Grundfos DME series, DME 12 series, DME 19 series, DME 48 series, DME 8 series Installation And Operating Instructions Manual

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DME
Installation and operating instructions Montage- und Betriebsanleitung Notice d’installation et d’entretien Istruzioni di installazione e funzionamento Instrucciones de instalación y funcionamiento Instruções de instalação e funcionamento
Installatie- en bedieningsinstructies Monterings- och driftsinstruktion Asennus- ja käyttöohjeet Monterings- og driftsinstruktion
GRUNDFOS INSTRUCTIONS
Declaration of Conformity
We GRUNDFOS declare under our sole responsibility that the prod­ucts DME, to which this declaration relates, are in conformity with the Council Directives on the approximation of the laws of the EEC Member States relating to
– Machinery (98/37/EEC).
Standard used: EN 292.
– Electromagnetic compatibility (89/336/EEC).
Standards used: EN 61 000-6-2 and EN 61 000-6-3.
– Electrical equipment designed for use within certain voltage lim-
its (73/23/EEC). Standards used: EN 60 335-1 and EN 60 335-2-41.
Konformitätserklärung
Wir GRUNDFOS erklären in alleiniger Verantwortung, daß die Pro­dukte DME, auf die sich diese Erklärung bezieht, mit den folgenden Richtlinien des Rates zur Angleichung der Rechtsvorschriften der EG-Mitgliedstaaten übereinstimmen:
– Maschinen (98/37/EWG).
Norm, die verwendet wurde: EN 292.
– Elektromagnetische Verträglichkeit (89/336/EWG).
Normen, die verwendet wurden: EN 61 000-6-2 und EN 61 000-6-3.
– Elektrische Betriebsmittel zur V erwendung innerhalb b estimmter
Spannungsgrenzen (73/23/EWG). Normen, die verwendet wurden: EN 60 335-1 und EN 60 335-2-41.
Déclaration de Conformité
Nous GRUNDFOS déclarons sous notre seule responsabilité que les produits DME auxquels se réfère cette déclaration sont confor­mes aux Directives du Conseil concernant le rapprochement des législations des Etats membres CEE relatives à
– Machines (98/37/CEE).
Standard utilisé: EN 292.
– Compatibilité électromagnétique (89/336/CEE).
Standards utilisés: EN 61 000-6-2 et EN 61 000-6-3.
– Matériel électrique destiné à employer dans certaines limites de
tension (73/23/CEE). Standards utilisés: EN 60 335-1 et EN 60 335-2-41.
Dichiarazione di Conformità
Noi GRUNDFOS dichia riamo sotto la nostra es clusiva respon sabilità che i prodotti DME ai quali questa dichiarazione se riferisce sono conformi alle Direttive del Consiglio concernente il ravvicinamento delle legislazioni degli Stati membri CEE relative a
– Macchine (98/37/CEE).
Standard usato: EN 292.
– Compatibilità elettromagnetica (89/336/CEE).
Standard usati: EN 61 000-6-2 e EN 61 000-6-3.
– Materiale elettrico destinato ad essere utilizzato entro certi limiti
di tensione (73/23/CEE). Standard usati: EN 60 335-1 e EN 60 335-2-41.
Declaración de Conformidad
Nosotros GRUNDFOS declaramos bajo nuestra única responsabili­dad que los productos DME a los cuales se refiere esta declaración son conformes con las Directivas del Consejo relativas a la aproxi­mación de las legislaciones de los Estados Miembros de la CEE sobre
– Máquinas (98/37/CEE).
Norma aplicada: EN 292.
– Compatibilidad electromagnética (89/336/CEE).
Normas aplicadas: EN 61 000-6-2 y EN 61 000-6-3.
– Material eléctrico destinado a utilizarse con determinadas lími-
tes de tensión (73/23/CEE). Normas aplicadas: EN 60 335-1 y EN 60 335-2-41.
Declaração de Conformidade
Nós GRUNDFOS declaramos sob nossa única responsabilidade que os produtos DME aos quais se refere esta declaração estão em conformidade com as Directivas do Conselho das Comunidades Europeias relativas à aproximação das legislações dos Estados Membros respeitantes à
– Máquinas (98/37/CEE).
Norma utilizada: EN 292.
– Compatibilidade electromagnética (89/336/CEE).
Normas utilizadas: EN 61 000-6-2 e EN 61 000-6-3.
– Material eléctrico destinado a ser utilizado dentro de certos limi-
tes de tensão (73/23/CEE). Normas utilizadas: EN 60 335-1 e EN 60 335-2-41.
¢‹ÏˆÛË ™щММЮЪКˆЫЛ˜
Ì›˜ Ë GRUNDF OS ‰ЛПТУФùМВ МВ ·рФОПВИЫЩИО¿ ‰ИО ‹ М·˜ Вùõ‡ÓË ÞÙÈ Ù· ðÚÔÈÞÓÙ· DME ÛùММФЪКТУФУЩ·И МВ ЩЛУ ‰ËÁ›· ÙÔù
ùÌ‚ÔùÏ›Ôù Вр› ЩЛ˜ Ы‡БОПИЫЛ˜ ЩˆУ УÞÌˆÓ ÙˆÓ Ú·ÙÒÓ MÂÏÒÓ Ù˘ ùÚˆð·È΋˜ ÓˆÛ˘ Û ۯ¤ ÛË Ì ٷ
– ªË¯·Ó‹ Ì·Ù· (9 8/37/EE C).
¶ÚÞÙùðÔ ðÔù ¯ЪЛЫ ИМФрФИ‹õËÎÂ: EN 292.
∏ПВОЩЪФМ·БУЛЩИО‹ ЫùÌ‚·ÙÞÙË Ù· (89/336/EEC).
¶ÚÞÙùð· ðÔù ¯ЪЛЫИМФрФИ‹õËηÓ: EN 61 000-6-2 Î·È EN 61 000-6-3.
