Grundfos DDI 222 Series, DDI 222 60-10, DDI 222 150-4, DDI 150-4, DDI 60-10 Installation And Operating Instructions Manual
DDI 222
Dosing pump
Installation and operating instructions
GRUNDFOS INSTRUCTIONS
English (GB) Installation and operating instructions
Note
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
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14
15
15
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18
18
18
18
18
19
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
2
4
4
5
5
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
5
1.1 Introduction
6
6
These installation and operating instructions contain all the
information required for starting up and handling the DDI 222
6
diaphragm dosing pump.
6
6
If you require further information or if any problems arise, which
6
are not described in detail in this manual, please contact the
6
nearest Grundfos company.
6
1.2 Service documentation
7
If you have any questions, please contact the nearest Grundfos
7
company or service workshop.
8
9
1.3 Information about the product
9
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
45
46
46
46
46
47
47
48
49
50
2
1.3.3 Pump performance
Note
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)
3
1.3.9 Ambient and operating conditions
Caution
Caution
Caution
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.
4
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.
5
2.10 Dosing chemicals
Caution
Caution
Caution
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.
6
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
7
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/
B1
cementing diameter 12 mm
Tube 13/20 mm/
B2
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
2
pressure; 0.05 bar discharge
opening pressure
For abrasive media
5
(stainless steel only)
Spring-loaded
(DN 20, stainless-steel balls)
6
0.8 bar discharge opening
pressure
8
Note
3a
3b
2
D
H
Caution
Caution
Q1 Q2 Q3
2
D
L
L
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.
9
4.4.3 Dosing control (Flow Monitor)
Note
Note
A4
A3
H2
D1
C4
C1
207
172.5
16.5
Ø7
10
7
61.5
105
123
B3
B4
230
175
(159)
A5
H3
MLS
DS
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
A3
[mm]A4[mm]A5[mm]B3[mm]B4[mm]
C1
[mm]
C4
[mm]
D1
H2
[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
10
TM03 6663 4506
H3
[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!
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!
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
Maximum ohmic load:
50 VDC / 75 VAC, 0.5 A
English (GB)
11
5. Installation
Note
Caution
Caution
7
9.95
7
(159)
172.5
16.5
105
C1
1i
2i
3i
4i
5i
6i
7i
9i
10i
8i
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
12
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
6i
10i
p
15i
7i
>
p _ 1bar
p 1 bar
7i
14i
1
2
>
p -p _ 1bar
p
1
p
2
p2 - p1 1 bar
15i
10i
6i
p
4i
8i
• 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
13
• When installing the suction line, observe the following:
Caution
12i
11i
Caution
A
B
C
D
3b
D
C
3a
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!
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!
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
14
6. Electrical connections
Caution
1
3
5
42
1
2
3
4
5
6
1
2
3
4
optional
5
1
2
3
4
2
1
4
3
1
2
3
4
5
1
2
4
3
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
15
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.
16
6.2 Connecting the power supply cable
Caution
Caution
Caution
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).
17
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