Grundfos DMX 12-10, DMX 25-3, DMX 17-4, DMX 7.2-16, DMX 8-10 Installation And Operating Instructions Manual
...
GRUNDFOS ALLDOS INSTRUCTIONS
DMX 221
Installation and operating instructions
Declaration of Conformity
We Grundfos Alldos declare under our sole responsibility that the
products DMX 221, to which this declaration relates, are in conformity with
the Council Directives on the approximation of the laws of the EC Member
States relating to
— Machinery (98/37/EC).
Standard used: EN ISO 12100.
— Electromagnetic compatibility (89/336/EEC).
Standards used: EN 61000-3-2: 1995, + A1 + A2, EN 61000-3-3: 1995
and EN 61326: 1997, + A1 + A2, Class B.
— Electrical equipment designed for use within certain voltage limits
(73/23/EEC) [95].
Standard used: EN 61010-1: 2002.
Pfinztal, 1st June 2007
W. Schwald
Managing Director
2
CONTENTS
Page
1. General 3
1.1 Introduction 3
1.2 Service documentation 3
2. Installation data 4
3. Installation sketch 4
4. General information 5
4.1 Applications 5
4.2 Warranty 5
5. Safety 5
5.1 Identification of safety instructions in this manual 5
5.2 Qualification and training of personnel 5
5.3 Risks when safety instructions are not observed 5
5.4 Safety-conscious working 5
5.5 Safety instructions for the operator/user 5
5.6 Safety instructions for maintenance, inspection and
installation work 5
5.7 Unauthorised modification and manufacture of
spare parts 5
5.8 Improper operating methods 6
5.9 Safety of the system in the event of a failure
in the dosing system 6
6. Technical data 6
6.1 Identification 6
6.2 Type key 7
6.3 Pump performance 8
6.4 Suction heights 9
6.5 Ambient and operating conditions 10
6.6 Dosing medium 10
6.7 Electrical data 10
6.8 AR control unit 10
6.9 Materials 11
6.10 Weights 11
6.11 Dimensional sketches 12
7. Transport and storage 13
7.1 Delivery 13
7.2 Intermediate storage 13
7.3 Unpacking 13
7.4 Return 13
8. Installation 14
8.1 Optimum installation 14
8.2 Installation tips 14
8.3 Mounting 15
8.4 Tube / pipe lines 15
8.5 Connecting the suction and discharge lines 15
9. Electrical connections 16
9.1 Versions with mains plug 16
9.2 Versions without mains plug 16
10. Commissioning 17
10.1 Checks before start-up 17
10.2 Start-up 17
11. Operation 17
11.1 Description of the pump 17
11.2 Switching on/off 17
11.3 Adjusting the dosing flow via the stroke length 18
11.4 Stroke-length adjustment 18
11.5 Adjustment of stroke rate using a frequency converter 18
11.6 Using the AR control unit 18
12. Operation with other electronics 18
12.1 Electronics version stroke sensor 18
13. Integral relief valve 19
13.1 Function 19
13.2 Permissible media 19
13.3 Connections 19
13.4 Setting of opening pressure 19
13.5 Venting 19
13.6 Fault finding chart 19
14. Maintenance 20
14.1 General notes 20
14.2 Changing the gear grease 20
14.3 Cleaning the suction and discharge valves 20
14.4 Maintenance of the relief valve 20
14.5 Replacing the diaphragm 21
15. Fault finding chart 22
16. Dosing curves 23
17. Disposal 27
Warnin g
These complete installation and operating
instructions are also available on
www.Grundfosalldos.com.
Prior to installation, read these installation and
operating instructions. Installation and operation
must comply with local regulations and accepted
codes of good practice.
1. General
1.1 Introduction
These installation and operating instructions contain all the
information required for starting up and handling the DMX 221
dosing pump.
If you require further information or if any problems arise, which
are not described in detail in this manual, please contact the
nearest Grundfos Alldos company.
1.2 Service documentation
If you have any questions, please contact the nearest Grundfos
Alldos company or service workshop.
3
2. Installation data
Please fill in the data below after commissioning.
Note
Owner:
Grundfos Alldos customer number:
Contract number:
Order number of pump:
Pump serial number:
Put into service on:
Location of pump:
Used for:
It will help you and your Grundfos Alldos service
partner to make subsequent adjustments to the
installation.
3. Installation sketch
4
4. General information
4.1 Applications
The DMX 221 pump is suitable for liquid, non-abrasive and noninflammable media strictly in accordance with the instructions in
this manual.
The DMX 221 dosing pumps have not been approved according
to the EC directive 94/9/EC, the so-called ATEX directive. The
application of these pumps in potentially explosive environments
according to ATEX directive is therefore not permitted.
Warnin g
Other applications or the operation of pumps in
ambient and operating conditions, which are not
approved, are considered improper and are not
permitted. Grundfos Alldos accepts no liability
for any damage resulting from incorrect use.
4.2 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.
• if original spare parts are used for repairs.
5. Safety
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.
5.1 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:
Warnin g
If these safety instructions are not observed,
it may result in personal injury!
If these safety instructions are not observed,
Caution
Note
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.
it may result in malfunction or damage to the
equipment!
Notes or instructions that make the job easier
and ensure safe operation.
5.2 Qualification and training of person nel
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.
5.3 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.
5.4 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.
5.5 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).
5.6 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.
Warnin g
Electrical connections must only be carried out
by qualified personnel!
The pump housing must only be opened by
personnel authorised by Grundfos Alldos!
5.7 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.
5
5.8 Improper operating methods
The operational safety of the supplied pump is only ensured if it is
used in accordance with section 1. General. The specified limit
values must under no circumstances be exceeded.