∏ПВОЩЪИО¤˜ ЫùÛÎÂù¤˜ ۯ‰ȷṲ̂Ó˜ ÁÈ¿ ¯Ú‹ÛË ÂÓÙÞ˜
ФЪИЫМ¤УˆУ ФЪ›ˆУ ЛПВОЩЪИО‹˜ Щ¿ЫЛ˜ (73/23/EEC). ¶ЪÞÙùð· ðÔù ¯ЪЛЫИМФрФИ‹õËηÓ: EN 60 335-1 Î·È EN 60 335-2-41.
Overeenkomstigheidsverklaring
Wij GRUNDFOS verklaren g eheel onder eige n verantwoordelijkheid dat de produkten DME waarop deze verklaring betrekking heeft in overeenstemming zijn met de Richtlijnen van de Raad inzake de onderlinge aanpassing van de wetgevingen van de Lid-Staten betreffende
– Machines (98/37/EEG).
Norm: EN 292.
– Elektromagnetische compatibiliteit (89/336/EEG).
Normen: EN 61 000-6-2 en EN 61 000-6-3.
– Elektrisch materiaal bestemd voor gebruik binnen bepaalde
spanningsgrenzen (73/23/EEG). Normen: EN 60 335-1 en EN 60 335-2-41.
Försäkran om överensstämmelse
Vi GRUNDFOS försäkrar under ansvar, att produkterna DME, som omfattas av denna försäkran, är i överensstämmelse med Rådets Direktiv om inbördes närmande till EU-medlemsstaternas lagstift­ning, avseende
– Maskinell utrustning (98/37/EC).
Använd standard: EN 292.
– Elektromagnetisk kompatibilitet (89/336/EC).
Använda standarder: EN 61 000-6-2 och EN 61 000-6-3.
– Elektrisk material avsedd för användning inom vissa spännings-
gränser (73/23/EC). Använda standarder: EN 60 335-1 och EN 60 335-2-41.
Vastaavuusvakuutus
Me GRUNDFOS vakuutamme yksin vastuullisesti, että tuotteet DME, jota tämä vakuutus koskee, noudattavat direktiivejä jotka
käsittelevät EY:n jäsenvaltioiden koneellisia laitteita koskevien lakien yhdenmukaisuutta seur.:
– Koneet (98/37/EY).
Käytetty standardi: EN 292.
– Elektromagneettinen vastaavuus (89/336/EY).
Käytetyt standardit: EN 61 000-6-2 ja EN 61 000-6-3.
– Määrättyjen jänniterajoitusten puitteissa käytettävät sähköiset
laitteet (73/23/EY). Käytetyt standardit: EN 60 335-1 ja EN 60 335-2-41.
Overensstemmelseserklæring
Vi GRUNDFOS erklærer under ansvar, at produkterne DME, som denne erklæring omhandler, er i overensstemmelse med Rådets direktiver om indbyrdes tilnærmelse til EF medlemsstaternes lovgiv­ning om
– Maskiner (98/37/EØF).
Anvendt standard: EN 292.
– Elektromagnetisk kompatibilitet (89/336/EØF).
Anvendte standarder: EN 61 000-6-2 og EN 61 000-6-3.
– Elektrisk materiel bestemt til anvendelse inden for visse
spændingsgrænser (73/23/EØF). Anvendte standarder: EN 60 335-1 og EN 60 335-2-41.
Bjerringbro, 1st January 2002
Jan Strandgaard
Technical Manager
4
CONTENTS
Page
1. General descr ipti on 4
1.1 Applications 4
1.2 Type key 5
2. Technical data 6
2.1 Mechanical da ta 6
2.2 Electrical data 6
2.3 Input/output d at a 6
2.4 Dimensions 7
3. Installation 7
3.1 Safety instructions 7
3.2 Installation envi r on m en t 7
3.3 Installation of p um p 7
3.4 Installation example 8
3.5 Electrical connection 8
3.6 Connection overview 9
4. Functions 10
4.1 Control panel 10
4.2 Start/sto p of pump 11
4.3 Priming/ventin g of pum p 11
4.4 Level control 11
4.5 Indicator ligh ts and ala r m outp ut 11
4.6 Fieldbus communicat ion 12
4.7 Menu 13
4.8 Operating mod e s 14
4.9 Manual 14
4.10 Pulse 14
4.11 Analo g 14
4.12 Timer 16
4.13 Batch 17
4.14 Anti-c avita t io n 17
4.15 Capacit y l imi t at i on 18
4.16 Counte r s 18
4.17 Resett ing 19
4.18 Return 19
4.19 Language 19
4.20 Input se tu p 20
4.21 Measu rin g uni ts 21
4.22 Dosing monitoring 22
4.23 Control panel lock 23
5. Start-up 24
6. Calibration 25
6.1 Direct calibration 26
6.2 Indirect cali bra tio n 27
6.3 Check calibration 28
7. Maintenan ce 28
8. Service 28
9. Fault finding chart 29
10. Disposal 29
Before beginning in stallation proc ed ur es, these installation an d opera ting instr uc­tions should be studie d caref ull y. The in­stallation and opera tio n shou ld also be in accordance with local regulations and ac­cepted codes of go od p rac ti ce.
1. General description
The GRUNDFOS DME dosing pump is a self-priming diaphragm pump.
The pump c on sis t s o f:
•a cabinet incorporating the drive unit and elec- tronics,
•a dosing head with back plate, diaphr ag m, valves, connections and vent valve and
•a control panel incorporating display and but tons. The control panel can be fitted either to the end or to the side of the cabinet.
Being equipped with a stepper motor, this dosing pump is unique in its field. The stepper motor offers the possibility of varying the capacity by changing the duration of the dosing stroke. Furthermore, the mot or is co nt rolled in s uch a wa y that the dosing gets as even and constant as possi­ble, irrespective of the capacity range in which the pump is oper a ting.
