump.

– The pump returns to the state it was in before the error

occurred.

If the cable is broken, the dosing controller and pressure control/pressure display functions are not active. When the "Menu/Info" button is pressed twice to display the chamber pressure, only "— — —" is displayed.

English (GB)

TM03 6580 4506

If the sensor fault cannot be corrected immediately and if the pump is to continue to run without a sensor, switch off the dosing controller (flow: OFF) and pressure control function (P:OFF).

9.10.6 Changing the number of permissible error strokes

To change the number of permissible error strokes during the start-up operation and during normal dosing operation.

Fig. 49 Permissible error strokes

1. Open the service level.

2. Repeatedly press the "Menu/Info" button to navigate in the

service level until you reach menu item "St:60" (error stroke during start-up operation).

– The display shows "St" and the number of currently defined

error strokes that are permissible during the start-up operation.

3. Use the "Up" and "Down" buttons to set the number of

permissible error strokes during the start-up operation in the range between 1 and 99.

4. Press the "Start/Stop" button. – Confirm the setting and go to menu item "FE: 7". – The display shows "FE" and the number of currently defined

error strokes that are permissible during normal dosing operation.

5. Use the "Up" and "Down" buttons to set the number of error strokes until the error message is triggered during normal dosing operation in the range between 3 and 99.

6. Press the "Start/Stop" button – to confirm the new settings – to exit the service level – to open the first function level.

TM03 6575 4506

9.10.7 Calibrating the sensor after the sensor has been

Stop Start

P:OFF

CAL

P:ON

CAL

P:- - -

CAL

P:CAL

CAL

Info

Calibration of pressure sensor

Prepare the pump first!

Wait approximately 2 seconds

Service level

Caution

English (GB)

replaced

Once a sensor has been replaced, the new sensor must be calibrated to the ambient pressure.

Prepare the pump for the calibration:

1. Before screwing in the sensor, check that no dosing liquid is left in the place where the pressure sensor will be screwed in!

2. Screw in the new sensor with the correctly fitting O-ring.

3. Screw the sensor plug into socket 2.

4. Unscrew the suction valve.

Calibration of sensor

Fig. 50

Calibration of pressure sensor

1. Open the service level.

2. Repeatedly press the "Menu/Info" button to navigate in the service level until you reach menu item "P" (calibration of pressure sensor).

– "P:OFF" appears in the display.

3. Press the "Up" button to prepare the calibration. – "P:ON" appears in the display.

When the pump is prepared for the calibration, calibrate the pressure sensor:

1. Press the "Start/Stop" button. – "P:- - -" is displayed for approximately 2 seconds. – "P:CAL" appears in the display. – The pressure sensor has been calibrated.

2. Press the "Start/Stop" button – to confirm the new settings – to exit the service level – to open the first function level.

3. Fit the pump back on.

4. Screw in the suction valve.

TM03 6581 4506

Warning

Risk of chemical burns!

Wear protective clothing (gloves and goggles) when working on the dosing head, connections or lines!

Do not allow any chemicals to leak from the pump. Collect and dispose of all chemicals correctly!

The O-rings must be correctly placed in the specified groove.

Observe the flow direction (indicated by an arrow)!

Only tighten the valve by hand.

9.11 Batch menu / batch mode

Caution

OFF

Down

2,00

Down

l/h

Stop

Start

OFF

Stop

Start

1,05 L

Down

Stop

Start

Info

Input of dosing rate with "Up" / "Down"

Input of batch quantity with "Up" / "Down"

In batch mode, a defined batch quantity is dosed with a defined dosing flow. The batch can be dosed manually or by an external contact signal.

Risk of dosing errors!

Batch dosing using contact inputs may be insufficiently or excessively triggered in the event of an error if the pump/system is not monitored. The system must be protected redundantly.

Batch mode is controlled at the first and second function levels.

• The batch quantity is set in the second function level.

• The batch function is enabled in the first function level.

Input range for the batch quantity:

0.0 - 999.9 ml / 1.00 - 99.99 l / 100.0 - 999.9 l.

Setting batch dosing

English (GB)

Fig. 51

Setting batch dosing

In the second function level, "OFF B" appears in the display.

1. Press the "Up" button. – "ON B" appears in the display.

2. Press the "Start/Stop" button. – The currently defined flow rate appears in the display.

3. Use the "Up" and "Down" buttons to enter the desired flow rate.

4. Press the "Start/Stop" button. – The currently defined batch quantity appears in the display.

5. Use the "Up" and "Down" buttons to enter the desired batch quantity.

• Press the "Menu/Info" button (confirm the setting and move on

to the next menu item), or

• press the "Start/Stop" button (confirm the setting, close the

second function level and enable batch dosing in the first function level).

Performing batch dosing

• In the first function level, only the batch function is displayed

with the "Batch manual" and "Batch contact" menu items.

• "Stop" and the preset batch quantity appear in the display.

The LED lights up red.

Use the "Menu/Info" button to select

• "Batch manual", or

• "Batch contact".

Enabling batch mode

Batch manual

Batch dosing is triggered manually.

• Press the "Start/Stop" button. – The LED and the "Stop" segment are turned off and "Run"

flashes in the display.

– The preset batch quantity is dosed.

Batch contact

Batch dosing is triggered by an external contact signal. To activate the batch contact function,

• press the "Start/Stop" button. – The LED lights up green, the "Stop" segment is turned off

and "Run" appears in the display.

When the external contact signal is received, "Run" flashes in the display.

• The preset batch quantity is dosed.

During batch dosing

The batch quantity still to be dosed appears in the display. To display the batch quantity already dosed,

• press the "Down" button.

To display the total batch quantity,

• press the "Up" button.