This is carried out as follows: The speed of the suction stroke is kept constant and
the stroke relatively short, irrespective of the capa­city. Contra ry to con v en tional pump s, whic h gener ate the dosing st ro ke as a short pu l se, th e du ration of the dosing stroke will be a s lo ng a s po ssible. Th us, an even dosing without peak values is ensured. As the pump is always dosing at full stroke length, it en­sures the same high accuracy and suction capability, irrespective of the capacity, which is infinitely varia­ble in the ratio of 1:1000 .
The pump features an LCD display and a user­friendly control panel whi ch giv es acce ss to the pump functions .
1.1 Applications
The DME dosin g pu m p is designed f or h an dl in g chemicals within the following ranges of applications, among others:
• Drinking water treatment.
• Wastewater treatment.
• Swimming pool water treatment.
• Boiler water treatment.
• Cooling wate r tr ea tm en t.
• Proc ess wate r tr ea tm en t.
• Washing sy ste ms.
5
1.2 Type key
(Cannot be u sed f or p um p co nf i gu ra tio n. )
Example
:
Pump range DME ..
Control variant Code
Standard A Standard + alarm relay AR Standard + Profibus AP Standard + GENIbus AG
Dosing head ma t eria l Code
Polypropylene PP PVDF PV Stainless steel 1.4401 SS
Code Mains plug
F EU (Schuko) B USA, CAN GUK
IAU ECH JJP
Code
Connection, suction/disch arge
1 Tubing 6/9
Tubing 4/6 supplied with the pump
2 Tubing 6/9
Tubing 6/12+9/12
supplied with the pump 3 Tubing 4/6 4 Tubing 6/9 5 Tubing 6/12 6 Tubing 9/12 A Threaded Rp 1/4 B Threaded Rp 3/8 E Cementing d. 10 F Cemen ting d. 12
Code Valves
1 Standard valve 2 Spring-loaded valve
Valve ball material Code
Ceramics C Stainless ste el 1. 44 01 SS
Gasket material Code
EPDM E FKM V PTFE T
Maximum pres sur e [b ar]
Control panel Code
Front-fitted F Side-fitted S
Voltage Code
1 x 100-240 V, 50-60 Hz 3
DME 2-18 A-PP/E/C-F-3 1 1E F
6
2. Technical data
2.1 Mechanical data
*1 Irrespective of counter pressure *
2
Maximum suction lift 1 metre
2.2 Electrical data
2.3 Input/output data
The pump offers vario us in put a n d o u tput po ssib ili­ties, depending on contro l var iant.
DME 2 DME 8 DME 12 DME 19 DME 48
Maximum capa city without anti- cavi ta tio n *
1
[l/h] 2.5 7.5 12 18.5 4 8
Maximum capacity with anti-cavitation *
1
[l/h] 1.8 5.6 9 14.5 37 Maximum pressur e [bar ] 18 10 6 6.2 2.6 Maximum stroke rate per minute [stroke/min.] 180 180 180 151 151 Maximum suctio n l ift during operation [m] 6 Maximum suction lift wh en p r imin g w ith wet valves [m] 1.8 3 3 3 3 Maximum viscosity wi th spr in g -lo ad ed valves *
2
[mPas] 500 500 500 500 100
Maximum viscosity w ithou t spr ing- loade d valves *
2
[mPas]
200 200 200 200 100
Diaphragm diameter [mm] 28 38 42.5 55 77 Liquid tempe rat ur e [°C] 0 to 50 Ambient temperature [°C] 0 to 45 Accuracy of repeatability ±1% Sound pressure level [dB(A)] <70
DME 2, 8, 12 DME 19, 48
Supply voltage [VAC] 1 x 100-240
Maximum current consumption [A]
at 100 V 0.30 0.36 at 230 V 0.16 0.26
Maximum power co ns um pt i on P
1
[W] 18 22 Frequency [Hz] 50-60 Enclosure class IP 65 Insulation class B Supply cable 1.5 m H05RN-F with plug
Signal input
Voltage in level sensor input [VDC] 5 Voltage in pulse input [VDC] 5 Minimum pulse-repetition period [ms] 3.3 Impedance in analog 4-20 mA input [Ω]250 Maximum loop resistan ce in p uls e s ign a l cir cu it [ Ω ]350 Maximum loop resistan ce in level signal circuit [Ω]350
Signal ou tput
Maximum load of a larm relay output , a t oh m i c lo ad [ A ] 2 Maximum voltage, al arm relay output [V ] 250
7
2.4 Dimensions
See dimensions at the end of these instructions. All dimensions are in mm.
3. Installation
3.1 Safety in structions
• When wor kin g w ith ch emica ls, lo ca l sa fety r ules and regulations must be observed (e.g. wear pro­tective clothes).
• Before starting work on the dosing pump and sys­tem, disconnect the electricity supply to the pump, ensuring that i t ca nn ot be a ccidentally switche d on. Before reconnecting the ele ctr icity sup ply, make sure that the dosing hose is positioned in such a way that any chemical left in the dosing head is not ej ect ed , the r eby expos ing persons to danger.
• If the vent valv e in the do sin g head i s used, i t must be connected to a hose which is led back to the tank.
• When changing a chemical, make sure that the materials of the dosing pump and system are re­sistant to the new c he mic al. If th e re is any r isk of chemical reaction between the two types of chem­icals, clean the pump and system thoroughly be­fore adding the new chemical. Proceed as follows: Place the suction tub e in wate r and pr ess the button until residual chemical has been removed. Note: When the buttons and are pressed simultaneously, the pump can be set to run for a specific number of seconds at maximu m ca pa cit y. The remaining number of se cond s w ill a ppea r in the display. The maximum value is 3 00 s eco n ds.
3.2 Installation environment
• Expos ure to dir ect sun lig ht shou ld be avoided. This applies especially to pu m ps with p la stic d os­ing heads, as this material can be damaged by sunlight.
• If the pump is instal le d ou tsi d e, a n en clo su re o r similar protection is requir ed t o pr otect the pump against rain and simil ar weath ers.
3.3 Installation of pump
• See also the installation example in section
3.4
.
Note: The dosing head may contain water from the factory test. If a liquid which must not come into contact with wate r is to be d os ed , i t is r eco m ­mended to le t th e pu mp run with an ot he r l iqu id to remove the water from the dosing head before in­stallation.
• Always install the pump on the supporting foot with vertical suction and discharge ports.
• Always use suitable tools for the mounting of plas­tic parts. Never apply un ne ce ssa ry force.
• Make sure that the dosing pump and system are designed in such a way that neither system equip­ment nor buildings are dama ged in ca se of leak­age from the pump or rupture of hoses/pipes. The installation of l e ak ag e ho ses and collectin g ta nk s is recommended.
• Make sure th at the drain hol e in th e dosing head points downwards, see fig. 1. Note: It is important that the drain pipe/ho le is not inserted dir ec t in to the tank conten ts, as ga sse s may penetrate into the pump.
Fig. 1
100%
100%
TM01 8420 5099
hole
Drain
8
3.4 Installation exam ple
The drawing in fig. 2 shows an installation example.
Fig. 2
3.5 Electrical connection
• The electrical connection of the pump should be carried out by qualified pers ons in a cco r dance with local regulations.
• For electrical data of the pump, see section
2.2
.
• Do not lay signal cabl es, if any, together with power cables.
TM01 8421 1600
The DME pump ca n be installed in ma ny different ways. The sketch below s ho ws an example w ith side­fitted control panel. Th e ta nk is a G RUN DF OS c hemi cal ta nk wit h a G RUN DF OS leve l c on trol un it.
9
3.6 Connection overview
Fig. 3
Control input:
1 = Contact for pulse signal 2 = Contact for external on/off
Level input:
TM01 8422 0603
2
3
1
4
1
3
4
5
1
3
4
5
3
1
4
2
2
Alarm relay (control variant “AR” only)
Control cable, see table below
Level cable, see table below
“NO” black
“NC” blue
“Com” brown
Empty tank Low level
Number / colour 1 / brown 2 / white 3 / blue 4 / black 5 / grey Description
Function
Manual 2 2 Pulse 1 1 Pulse + external on/o ff 1 1 + 2 2 Analog + mA signal Analog + external on/off 2 2 + mA signal Timer + external on /off 2 2 Batch 1 1
Number / colour 1 / brown 2 / white 3 / blue 4 / black
Function
Low level Low level
Empty tank Empty tank
Low level Empty ta nk Low level + empty tank
Dosing monitoring Dosing monitoring
10
4. Functions
4.1 Control panel
Fig. 4
TM01 8423 0100
ml/h
100%
LCD display, see section
4.7
Navigation/ settings, see section
4.7
Menu, see section
4.7
On/off button, see section
4.7
Mains connectionM12 connection level control, see section
4.4
M12 connection pulse/analog input, see section
4.4
Connection alarm relay/bus. Control variants “AR”, “AP” and “ A G” , see sections
4.5
and
4.6
Red indicator light, see section
4.5
Green indicator light, see section
4.5
Maximum capacity (priming), see section
4.3
Navigation/ settings, see section
4.7
11
4.2 Start/stop of pump
The pump can be started/stopped in three different ways:
• Locally on the pump control panel.
• By mean s of an extern al on /off switch con necte d to the pulse input. See connection overview in section
3.6
.
• By switching on/ off t he e lectr ic ity su pp ly.
4.3 Priming/venting of pump
The pump control panel incorporates a button. Press this button if the maximum pump capacity is required ove r a s ho rt p er iod , e.g. during st ar t- up . When the button i s rel ea se d, th e pu mp au t oma tic a lly returns to the previou s oper at ing mod e.
During priming/venting, it is recommended to let the pump run without a counter pressure or to loosen the vent valve by giving it a 1/8 to 1/4 turn.
Note: When the butt on s and are pr ess ed si- multaneously, the pump can be set to run for a spe­cific number of seco nd s a t ma ximu m ca pacity. The remaining number of seco nds will appear in the dis ­play. The maximum value is 300 seconds.
4.4 Level control
The pump can be fitted with a level control unit for monitoring of the chemical level in the tank.
The pump can react to two level signals. The pump will react differently, depending on the influenc e on the individual level sensors.
* Control variant “AR” o nl y. See section
3.6
for connectio n of th e level control
unit and alar m output.
4.5 Indicator lights and alarm output
The green and red indicator lights on the pump are used for ope rat in g an d fault indicati on .
In control varia nt “A R ”, th e pump can activ at e an ex­ternal alarm s ign al by mea ns of a b ui lt -i n al arm r el ay. The alarm signal i s act i vat ed by m eans of an in te rn al potential-free contact.
The functions of the i ndica tor li ghts and the bu ilt-in alarm relay appear from th e table belo w:
!1
Control variant AR only.
!2
Requires connection to level sensors.
!3
Requires activation of the dosing monitoring function and connection to a dosing monitor.
Level sensors Pump reaction
Upper sensor
activated
(closed contact )
• Red indicat or lig h t is o n.
• Pump running.
• Alar m r elay activated.*
Lower sensor
activated
(closed contact )
• Red indicat or lig h t is o n.
• Pump stopped.
• Alar m r elay activated.*
100%
100%
Condition
Green
LED
Red
LED
Dis­play
Alarm
output
!1
Pump running
On Off
Normal
indication
Set to stop
Flash-
ing
Off
Normal
indication
Pump fault Off On EEPROM
Supply failure
Off Off Off
Pump run­ning, low chemical level
!2
On On
Normal
indication
Empty tank
!2
Off On
Normal
indication
Analog signal < 2 mA
Off On
Normal
indication
The dosed quantity is too small according to the sig­nal from the dosing monitor
!3
On On
Normal
indication
Overheat­ing
Off On
MAX.
TEMP.
132
NC NO C
132
NC NO C
1
23
NC NO C
132
NC NO C
1
23
NC NO C
1
23
NC NO C
1
23
NC NO C
1
23
NC NO C
1
23
NC NO C
12
4.6 Fieldbus communication
The pump can be configured for fieldbus applica­tions.