Stop/start of pump during batch dosing

To stop the pump,

• press the "Start/Stop" button, or

• actuate remote on/off.

To re restart the pump,

• press the "Start/Stop" button. – The preset batch cycle continues. – For the "Contact" timer, an external contact signal must also

be received.

Deactivating the batch function

1. Open the second function level.

2. Repeatedly press the "Menu/Info" button. – "ON B" appears in the display.

3. Press the "Up" button. – "OFF B" appears in the display. – The batch function is deactivated.

TM03 6615 4506

9.12 Timer menu / timer mode

Batch 1 Batch 2 Batch n

Dosing

Start time t

Repetition time t

Caution

OFF

Down

Stop

Start

Down

Stop

Start

Stop

Start

Stop

Start

Down

Stop

Start

Down

6.00

l/h

890.0

1:00

t 1

2:00

t 2

Info

English (GB)

In timer mode, a defined batch quantity is dosed with a defined dosing flow. The first dosing starts after the start time t elapsed. Batch dosing is then repeated after the repetition time t has elapsed until the user stops the process by pressing the "Start/Stop" button or with remote off.

• Input range for the batch quantity:

0.0 - 999.9 ml / 1.00 - 99.99 l / 100.0 - 999.9 l

• Input range for the times t 1 min. < t

< 999 h / 1 min. < t2 < 999 h

and t2:

Input: hh:mm.

Fig. 52 Timer mode

Risk of dosing errors!

If repetition time t the batch quantity at the set dosing flow within

is not long enough to dose

this time, the pump continues dosing until the current batch quantity is finished. The pump is then stopped and the next batch dosing is triggered after the next repetition time.

Batch dosing in timer mode may be insufficiently or excessively triggered in the event of an error if the pump/system is not monitored. The system must be protected redundantly.

Timer mode is controlled at the first and second function levels.

• The batch quantity and times t function level.

and t2 are set in the second

• Timer mode is enabled in the first function level.

has

TM03 6616 4506

Fig. 53 Setting timer mode

"OFF t" appears in the display.

1. Press the "Up" button.

– "ON t" appears in the display.

2. Press the "Start/Stop" button.

3. Use the "Up" and "Down" buttons to enter the desired dosing

flow. – The selected dosing flow appears in the display.

4. Press the "Start/Stop" button.

5. Use the "Up" and "Down" buttons to enter the desired batch

quantity. – The selected batch quantity appears in the display.

6. Press the "Start/Stop" button. – "t1" appears in the display.

7. Use the "Up" and "Down" buttons to enter start time t

8. Press the "Start/Stop" button. – "t2" appears in the display.

9. Use the "Up" and "Down" buttons to enter repetition time t

• Press the "Menu/Info" button (confirm the setting and move on

to the next menu item), or

• press the "Start/Stop" button (confirm the setting, close the

second function level and enable timer mode in the first function level).

TM03 6617 4506

Selecting "Manual" or "Contact" timer mode

Note

Caution

• When the pump is running (LED lights up green), press the "Start/Stop" button.

– "Stop" and the preset start time t

The LED lights up red.

appear in the display.

– "Manual" or "Contact" appears in the display ("Manual" is

default setting).

In the first function level, only the timer function is displayed with the "Timer manual" and "Timer contact" menu items.

• Use the "Menu/Info" button to select

– "Timer manual", or – "Timer contact".

Enabling timer mode

Timer manual

Batch dosing with the preset pause time is triggered manually.

• Press the "Start/Stop" button.

– The LED lights up green, the "Stop" segment is turned off

and "Run" flashes in the display.

– The preset batch cycle is started.

Timer contact

Batch dosing with the preset pause time is triggered by an external contact signal.

To activate the batch contact function,

• press the "Start/Stop" button.

– The LED lights up green, the "Stop" segment is turned off

and "Run" appears in the display.

When the external contact signal is received, "Run" flashes in the display.

• The preset batch cycle is started.

During pause times

The time remaining until the next dosing appears in the display. To display the time already elapsed,

• press the "Down" button.

To display the total time t

or t2,

• press the "Up" button.

During timer dosing

The batch quantity still to be dosed appears in the display. To display the batch quantity already dosed,

• press the "Down" button.

To display the total batch quantity,

• press the "Up" button.

Stop/start of pump during timer dosing

To stop the pump,

• press the "Start/Stop" button, or

• actuate remote on/off.

To restart the pump,

• press the "Start/Stop" button.

– The preset batch cycle continues. – For the "Contact" timer, an external contact signal must also

be received.

Deactivating the timer function

1. Open the second function level.

2. Repeatedly press the "Menu/Info" button.

– "ON t" appears in the display.

3. Press the "Up" button.

– "OFF t" appears in the display. – The timer function is deactivated.

9.13 Creating a master/slave application

You can connect several secondary pumps and control the secondary pumps (slaves) via the first pump (master).

9.13.1 Master

All operating modes are available for the master pump:

• Manual

• Contact

• Batch dosing with manual/contact start

• Timer mode with manual/contact start

• Current control.

Select the output signal of the master pump in the service level (relay 1) (output socket 3):

• Stroke signal (emits one output signal per stroke) must be used for manual or current control of the master pump, or

• pulse input (emits one output signal per contact input signal) must be used for contact control of the master pump.

Alternatively select the current output (output socket 2) for current control of the slave pump.

Please note that the current output can differ from the current input, e.g. when the pump is stopped, and please observe the modified current output values with weighted current control.

9.13.2 Slave

The following operating modes are available for slave pumps in contact or current control (input socket 4):

• Contact

• Batch dosing with contact start

• Timer mode with contact start

• Current control.

The settings for the operating modes of the slave pumps are implemented independently of settings for the master pump.

Unused pulse inputs from the master pump are forwarded to the slave pumps when output signal = pulse input is set. They are processed on the slave pumps according to the slave pump settings!

English (GB)

9.14 Hotkeys / info keys

English (GB)

The following important displays and functions of the DDI 222 can be accessed quickly using button combinations (hotkeys).

Service functions

Function Operating state of the pump Activate function / display Deactivate function / display

Suction.

Move back the diaphragm for servicing.

Boot function.

Delete the total dosing capacity.

Display functions in batch and timer operation

Display/function Operating state of the pump Activate function / display Deactivate function / display

Display the batch quantity already dosed since start of the batch.

Display total batch quantity. Press the "Up" button. Release the "Up" button. Display the time that has

already elapsed. Display the total time. Press the "Up" button. Release the "Up" button.

In "Run", "Stop" or "Menu/Info" mode.

The pump must be in "Stop" mode.

The pump is disconnected from the power supply.

In "Run" mode.

During the batch dosing in batch or timer operation.

During pause times in timer operation.

Press the "Start/Stop" button for at least 1 second.

Simultaneously press the "Up" and "Down" buttons.

Simultaneously press the "Up" and "Down" buttons while switching on the power supply.

Press the "Menu/Info" button for 5 seconds.

Press the "Down" button. Release the "Down" button.

Release the "Start/Stop" button.

—

Other display functions

Display/function Operating state of the pump Activate function / display Deactivate function / display

Display the total dosing capacity.

Display the input current.

Display of pressure in the dosing head.

In "Run" mode. Press the "Menu/Info" button.

In "Analog" mode (0-20 mA / 4-20 mA).

In "Run" mode.

Press the "Down" button.

Press the "Menu/Info" button twice.

Display automatically jumps back after 5 seconds.

Display automatically jumps back after 10 seconds.

9.15 Pump safety functions

The DDI 222 pump is equipped with various safety functions as standard, which are indicated by the following indicators and behaviour of the pump.

Safety functions

Designation Error Pump behaviour LED/display/relay

The LED flashes red/green. "ERROR", "bar" and "l/min" appear in the display. The error signal relay switches on.

The LED flashes red. "ERROR", "bar" and "l/min" appear in the display. The error signal relay switches on.

The LED flashes red/green. "ERROR" and "bar" flash in the display.

The LED flashes red. "ERROR" and "MBS" flash in the display. The error signal relay switches on.

Power off.

Blocking safety.

Pressure control (can be switched on and off).

Diaphragm leakage detection (optional).

Flow Monitor (dosing controller).

Excess pressure in the dosing head, or motor power consumption too high.

Clogged discharge line / blocked motor.

When the pressure control function is switched on: Excess pressure in the dosing head (with pressure sensor) or motor power consumption too high.

Diaphragm leakage.

See section

9.10 Flow Monitor.

The pump stops. An attempt to restart automatically is made every 10 minutes.

The pump stops after 1 stroke.

The pump stops after 3 strokes. An attempt to restart automatically is made every 10 minutes up to 5 times with an increasing number of strokes.

The pump starts running again (in emergency mode).

Behaviour after error removal

Restart after error confirmation and pressing the "Start/Stop" button, or on an automatic restart attempt.

Restart after error confirmation and pressing the "Start/Stop" button.

Restart after error confirmation and pressing the "Start/Stop" button, or on an automatic restart attempt.

The error signal relay switches off after error confirmation.

English (GB)

10. Maintenance

Caution

Note

Caution

Stainless

steel

Plastic

2)1)

Stainless

steel

Plastic

English (GB)

10.1 General notes

Warning

When dosing dangerous media, observe the corresponding safety precautions!

Risk of chemical burns!

Wear protective clothing (gloves and goggles) when working on the dosing head, connections or lines!

Do not allow any chemicals to leak from the pump. Collect and dispose of all chemicals correctly!

Warning

The pump housing must only be opened by personnel authorised by Grundfos!

Repair must only be carried out by authorised and qualified personnel!

Switch off the pump and disconnect it from the power supply before carrying out maintenance work and repair!

10.2 Maintenance intervals

Observe section 10.5 Diaphragm breakage

For maximum safety, we recommend the pump version with diaphragm leakage detection.

• At least every 12 months or after 4,000 operating hours. When dosing crystallising liquids, more frequently.

• In the event of a fault.

10.2.1 Cleaning

• If necessary, clean all pump surfaces with a dry and clean cloth.

10.2.2 Cleaning the valves and diaphragm

• Clean the diaphragm and valves and replace, if necessary (for stainless-steel valves: inner valve parts).

10.3.2 Unscrewing suction and discharge valves / cleaning valves

1. Unscrew the suction and discharge valves.

2. Remove the screw part and valve seat with round nose pliers.

3. Dismantle the inner parts.

4. Clean all parts. Replace faulty parts by new ones.

– For plastic DN 8 valve, replace the valve completely. – For stainless-steel DN 8 valve or DN 20 valve, replace the

inner valve parts.

5. Re-assemble the valve.

6. Replace the O-rings by new ones. Refit the valve.

TM03 6685 4506TM03 6686 4506

Fig. 54 Stainless-steel or plastic DN 20 valve, spring-loaded

as an option

10.3 Cleaning suction and discharge valves

If possible, rinse the dosing head, e.g. by flushing it with water.

10.3.1 Switching off the pump

1. Switch off the pump and disconnect it from the power supply.

2. Depressurise the system.

3. Take suitable steps to ensure that the returning dosing medium is safely collected.

Fig. 55 Stainless-steel or plastic DN 20 valve, spring-loaded

as an option

The O-rings must be correctly placed in the specified groove.

Observe the flow direction (indicated by an arrow on the valve body)!

Only tighten the valve by hand.