The following b u s t ype s ar e ava i la ble:
Separate instructions are supplied with each bus type.
Control variant Bus type
AP Profibus AG GENIbus
13
4.7 Menu
The pump features a user-friendly menu which is ac­tivated by pressing the button. During start-up, all texts will appear in English la ngua g e. T o s elect la n­guage, see section
4.19
.
All menu items are described in the following sec­tions. When appears at a menu item, it means that this item is activated. By sele ct ing “ RETURN” anywhere in the menu structure, you will return to the operating display without changes.
Fig. 5
See section
4.9
See section
4.23
See section
4.10
See section
4.17
See section
4.11
See section
4.18
See section
4.12
See section
4.19
See section
4.13
See section
4.15
See section
4.14
See section
4.20
See section
6
See section
4.21
See section
4.16
14
4.8 Operating modes
Note: The displayed l and ml v alu es ar e on ly re l iab l e
if the pump has been calibrated to the actual installa­tion, see section
6
.
The pump can run in five different operating modes:
•Manual
•Pulse
•Analog
•Timer (internal batch control)
• Batch (external batch control)
See description in the following sections.
4.9 Manual
The pump is dosi ng as constantl y and evenly as pos­sible, without a ny ex te rn al sig na l s.
Set the quanti ty to be dosed in l/h or ml/h. The pump automatically ch a ng es over betwee n th e me as ur i ng units.
Setting range: DME 2: 2.5 ml/h - 2.5 (1.8*) l/h
DME 8: 7.5 ml/h - 7.5 (5.6*) l/h DME 12: 12 ml/h - 12 (9*) l/h DME 19: 18.5 ml/h - 18.5 (14.5*) l/h DME 48: 48 ml/h - 48 (37*) l/h
* The figures in brac kets ind icat e the ma ximum ca-
pacity when the anti-ca vitation fu nction is acti­vated.
Fig. 6
4.10 Pulse
The pump is dosing according to an external pulse signal, i.e. a water meter with pulse output or a con­troller.
Set the quantity to be dosed per pulse in ml/pulse. The pump adjusts its capacity acco rding to two fac­tors:
• Frequency of external pulses.
• The set quantity per pulse. Setting range: DME 2: 0.000018 m l/pulse - 5 ml/pulse
DME 8: 0.000069 m l/pulse - 15 ml/pulse DME 12: 0.000111 ml/puls e - 24 ml/pulse DME 19: 0.000204 ml/puls e - 37 ml/pulse DME 48: 0.0053 0 ml/pulse - 96 ml/pulse
Fig. 7
If the set qu an tit y p e r p u lse mu l ti pl ie d by the pulse frequency exceeds the pump capacity, the pump will run at maximum capacity. Exc es s p uls es will be ig ­nored and the “actual capacity” display will flash.
4.11 Analog
The pump is d osin g according to a n ex te rn al an alog signal. The dosed quantity is proportional to the input value in mA.
4-20 (default): 4 mA = 0%.
20 mA = 100%.
20-4: 4 mA = 100%.
20 mA = 0%.
0-20: 0 mA = 0%.
20 mA = 100%.
20-0: 0 mA = 100%.
20 mA = 0%. See fig. 8. The capacity limitatio n will i nfl uenc e t he capacity.
100% corresponds to the maximum capacity of the pump or the set m aximu m ca pa city , s ee se ct ion
4.15
.
Fig. 8
Set valu e
TM02 4498 1102
Set quantity in ml/pulse
Actual capacity in ml/h or l/h
0 4 8 12 16 20
0
20
40
60
80
100
4-20 mA
0-20 mA
[mA]
[%]
15
Fig. 9
If 4-20 mA or 20-4 mA is selected and the signal falls below 2 mA, the pump will indicate a fault. This situa­tion occurs if the connection is interrupted, for in­stance if the wire is damaged.
Change the analog mo de as illu st ra te d in fig . 1 0:
Fig. 10
Value according to analog signal
Use the buttons
for navigation
16
4.12 Timer
The pump is dosing th e s et quan ti t y in bat che s a t t he maximum capacity or the set maximum capacity, see section
4.15
.
The time until the first dosing “NX” and the following sequences “IN” c an b e set in m i nu te s, ho u rs an d days. The maxim um t i me li mi t is 9 days, 23 ho ur s and 59 minut es (9 :2 3: 59 ). T he l o we st acceptable value is 1 minute.
The interna l time r cont inues even
if the pump is stopped by means of the on/off button, empty tank or stop signal , see fig . 11.
During operation, “NX” will alwa ys cou n t dow n fro m “IN” to zero. In th is way, the remaining tim e un til th e next batch can a l wa ys be r ea d.
“IN” must be higher than the time required to perform one batch. If “IN” is low er, t he n ext b at ch will be ig ­nored.
In case of supply fa ilu re , the s et qu a nti ty to be dosed, the “IN” time and the remaining “NX” time are stored. When the sup ply is re conn ecte d, the pu mp will start up with the “NX” time at the time of the sup­ply failure. In this way , t he ti me r cyc le will c ontin ue , but it has been delayed by the duration of the supply failure.
Fig. 11
Setting range: DME 2: 0.23 ml/batch - 5 l/batch
DME 8: 0.69 ml/batch - 15 l/batch DME 12: 1.11 ml/batch - 24 l/batch DME 19: 2.04 ml/batch - 37 l/batch DME 48: 5.3 ml/batch - 96 l/batch
Only values corresponding to complete dosing strokes (accordi ng to t he ca lib ra tio n fa ctor) ca n be selected.
Example: If the calibration factor is 23.3 (= 0.233 ml/ stroke), the minim um se tta bl e val ue in time r or batch mode will be 0.233 ml -> the n ext will be 0 .4 66 ml -> the next will be 0.699 ml, etc.