10.4 Resetting the diaphragm

Note

Caution

10.6 Replacing the diaphragm

Warning

Danger of explosion, if dosing liquid has entered the pump housing!

If the diaphragm is possibly damaged, don’t connect the pump to the power supply!

If nothing indicates that dosing liquid has entered the pump housing, the diaphragm must be reset to the back dead point (end of suction stroke). As the stroke usually ends at the front dead point, reset the diaphragm as follows:

• Stop the pump (LED lights up red),

• Press the "Up" and "Down" buttons simultaneously. – The diaphragm is reset.

10.5 Diaphragm breakage

If the diaphragm leaks or is broken, dosing liquid escapes from the drain opening (fig. 56, 57, pos. H) on the dosing head flange.

In case of diaphragm breakage, the safety diaphragm (pos. S) and the O-rings (pos. Y) protect the pump housing against ingress of dosing liquid.

When dosing crystallising liquids the drain opening can be blocked by crystallisation. If the pump is not taken out of operation immediately, pressure can build up between the diaphragm (pos. Q) and the safety diaphragm in the flange (pos. S) and the O-rings (pos. Y). The pressure can press dosing liquid through the safety diaphragm or the screw holes 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 can produce explosive gases in the pump housing.

Warning

Danger of explosion, if dosing liquid has entered the pump housing!

When operating the pump with a damaged diaphragm, dosing liquid can enter the pump housing.

In case of diaphragm breakage, immediately separate the pump from the power supply!

Make sure that the pump cannot be put back into operation by accident!

Dismantle the dosing head without connecting the pump to the power supply. Make sure that no dosing liquid has entered the pump housing. Proceed as described in section 10.6 Replacing the diaphragm.

To avoid any danger resulting from diaphragm breakage, observe the following:

• Perform regular maintenance.

See section

• Never operate the pump with blocked or soiled drain opening. – If the drain opening is blocked or soiled, proceed as

described in section

• 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.

10.2 Maintenance intervals.

10.6 Replacing the diaphragm.

Warning

Risk of chemical burns!

Wear protective clothing (gloves and goggles) when working on the dosing head, connections or lines!

Do not allow any chemicals to leak from the pump. Collect and dispose of all chemicals correctly!

If possible, rinse the dosing head, e.g. by flushing it with water.

10.6.1 Resetting the diaphragm

If nothing indicates that dosing liquid has entered the pump housing when replacing the diaphragm, reset the diaphragm as described in section

10.6.2 Switching off the pump

1. Switch off the pump and disconnect it from the power supply.

2. Depressurise the system.

3. Take suitable steps to ensure that the returning dosing medium is safely collected.

10.6.3 Replacing the diaphragm

The O-rings must be correctly placed in the specified groove.

See fig. 56 or 57.

1. Loosen the screws (1q) on the dosing head (2).

2. Remove the dosing head (2) with dosing head disk (2q).

3. Unscrew the diaphragm (Q) counter-clockwise.

4. Make sure that the drain opening (H) is not blocked or soiled. Clean if necessary.

5. Only for DDI 150-4: loosen the screws (X) on the intermediate flange (5q) and remove the intermediate flange.

6. Check the safety diaphragm (S) for wear and damage. Additional check the screws (X) and o-rings (Y) for signs of contact with medium.

– If dosing liquid has possibly entered the pump housing

proceed as described in section

pump housing

– If nothing indicates that dosing liquid has entered the pump

housing, go on with the next step.

7. Replace the O-rings (Y) by new ones.

8. Only for DDI 150-4: replace the intermediate flange (5q) and cross-tighten the screws (X). Torque: 7 Nm (+ 1 Nm).

9. Screw in the new diaphragm (Q). – For pumps with diaphragm leakage detection: Screw in the

complete diaphragm package.

10. Replace the dosing head (2) with dosing head disk (2q) and cross-tighten the screws (1q). Torque: 7 Nm (+ 1 Nm).

11. Restart the dosing pump.

After initial start-up and after each time the diaphragm is changed, tighten the dosing head screws.

After approximately 6-10 operating hours or two days, cross-tighten the dosing head screws using a torque wrench.

Torque: 7 Nm (+ 1 Nm).

10.4 Resetting the diaphragm

10.6.4 Dosing liquid in the

English (GB)

Caution

Fig. 56 Replacing the diaphragm for DDI 60-10

10.7 Repair

Warning

The pump housing must only be opened by personnel authorised by Grundfos!

Repair must only be carried out by authorised and qualified personnel!

Switch off the pump and disconnect it from the voltage supply before carrying out maintenance work and repair!

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

TM06 1274 2014TM06 1275 2014

instructions. It must be copied, completed and attached to the pump.

The pump must be cleaned prior to dispatch!

If dosing liquid has possibly entered the pump housing, state that explicitly in the safety declaration! Observe section 10.5 Diaphragm breakage.

If the above requirements are not met, Grundfos may refuse to accept delivery of the pump. The shipping costs will be charged to the sender.

Fig. 57 Replacing the diaphragm for DDI 150-4

Pos. Components

Q Diaphragm (package)

2 Dosing head 1q Dosing head screws 2q Dosing head disk 3q Intermediate ring 5q Intermediate flange

S Safety diaphragm H Drain opening X Intermediate flange screws Y O-rings

10.6.4 Dosing liquid in the pump housing

Warning

Danger of explosion!

Immediately separate the pump from the power supply!

Make sure that the pump cannot be put back into operation by accident!