These steps wi ll continue up to a value correspond ­ing to 100 dosing strokes. Abov e this val ue, the set ­ting range has standard steps as in other operating modes.
If the calibration f ac tor is changed after se ttin g of timer or batch mode , the p ump will automatically re­calculate a new amount of dosing strokes per batch and change the dis pl a y val ue to t he ne ar est pos s ibl e value compared to the first one set.
Fig. 12
TM01 8942 0900
NX
IN
Quantity per bat ch
Set quantity per batch
Set IN value in minutes
Set IN value in hours
Set IN value in days
Set NX value in hours
Set NX value in minutes
Set NX value in days
17
4.13 Batch
The pump is dosi ng th e s et qua nt it y in bat c he s a t the maximum capacity or the set maximum capacity, see section
4.15
.
The quantity is dosed every time the pump receives an external pulse.
If the pump receives new pulses before the previous batch is performed, these pulses will be ignored.
Fig. 13
The setting range is the same as for Timer, see sec­tion
4.12
.
Fig. 14
4.14 Anti-cavitation
The pump features an anti-cavitation function. When this function is selected, the pump extends and smooths its suct ion stroke, resulting i n s of te r pr im­ing.
The anti-cavitation function is used:
• when pu mp in g liquids of high viscosity,
• in the case of a long suction tube and
• in the case of a high suction lift. The maximum pump capacity is reduced when this
function is selected. See section
2.1 Mechanical
data
.
Fig. 15
TM01 8947 0900
Pulse Pulse
Quantity per bat ch
Set value per batch
Operating display
18
4.15 Capacity limitat ion
This function offers the p ossib ility of r ed uci ng t he maximum pump capac ity (MAX CAP). It influen ces the function s in whic h the pu mp is nor mally oper ating at maximum capacity.
Under normal operating conditions, the pump cannot operate at a capacity which is higher than the one stated in the display. This does not apply to the max­imum capacity button , see section
4.3
.
Fig. 16
4.16 Counters
The pump can display “non-resettable” counters for:
•“QUANTITY” Accumulated value of dosed quantity in litres or US gallons.
•“STROKES” Accumulated number of dosing strokes.
•“HOURS” Accumulated number of operating hours (Power on).
•“POWER ON” Accumulated number of times the electricity sup­ply has been switc he d on .
Fig. 17
100%
Set maximum capacity
Operating display
Operating display
Total number of strokes
Total number of operating hours
Total number of starts
Total dosed quantity
19
4.17 Resetting
When “DEFAULT” is activate d, th e pum p will r etur n to the factory settings.
Note: The calibration is also set b ac k t o th e d e fau lt setting. This means that a new calibration is required when the “DEFAULT” function has been used.
Fig. 18
4.18 Return
Fig. 19
The “RETURN” function m ake s it p o ssible to r etur n from any level in the menu to the operating display without changes after the menu functions have been used.
4.19 Language
The display text can be displayed in one of the fol­lowing languages:
•English
•German
•French
• Italian
• Spanish
• Portugu es e
•Dutch
•Swedish
•Finnish
•Danish
•Czech
• Slovak
• Polish
• Russian
Operating display Operating display
without changes
20
Fig. 20
4.20 Input setup
Fig. 21 shows all possible settings. The level and st op i n pu ts ca n be ch an ge d fr om N O
(normally open) t o N C (no rm a lly clos ed ) fu nction. If changed, the i n pu ts mu st be s ho rt -circuited in no r ­mal operation.
For the analog input, one of the following signal types can be selected:
• 4-2 0 mA (defa ult),
• 20- 4 mA,
• 0-2 0 mA,
• 20- 0 mA. See also section
4.11 Analog
.
Change the level input to an input for dosing monitor­ing as illustrated i n fig. 2 1.
Fig. 21
Operating display Operating display Operating display
without changes
Use the buttons
for navigation
21
4.21 Measuring units
It is possible to s elect m etr ic units (l itr e/m illi litr e) o r US units (gallons/millilitre).
Metric measuring units:
In manual and analog modes, set the quantity to be dosed in litres per h our ( l/h ) or millilit re s p er hour (ml/h).
In pulse mode, set the qu an ti t y t o be dosed in ml/pulse. The actual capacity is indicate d in litres per hour (l/h) or millilitres per hour (ml /h).
For calibration, set the quantity to be dosed in ml per 100 strokes.
In timer and batch modes, set the quantity to be dosed in litres (l) or millilitres (ml).
• Under th e “ QUANTITY ” me nu ite m in th e “COUNTERS” me nu, the dosed qu an ti t y i s in di ­cated in litres.
US measuring units:
In manual and analog modes, set the quantity to be dosed in gallons per ho ur (gp h).
In pulse mode, set the quantity to be do se d in ml/pulse. The actual capacity is indicated in gallons per hour (gph).
For calibration, set the quan tity to b e do se d in ml per 100 strokes.
In timer and batch modes, set the quantity to be dosed in gallons (gal).
• Under th e “QUANTI TY” m e nu item in the “COUNTERS” menu, the dosed quantity is indi­cated in US gallons (gal).
Fig. 22
Operating display Operating display
3 x
22
4.22 Dosing monitoring
A dosing monitor is available as an accessory . Sepa­rate instructions are su pp lie d with t he m oni tor.
Fig. 23
The dosing moni tor is desig ned t o moni tor the dos ing of liquids whi c h ma y cau se g as accumulation in the dosing head, thus stopping the dosing process even if the pump is still ope ratin g.
For every meas ur ed d osing stroke, t he d os ing m on i ­tor gives a pulse signal to the level input so that the pump can compare performed dosing strokes (from internal stroke sensor) with externally measured physical strokes (from the dosing monitor). If an ex­ternal dosing str o ke is n o t m e asu re d to ge th er wi th the internal dos ing stroke, this is co ns ide re d a fa ult that may have been provoked by empty tank or gas in the dosing head.