If dosing liquid has entered the pump housing:

• Send the pump to Grundfos for repair following the instructions given in section

• If a repair isn’t economically reasonable, dispose of the pump observing the information in section

10.7 Repair.

12. Disposal.

11. Fault finding chart

Note

Fault Cause Remedy

1. Dosing pump does not run.

2. Pump does not suck in or dose.

3. Dosing pump does not suck in.

4. Dosing pump does not dose.

5. Dosing flow of the pump is inaccurate.

6. Liquid leaks out of the hole in the intermediate flange between the pump and the dosing head.

a) Not connected to the mains. Connect the power supply cable. b) Incorrect mains voltage. Switch off the pump. Check voltage and motor. If the

motor is faulty, return the pump for repair. c) Electrical failure. Return the pump for repair. a) Crystalline deposits in the valves. Clean the valves. b) Empty dosing tank. Fill dosing tank. c) Air in the suction line and dosing head. Fill dosing head and suction line. d) Valves not correctly assembled. Assemble the valve inner parts in the right order and

check or possibly correct the flow direction. a) Leaking suction line. Replace or seal the suction line. b) Cross-section of the suction line too small or

suction line too long. c) Clogged suction line. Rinse or replace the suction line. d) Foot valve covered by sediment. Suspend the suction line from a higher position. e) Buckled suction line. Install the suction line correctly. Check for damage. f) Crystalline deposits in the valves. Clean the valves. g) Diaphragm broken or diaphragm tappet torn out. Replace the diaphragm. h) Excess counter-pressure. Depressurise the system on the discharge side of the

i) Empty dosing tank. Fill the dosing tank. a) Viscosity or density of medium too high. Check the installation. b) Crystalline deposits in the valves. Clean the valves. c) Valves not correctly assembled. Assemble the inner valve parts in the right order and

d) Injection unit blocked. Check and possibly correct the flow direction, or

e) Incorrect installation of lines and peripheral

equipment. f) Empty dosing tank. Fill the dosing tank. g) Sealing elements not chemically resistant. Replace sealing elements. a) Degassing medium. Check the installation. b) Parts of the valves covered in dirt or incrusted. Clean the valves. c) Incorrect dosing flow display. Calibrate. d) Counter-pressure fluctuations. Install a pressure-loading valve and a pulsation

e) Suction lift fluctuations. Keep the suction level constant. f) Siphon effect (inlet pressure higher than

counter-pressure). g) Leaking or porous suction line or discharge line. Replace the suction line or discharge line. h) Parts in contact with the medium are not

resistant to it. i) Dosing diaphragm worn (incipient tears). Replace the diaphragm. Also observe the

j) Variation of the dosing medium (density,

viscosity). k) Overflow. Install or check suction and pressure pulsation

a) A diaphragm leakage has occurred.

Check with Grundfos specification.

pump.

check or possibly correct the flow direction.

remove the obstruction. Check the lines for free passage and correct

installation.

damper, if necessary.

Install a pressure-loading valve.

Replace with resistant materials.

maintenance instructions.

Check the concentration. Use an agitator, if necessary.

damper, recalculate installation, install a pressure-loading valve.

Replace the diaphragm.

English (GB)

For further error signals for the control unit, refer to the relevant section.

12. Disposal

English (GB)

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.

Appendix 1

Note

Safety declaration

Please copy, fill in and sign this sheet and attach it to the pump returned for service.

Fill in this document using english or german language.

Product type (nameplate)

Model number (nameplate)

Dosing medium

Fault description

Please make a circle around the damaged parts. In the case of an electrical or functional fault, please mark the cabinet.

Appendix

Please describe the error/cause of the error in brief.

Dosing liquid has possibly entered the pump housing. The pump must not be connected to the power supply! Danger of explosion!

We hereby declare that the pump has been cleaned and is completely free from chemical, biological and radioactive substances.

_____________________________________ Date and signature

_____________________________________ Company stamp

GrA3502

Declaration of conformity

Declaration of conformity 2

GB: EC declaration of conformity

We, Grundfos, declare under our sole responsibility that the products DDI 222, to which this declaration relates, are in conformity with these Council directives on the approximation of the laws of the EC member states:

ES: Declaración CE de conformidad

Nosotros, Grundfos, declaramos bajo nuestra entera responsabilidad que los productos DDI 222, a los cuales se refiere esta declaración, están conformes con las Directivas del Consejo en la aproximación de las leyes de las Estados Miembros del EM:

IT: Dichiarazione di conformità CE

Grundfos dichiara sotto la sua esclusiva responsabilità che i prodotti DDI 222, ai quali si riferisce questa dichiarazione, sono conformi alle seguenti direttive del Consiglio riguardanti il riavvicinamento delle legislazioni degli Stati membri CE:

PL: Deklaracja zgodności WE

My, Grundfos, oświadczamy z pełną odpowiedzialnością, że nasze wyroby DDI 222, których deklaracja niniejsza dotyczy, są zgodne z następującymi wytycznymi Rady d/s ujednolicenia przepisów prawnych krajów członkowskich WE:

RU: Декларация о соответствии ЕС

Мы, компания Grundfos, со всей ответственностью заявляем, что изделия DDI 222, к которым относится настоящая декларация, соответствуют следующим Директивам Совета Евросоюза об унификации законодательных предписаний стран-членов ЕС:

SI: ES izjava o skladnosti

V Grundfosu s polno odgovornostjo izjavljamo, da so naši izdelki DDI 222, na katere se ta izjava nanaša, v skladu z naslednjimi direktivami Sveta o približevanju zakonodaje za izenačevanje pravnih predpisov držav članic ES:

TR: EC uygunluk bildirgesi

Grundfos olarak bu beyannameye konu olan DDI 222 ürünlerinin, AB Üyesi Ülkelerin kanunlarını birbirine yaklaştırma üzerine Konsey Direktifleriyle uyumlu olduğunun yalnızca bizim sorumluluğumuz altında olduğunu beyan ederiz:

DE: EG-Konformitätserklärung

Wir, Grundfos, erklären in alleiniger Verantwortung, dass die Produkte DDI 222, auf die sich diese Erklärung bezieht, mit den folgenden Richtlinien des Rates zur Angleichung der Rechtsvorschriften der EU-Mitgliedsstaaten übereinstimmen:

FR: Déclaration de conformité CE

Nous, Grundfos, déclarons sous notre seule responsabilité, que les produits DDI 222, auxquels se réfère cette déclaration, sont conformes aux Directives du Conseil concernant le rapprochement des législations des Etats membres CE relatives aux normes énoncées ci-dessous:

NL: EC overeenkomstigheidsverklaring

Wij, Grundfos, verklaren geheel onder eigen verantwoordelijkheid dat de producten DDI 222 waarop deze verklaring betrekking heeft, in overeenstemming zijn met de Richtlijnen van de Raad in zake de onderlinge aanpassing van de wetgeving van de EG Lidstaten betreffende:

PT: Declaração de conformidade CE

A Grundfos declara sob sua única responsabilidade que os produtos DDI 222, aos quais diz respeito esta declaração, estão em conformidade com as seguintes Directivas do Conselho sobre a aproximação das legislações dos Estados Membros da CE:

RO: Declaraţie de conformitate CE

Noi, Grundfos, declarăm pe propria răspundere că produsele DDI 222, la care se referă această declaraţie, sunt în conformitate cu aceste Directive de Consiliu asupra armonizării legilor Statelor Membre CE:

SE: EG-försäkran om överensstämmelse

Vi, Grundfos, försäkrar under ansvar att produkterna DDI 222, som omfattas av denna försäkran, är i överensstämmelse med rådets direktiv om inbördes närmande till EU-medlemsstaternas lagstiftning, avseende:

CN: EC 产品合格声明书

我们格兰富在我们的全权责任下声明，产品 DDI 222，即该合格证所指之产品，符合欧共体使其成员国法律趋于一致的以下欧共理事会指令：

— 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 61326-1:2013-07, EN 61000-3-2:2006+A1:2009+A2:2009, EN 61000-3-3:2013.

This EC declaration of conformity is only valid when published as part of the Grundfos installation and operating instructions.

Pfinztal, 1st May 2014

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.

Argentina

Bombas GRUNDFOS de Argentina S.A. Ruta Panamericana km. 37.500 Centro Industrial Garin 1619 - Garin Pcia. de B.A. Phone: +54-3327 414 444 Telefax: +54-3327 411 111

Australia

GRUNDFOS Pumps Pty. Ltd. P.O. Box 2040 Regency Park South Australia 5942 Phone: +61-8-8461-4611 Telefax: +61-8-8340 0155

Austria

GRUNDFOS Pumpen Vertrieb Ges.m.b.H. Grundfosstraße 2 A-5082 Grödig/Salzburg Tel.: +43-6246-883-0 Telefax: +43-6246-883-30

Belgium

N.V. GRUNDFOS Bellux S.A. Boomsesteenweg 81-83 B-2630 Aartselaar Tél.: +32-3-870 7300 Télécopie: +32-3-870 7301

Belarus

Представительство ГРУНДФОС в Минске 220125, Минск ул. Шафарнянская, 11, оф. 56 Тел.: +7 (375 17) 286 39 72, 286 39 73 Факс: +7 (375 17) 286 39 71

E-mail: minsk@grundfos.com

Bosnia/Herzegovina

GRUNDFOS Sarajevo Trg Heroja 16, BiH-71000 Sarajevo Phone: +387 33 713 290 Telefax: +387 33 659 079 e-mail: grundfos@bih.net.ba

Brazil

BOMBAS GRUNDFOS DO BRASIL Av. Humberto de Alencar Castelo Branco, 630 CEP 09850 - 300 São Bernardo do Campo - SP Phone: +55-11 4393 5533 Telefax: +55-11 4343 5015

Bulgaria

Grundfos Bulgaria EOOD Slatina District Iztochna Tangenta street no. 100 BG - 1592 Sofia Tel. +359 2 49 22 200 Fax. +359 2 49 22 201 email: bulgaria@grundfos.bg

Canada

GRUNDFOS Canada Inc. 2941 Brighton Road Oakville, Ontario L6H 6C9 Phone: +1-905 829 9533 Telefax: +1-905 829 9512

China

Grundfos Alldos Dosing & Disinfection

ALLDOS (Shanghai) Water Technology Co. Ltd. West Unit, 1 Floor, No. 2 Building (T 4-2) 278 Jinhu Road, Jin Qiao Export Processing Zone Pudong New Area Shanghai, 201206 Phone: +86 21 5055 1012 Telefax: +86 21 5032 0596 E-mail: grundfosalldos-C N@grundfos.com

China

GRUNDFOS Pumps (Shanghai) Co. Ltd. 50/F Maxdo Centre No. 8 Xing Yi Rd. Hongqiao Development Zone Shanghai 200336 PRC Phone: +86-21 6122 5222 Telefax: +86-21 6122 5333

Croatia

GRUNDFOS CROATIA d.o.o. Cebini 37, Buzin HR-10010 Zagreb Phone: +385 1 6595 400 Telefax: +385 1 6595 499 www.hr.grundfos.com

Czech Republic

GRUNDFOS 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 Phone: +358-(0)207 889 900 Telefax: +358-(0)207 889 550

France

Pompes GRUNDFOS Distribution S.A. Parc d’Activités de Chesnes 57, rue de Malacombe F-38290 St. Quentin Fallavier (Lyon) Tél.: +33-4 74 82 15 15 Télécopie: +33-4 74 94 10 51