TM02 2029 3201
Monitor mounted on the suction side of the pump
Dosing stroke measu re d
23
4.23 Control panel lock
It is possible to l o ck t he b ut ton s on th e con tr ol pa ne l to prevent malfunction of the pump. The locking function can be set to “ON” or “OFF”. The default setting is “OFF”.
A PIN code must be entered to change from “OFF” to “ON”. When “ON” is selected for the first tim e, “_ _ _ _” will appear in t he d isp lay. I f a co d e ha s a l­ready been entered, it will a ppe ar wh en a n atte mp t to change to “O N” is ma d e. T his co de ca n ei the r be re-entered or changed.
If no code has been entered, a code must be set in the same way as the “NX” and “IN” values desc rib ed in section
4.12
.
If a code has already been entered, active digits are flashing.
If attempts are made to operate the pump in locked condition, “LOCKED” will app ear in the disp la y for 2 seconds, followed by “_ _ _ _”. A code must be en­tered. If the entering of a code has not been started within 10 seconds, the operating display without changes will appear.
If a wrong code is entered, “L OCKED ” will a p pear in the display for 2 seconds, followed by “_ _ _ _”. A new code must be entered. If the entering of a code has not been started within 10 seconds, the operat­ing display without changes will appear. This display will also appear if the entering of the correct code ex­ceeds 2 minutes.
If the locking function has been activated but the control panel is unlocke d , the co ntro l pan e l will be locked autom at ica ll y i f i t is no t op er at ed f or 2 m i n­utes.
The locking f un c t ion ca n al s o be r ea cti v at ed b y s e­lecting “ON” in the “LOCK” menu. The previously en­tered code will then appear and must be re-entere d by pressing the button four times. The code can also be change d.
The control panel can be unlocked either by means of the selected co de o r th e fa cto ry co de 2 58 3.
The following buttons and inputs are still active when the panel is locked:
• Prim i ng ( -button).
• On/of f but to n.
• All externa l i np ut s.
Fig. 24
Activating the locking function and locking the control panel:
1. Select “LOCK” in the menu.
2. Select “ON” by means of the buttons and and confirm with .
3. Enter or re-ent er a co d e by me an s o f th e buttons
, and .
The locking functi o n ha s no w been act iv at ed and th e control panel is locked.
Unlocking the co ntrol panel ( with out deac tiva ting the locking function):
1. Press once. “LOCKED” appears in the display for 2 seconds, followed by “_ _ _ _”.
2. Enter the code by means of the buttons , and *.
The control panel has now been unlocked and will automatically be locked again if the control panel is not operated f or 2 m i nu te s.
Deactivating the locking function:
1. Unlock the control panel as described above.
2. S e lect “ LO CK ” in th e me nu.
3. Select “OFF” by mean s of t he b u tton s and and confirm with .
The locking function has now been deactivated and the control panel is unlo cke d.
* The panel can always be unlocked with code 2583.
100%
Operating disp lay
Operating display
24
5. Start-up
If the pump is n ot operating sat isf act or i ly, se e se cti o n
9. Fault finding char t
.
Step Action
1
Connect the hoses/pipes:
• Connect the suction and dosing tubes/pipes to the pump.
• Connect a tube to the vent valve, if required, and lead the hose to the tank.
2
Switch on the electricity supply:
• The di splay is o n.
• The gree n indi cato r light i s flashi ng (t he pum p has sto pped ).
• Select language, if required, see section
4.19
.
3
Select the operating mode (see section
4.8
):
• Manual .
•Pulse.
•Analog.
•Timer.
•Batch.
4
Connect the cables:
• Connect the control/level cables, if any, to the pump, see section
3.6
.
5
Start the pump:
• Start the pump by p re ssin g th e on /o ff butto n.
• The gree n indi cato r ligh t is per ma nent ly on .
6
Priming/venting:
• Press the button on the pump control panel and let the pump run without a counter pr essu re. Loose n the vent valve by giving it a 1/ 8 to 1/4 turn, if required. When the buttons and are pressed simultaneously during prim­ing, the pump can be set to run for a specific number of seconds at maximum capacity.
7
Calibration:
• When the pump has been primed and is running at the right counter pressure, calibrate th e pu m p, see se ctio n
6
.
100%
100%
100%
100%
100%
25
6. Calibration
It is important that th e p um p is ca lib rate d a ft er in sta l­lation to ensure that the correct value (ml/h or l/h) appears in the display.
The calibration can be carried out in three different ways:
Dire ct c alibration (recommended). The dosed quan tity of 100 strokes i s me as ur ed di­rectly. See section
6.1
.
Ind irec t ca libration. A calibration factor selected from a table is used for the specific installa tio n. Thi s m et hod ca n be used if it is not pos sible to ca rry o u t a d irect ca li­bration. Indirect calib rati on will ne ve r be a s a ccu ­rate as direct ca lib ra tio n. Se e sec tio n
6.2
.
Check ca libr atio n. See section
6.3
.
26
6.1 Direct calibratio n
Before calibration, ma ke sur e :
• that the pum p is in sta lle d with foot valve, injection
valve, etc. in the existing system.
• that the pump is running at the coun te r pre s su re it
is supposed to operate at (adjust the counter pres­sure valve, if required).
• that the pump is operating with the correct suction lift.
To carry out a direct calibration, proceed as follows:
Action Pump display
1. Prime the dosing hea d and th e suctio n tubi ng.
2. Stop the pump. The gr ee n LE D i s fl a shin g.
3. F ill a graduated glass with dos ing liquid, Q
1
.
DME 2: approx. 40 ml DME 19: approx. 500 ml DME 8: approx. 150 ml DME 48: approx. 1000 ml DME 12: approx. 250 ml
4. Read and note the quantit y Q
1
.
5. Place the suction tu bi ng i n th e grad ua te d gl a ss .
6. Go to the calibration menu, see secti on
4.7
.
7. Press the button twice.
8. The pump is performing 100 dosing strokes.
9. The factory-calibrat i on value a pp ea rs in the display.
10.Remove the suction tubing from the graduated glass and read Q
2
.
11.Set the display value to Q
d
= Q1 – Q2.
12.C on firm with th e button.
13.Th e pump is now cali bra te d an d re tu rns to the op ­erating display.
Set value to Q
d
Operating display
Q
1
Q
2
Q
d
27
6.2 Indirect cal i bration
A value from th e following table is to be added to the default factory cal ibrat ion value in th e displ ay. To re­set the pump to the factory calibration value, activate the “DEFAULT” fu nctio n, see sec tio n
4.17
.
To use the values, the fo llo wing m u st be fu lfi lled :
• The viscosity and density of th e liquid to be dosed must not differ considerably from water at 20°C.
• A GRUNDFOS installat ion k it o r co rres pond ing foot valve, in jection valve and hose diameter must be used.
• The length of the dosing hose must not exceed 6 metres.
• The suction lift must lie between 0.1 and 1.5 me­tres.
Adding the value:
Fig. 25
Pump type
Values to be added to the calibration value at various counter pressures [bar]
0-1 1-2 2-3 3-4 4-5 5-6 6-8 8-10 10- 12 12-14 14-16 16-18
DME 2 1.4 1.1 0.8 0.5 0.2 -0.2 -0.6 -1.2 -1.8 -2 .4 - 3. 0 -3 .6 DME 8 3.5 2.7 2.0 1.2 0.4 -0.4 -1.6 -3.1 - - - ­DME 12 2.1 1.3 0.4 -0.4 -1.3 -2.1 -3.4 - - - - ­DME 19 18.3 12.2 6.1 0 -6 .1 -12.2 -21.4 - - - - ­DME 48 24.38.3-8.3---------
Operating display without changes
Operating display
Set value to table value + display value
28
6.3 Check calibration
In check calibration, the c alibra tio n value is ca lcu­lated by reading the consumption of chemical in a specific perio d and co mpar ing this with the number of dosing strokes performed in the same period. This calibration method is very accurate and espe­cially suitable for check calibration after long periods of operation or if d i re ct c ali b rat i on is i m po ssible. Th e calibration can for instance be carried out when the chemical tank is replac ed o r fille d.
To carry out a check calibration, proceed as follows:
1. Stop the pump by pr es sin g the button.
2. Read the counter and note the number of dosing
strokes, see s e ction
4.16
.
3. Read and note the quantity in t he ch e mical tank.
4. Start the pump by pressing the button and let
it run for at least 1 hour. The longer the pump is operating, the more accurate the calibration will be.
5. Stop the pump by pr es sin g the button.
6. Read the counter and note the number of dosing
strokes, see s e ction
4.16
.
7. Read and note the quantity in t he ch e mical tank.
8. Calculate the dose d quantity in m l a nd t he
number of dosing strokes pe rfor med du rin g the operating period.
9. C alcula te the calibration value as follows:
(dosed quantity in ml/dosin g s t rokes) x 100.
10.Se t the cal cul ate d value in the calib ration menu
like for indirect calibration, see se ct ion
6.2
.
7. Maintenance
The pump is maintenance-free. However, it is recom­mended to kee p th e p ump clean.
The dosing pump is produced according to the high­est quality standards and has long life. The pump in­corporates wear part s such as di aphra gm, v alve s eat and valve balls.
To ensure long life and to reduce the risk of distur­bance of operation, visual checks should be carried out regularly.
It is possible to order dosing heads, valves and dia­phragms in ma te ri a ls which are suit ab le fo r the spe­cific liquid to be pumped. See the product numbers at the end of these instructions.
8. Service
Before returnin g th e pu m p t o GRU NDF OS fo r s er v­ice, the safety declaration at the end of these instruc­tions must be filled in b y a u thor ize d pe rso nne l a nd attached to the pump in a visible position.
Note: If a pump has been used for a liquid which is injurious to health o r to xic, th e pu m p will be cla ssi­fied as contaminated.
If GRUNDFOS 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 p ossib le, all r ele vant infor ­mation about the chemical must be provided.
If the above is not fu lfille d, G RUNDFO S ca n re fu se 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 (only in English).
Note: The replacement of the supply cable must be carried out by an authorised GRUNDFOS service workshop.
29
9. Fault finding chart
10. Disposal
Disposal of this product or parts of it must be carried out according to the f ollowin g guide lin es:
1. Use the local pu blic or p r i vate wast e col l ect i on
service.
2. In case such waste collection ser vice do es not
exist or cannot handle the materials used in the product, please deliver the product or any haz­ardous materi als fr om it to you r near es t G RUND­FOS company or service workshop.
Fault Cause Reme dy
The dosing has stopped or the output is too low.
Valves leaking or blocked. Check and clean valves. Valves incorrectly installed. Remove and fit valves. Check that the arrow
on the valve casing is point ing in t he liq uid flow direction. Check that all O-rings have been fitted co rr ec tly.
Suction valve or suction pipe/hose leaking or blocked.
Clean and seal th e su ctio n pipe/hose.
Suction lift too high. Install the pump in a lower position.
Install a priming tank.
Viscosity too high. Select the anti-cavitation function, see sec-
tion
4.14
. Install a pipe/hose with larger cross-section. Fit spring-loa ded valves.
Pump out of calibration. Ca librate the pu mp, see sec tio n
6
.
Pump dosing too little or too much.
Pump out of calibration. Ca librate the pu mp, see sec tio n
6
.
Pump dosing irregu­larly.
Valves leaking or blocked. Check and clean the valves.
Leakage from drain hole.
Diaphragm defective. Install a new diaphragm.
Frequent diaphragm failures.
Diaphragm not fastened properly. Install a new diaphragm and ensure that the
diaphragm is fastened properly.
Counter-pressure too high (meas­ured at the pump discharge port).
Check the system. Check the injection valve, if required. Redu ce t he dosi ng s trok e b y f itti ng a pulsation damp ene r.
Sediment in dosing head. Clean/flush the dosing head.
Subject to alteratio ns.
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