Germany

GRUNDFOS Water Treatment GmbH Reetzstraße 85 D-76327 Pfinztal (Söllingen) Tel.: +49 7240 61-0 Telefax: +49 7240 61-177 E-mail: gwt@grundfos.com

Germany

GRUNDFOS GMBH Schlüterstr. 33 40699 Erkrath Tel.: +49-(0) 211 929 69-0 Telefax: +49-(0) 211 929 69-3799 E-mail: infoservice@grundfos.de Service in Deutschland: E-mail: kundendienst@grundfos.de

Greece

GRUNDFOS Hellas A.E.B.E. 20th km. Athinon-Markopoulou Av. P.O. B o x 7 1 GR-19002 Peania Phone: +0030-210-66 83 400 Telefax: +0030-210-66 46 273

Hong Kong

GRUNDFOS Pumps (Hong Kong) Ltd. Unit 1, Ground floor Siu Wai Industrial Centre 29-33 Wing Hong Street & 68 King Lam Street, Cheung Sha Wan Kowloon Phone: +852-27861706 / 27861741 Telefax: +852-27858664

Hungary

GRUNDFOS Hungária Kft. Park u. 8 H-2045 Törökbálint, Phone: +36-23 511 110 Telefax: +36-23 511 111

India

GRUNDFOS Pumps India Private Limited 118 Old Mahabalipuram Road Thoraipakkam Chennai 600 097 Phone: +91-44 4596 6800

Indonesia

PT GRUNDFOS Pompa Jl. Rawa Sumur III, Blok III / CC-1 Kawasan Industri, Pulogadung Jakarta 13930 Phone: +62-21-460 6909 Telefax: +62-21-460 6910 / 460 6901

Ireland

GRUNDFOS (Ireland) Ltd. Unit A, Merrywell Business Park Ballymount Road Lower Dublin 12 Phone: +353-1-4089 800 Telefax: +353-1-4089 830

Italy

GRUNDFOS Pompe Italia S.r.l. Via Gran Sasso 4 I-20060 Truccazzano (Milano) Tel.: +39-02-95838112 Telefax: +39-02-95309290 / 95838461

Japan

GRUNDFOS Pumps K.K. Gotanda Metalion Bldg. 5F, 5-21-15, Higashi-gotanda Shiagawa-ku, Tokyo, 141-0022 Japan Phone: +81 35 448 1391 Telefax: +81 35 448 9619

Korea

GRUNDFOS Pumps Korea Ltd. 6th Floor, Aju Building 679-5 Yeoksam-dong, Kangnam-ku, 135-916 Seoul, Korea Phone: +82-2-5317 600 Telefax: +82-2-5633 725

Latvia

SIA GRUNDFOS Pumps Latvia Deglava biznesa centrs Augusta Deglava ielā 60, LV-1035, Rīga, Tālr.: + 371 714 9640, 7 149 641 Fakss: + 371 914 9646

Lithuania

GRUNDFOS Pumps UAB Smolensko g. 6 LT-03201 Vilnius Tel: + 370 52 395 430 Fax: + 370 52 395 431

Malaysia

GRUNDFOS Pumps Sdn. Bhd. 7 Jalan Peguam U1/25 Glenmarie Industrial Park 40150 Shah Alam Selangor Phone: +60-3-5569 2922 Telefax: +60-3-5569 2866

Mexico

Bombas GRUNDFOS de México S.A. de C.V. Boulevard TLC No. 15 Parque Industrial Stiva Aeropuerto Apodaca, N.L. 66600 Phone: +52-81-8144 4000 Telefax: +52-81-8144 4010

Netherlands

GRUNDFOS Netherlands Velu we zo om 35 1326 AE Almere Postbus 22015 1302 CA ALMERE Tel.: +31-88-478 6336 Telefax: +31-88-478 6332 E-mail: info_gnl@grundfos.com

New Zealand

GRUNDFOS Pumps NZ Ltd. 17 Beatrice Tinsley Crescent North Harbour Industrial Estate Albany, Auckland Phone: +64-9-415 3240 Telefax: +64-9-415 3250

Norway

GRUNDFOS Pumper A/S Strømsveien 344 Postboks 235, Leirdal N-1011 Oslo Tlf.: +47-22 90 47 00 Telefax: +47-22 32 21 50

Poland

GRUNDFOS Pompy Sp. z o.o. ul. Klonowa 23 Baranowo k. Poznania PL-62-081 Przeźmierowo Tel: (+48-61) 650 13 00 Fax: (+48-61) 650 13 50

Portugal

Bombas GRUNDFOS Portugal, S.A. Rua Calvet de Magalhães, 241 Apartado 1079 P-2770-153 Paço de Arcos Tel.: +351-21-440 76 00 Telefax: +351-21-440 76 90

Romania

GRUNDFOS Pompe România SRL Bd. Biruintei, nr 103 Pantelimon county Ilfov Phone: +40 21 200 4100 Telefax: +40 21 200 4101 E-mail: romania@grundfos.ro

Russia

ООО Грундф ос Россия, 109544 Москва, ул. Школьная

Тел. (+7) 495 737 30 00, 564 88 00 Факс (+7) 495 737 75 36, 564 88 11

E-mail grundfos.moscow@grundfos.com

Serbia

GRUNDFOS Predstavništvo Beograd Dr. Milutina Ivkovića 2a/29 YU-11000 Beograd Phone: +381 11 26 47 877 / 11 26 47 496 Telefax: +381 11 26 48 340

Singapore

GRUNDFOS (Singapore) Pte. Ltd. 25 Jalan Tukang Singapore 619264 Phone: +65-6681 9688 Telefax: +65-6681 9689

Slovakia

GRUNDFOS s.r.o. Prievozská 4D 821 09 BRATISLAVA Phona: +421 2 5020 1426 sk.grundfos.com

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

Spain

Bombas GRUNDFOS España S.A. Camino de la Fuentecilla, s/n E-28110 Algete (Madrid) Tel.: +34-91-848 8800 Telefax: +34-91-628 0465

Sweden

GRUNDFOS AB (Box 333) Lunnagårdsgatan 6 431 24 Mölndal Tel.: +46 31 332 23 000 Telefax: +46 31-331 94 60

Switzerland

GRUNDFOS ALLDOS International AG Schönmattstraße 4 CH-4153 Reinach Tel.: +41-61-717 5555 Telefax: +41-61-717 5500 E-mail: grundfosalldos-CH@grundfos.com

Switzerland

GRUNDFOS Pumpen AG Bruggacherstrasse 10 CH-8117 Fällanden/ZH Tel.: +41-44-806 8111 Telefax: +41-44-806 8115

Taiwan

GRUNDFOS Pumps (Taiwan) Ltd. 7 Floor, 219 Min-Chuan Road Taichung, Taiwan, R.O.C. Phone: +886-4-2305 0868 Telefax: +886-4-2305 0878

Thailand

GRUNDFOS (Thailand) Ltd. 92 Chaloem Phrakiat Rama 9 Road, Dokmai, Pravej, Bangkok 10250 Phone: +66-2-725 8999 Telefax: +66-2-725 8998

Turkey

GRUNDFOS POMPA San. ve Tic. Ltd. Sti. Gebze Organize Sanayi Bölgesi Ihsan dede Caddesi,

2. yol 200. Sokak No. 204 41490 Gebze/ Kocaeli Phone: +90 - 262-679 7979 Telefax: +90 - 262-679 7905 E-mail: satis@grundfos.com

Ukraine

Бізнес Центр Європа Столичне шосе, 103 м. Київ, 03131, Україна Телефон : (+38 044) 237 04 00 Факс.: (+38 044) 237 04 01

E-mail: ukraine@grundfos.com

United Arab Emirates

GRUNDFOS Gulf Distribution P.O. Box 16768 Jebel Ali Free Zone Dubai Phone: +971-4- 8815 166 Telefax: +971-4-8815 136

United Kingdom

GRUNDFOS Pumps Ltd. Grovebury Road Leighton Buzzard/Beds. LU7 4TL Phone: +44-1525-850000 Telefax: +44-1525-850011

U.S.A.

GRUNDFOS Pumps Corporation 17100 West 118th Terrace Olathe, Kansas 66061 Phone: +1-913-227-3400 Telefax: +1-913-227-3500

Uzbekistan

Grundfos Tashkent, Uzbekistan The Representative Office of Grundfos Kazakhstan in Uzbekistan 38a, Oybek street, Tashkent Телефон: (+998) 71 150 3290 / 71 150 3291 Факс: (+998) 71 150 3292

Addresses revised 21.05.2014

Grundfos companies

96690281 0514

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Grundfos DDI 222 Series, DDI 222 60-10, DDI 222 150-4, DDI 150-4, DDI 60-10 Installation And Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

English (GB)

1. General information

1.1 Introduction

1.2 Service documentation

1.3 Information about the product

1.3.1 Pump types

1.3.2 Connection size

1.3.3 Pump performance

1.3.4 Accuracy

1.3.6 Sound pressure level

1.3.7 Enclosure class

1.3.8 Required energy

1.3.9 Ambient and operating conditions

1.3.10 Dosing medium

1.4 Applications

1.4.1 Appropriate, acceptable and correct usage

1.5 Warranty

2. Safety

2.1 Identification of safety instructions in this manual

2.2 Qualification and training of personnel

2.3 Risks when safety instructions are not observed

2.5 Safety instructions for the operator/user

2.6 Safety instructions for maintenance, inspection and installation work

2.7 Unauthorised modification and manufacture of spare parts

2.8 Improper operating methods

2.9 Safety of the system in the event of a failure in the dosing system

2.4 Safety-conscious working

2.10 Dosing chemicals

2.11 Diaphragm breakage

3. Transport and intermediate storage

3.1 Transport

3.2 Delivery

3.3 Unpacking

3.4 Intermediate storage

3.5 Return

4. Technical data

4.1 Identification

4.2 Type key

4.3 General description

4.3.1 HV variant for liquids which are more viscous than water

4.4 Safety functions

4.4.1 Diaphragm leakage detection (optional)

4.4.2 Pressure control

4.4.3 Dosing control (Flow Monitor)

4.5 Dimensional sketches

4.4.4 Flow compensation

4.6 Weight

4.7 Materials

4.8 Control unit

4.8.1 Interface (optional)

5. Installation

5.1 General information on installation

5.2 Installation location

5.2.1 Space required for operation and maintenance

5.2.2 Permissible ambient influences

5.2.3 Mounting surface

5.3 Mounting

5.4 Installation examples

5.4.1 Installation tips

5.5.2 Sizing of tube / pipe lines

5.5 Tube / pipe lines

5.5.1 General

5.5.3 Connecting the suction and discharge lines

6. Electrical connections

6.1 Connecting the signal lines for DDI 222

6.1.1 Diaphragm leakage signal / (pressure sensor - Flow Monitor)

6.1.2 Current output / Flow Monitor (pressure sensor)

6.1.3 Stroke/pulse signal / pre-empty signal / error signal

6.1.4 Remote on/off / contact input / current input

6.1.5 Empty signal only / pre-empty and empty signal

6.1.6 PROFIBUS (optional)

6.2 Connecting the power supply cable

7. Start-up/shutdown

6.2.1 Versions without mains plug

6.2.2 Version with mains plug

7.1 Initial start-up / subsequent start-up