5.9 Safety of the system in the event of a failure in the
dosing system
DMX 221 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.
6. Technical data
6.1 Identification
Fig. 1 DMX pump 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
TM03 8599 2207
6
6.2 Type key
Example: DMX 115 - 3 B PP /E /T -X -E 1 QQ X E0
Type range Motor variant
Maximum flow [l/h] E0 PTC motor for frequency control
Maximum counter-pressure [bar] E1
Control variant E2
B Standard - manual control Mains plug
AR* Analog/pulse control F EU (Schuko)
AT0 Prepared for servomotor B USA, Canada
AT3
AT5
AT8
AT9
Dosing head variant Q Tube 19/27 mm and 25/34 mm
PP Polypropylene R Tube 1/4" / 3/8”
PV PVDF (polyvinylidene fluoride) S Tube 3/8" / 1/2”
PVC Polyvinyl chloride C5 Hose clamp 1/2"
SS Stainless steel, DIN 1.4401 A Threaded Rp 1/4
PV-R PVDF + integrated relief valve A1 Threaded Rp 3/4
PVC-R PVC + integrated relief valve V Threaded 1/4" NPT, female
PP-L PP + integrated diaphragm leakage detection A9 Threaded 1/2" NPT, male
PV-L PVDF + integrated diaphragm leakage detection A3 Threaded 3/4" NPT, female
PVC-L PVC + integrated diaphragm leakage detection A7 Threaded 3/4" NPT, male
SS-L SS + integrated diaphragm leakage detection B3 Welding, diameter 16 mm
PV-RL
PVC-RL
Gasket material
EEPDM 4
VFKM 5 Valve for abrasive media
T PTFE Supply voltage
Valve ball material G 1 x 230 V, 50/60 Hz
GGlass H 1 x 120 V, 50/60 Hz
T PTFE
SS Stainless steel, DIN 1.4401
Control panel position F Without motor, NEMA flange (US)
F Front-mounted (opposite to the dosing head) 0 Without motor, IEC flange
S
Sx
W Wall-mounted
X No control panel
* Only pumps up to and including 0.37 kW and only single-phase pumps
Servomotor, 1 x 230 V, 50/60 Hz supply,
4-20 mA control
Servomotor, 1 x 115 V, 50/60 Hz supply,
4-20 mA control
Servomotor, 1 x 230 V, 50/60 Hz supply,
1 kΩ potentiometer control
Servomotor, 1 x 115 V, 50/60 Hz supply,
1 kΩ potentiometer control
PVDF + integrated relief valve and
diaphragm leakage detection
PVC + integrated relief valve and
diaphragm leakage detection
Side-mounted (same side as the stroke-length adjustment
knob)
Side-mounted (side opposite to the stroke-length adjustment
knob)
Motor type EEx de C T3, 3 x 400 V,
50 Hz (only DMX-B or DMX-AT)
Motor type EEx de C T4, 3 x 400 V,
50 Hz (only DMX-B or DMX-AT)
I Australia, New Zealand, Taiwan
E Switzerland
X No plug
Connection, suction/discharge
4 Tube 6/9 mm
Tube 6/12 mm/
B1
cementing d. 12 mm
6 Tube 9/12 mm
Tube 13/20 mm/
B2
cementing d. 25 mm
B4 Welding, diameter 25 mm
Valve type
1 Standard valve
Spring-loaded
3
0.05 bar suction opening pressure
0.8 bar discharge opening pressure
Spring-loaded, discharge side only
0.8 bar opening pressure
3 x 230/400 V, 50/60 Hz
E
or 3 x 440/480 V, 60 Hz
7
6.3 Pump performance
6.3.1 Accuracy
• Dosing flow fluctuation: ± 1.5 % within the control range 1:10
• Linearity deviation: ± 4 % of the full-scale value.
Adjustment from max. to min. stroke length, within the control
range 1:5.
Applies to:
• water as dosing medium
• fully deaerated dosing head
• measurement according to Grundfos Alldos factory standard
no. 0010/0011
• standard pump version.
6.3.2 Performance
Applies to:
• maximum counter-pressure
• water as dosing medium
• flooded suction 0.5 mWC
• fully deaerated dosing head
• three-phase 400 V motor.
Stroke
Pump type
DMX 4-10 2.2 4 10 29 5 1.3 10 145 35
DMX 7-10 3.8 7 10 29 8 2.1 10 145 35
DMX 9-10 4.9 9 10 29 11 2.9 10 145 35
DMX 12-10 6.9 12 10 29 14 3.7 10 145 35
DMX 17-4 10.4 17 4 29 20 5.3 4 58 35
DMX 25-3 16 27 3 29 32 8.5 3 43 35
DMX 7.2-16** 1.9 7.2 16 63 10 2.6 16 232 75
DMX 8-10 2.2 8 10 63 10 2.6 10 145 75
DMX 14-10 3.8 14 10 63 17 4.5 10 145 75
DMX 18-10 4.9 18 10 63 22 5.8 10 145 75
DMX 26-10 6.9 26 10 63 31 8.2 10 145 75
DMX 39-4 10.4 39 4 63 47 12.4 4 58 75
DMX 60-3 16 60 3 63 72 19.0 3 43 75
DMX 13.7-16** 1.9 13.7 16 120 19 5.0 16 232 144
DMX 16-10 2.2 16 10 120 19 5.0 10 145 144
DMX 27-10 3.8 27 10 120 32 8.5 10 145 144
DMX 35-10 4.9 35 10 120 42 11.1 10 145 144
DMX 50-10 6.9 50 10 120 60 15.8 8 116 144
DMX 75-4 10.4 75 4 120 90 23.8 3.5 50 144
DMX 115-3 16 115 3 120 138 36.5 2.5 36 144
* Maximum counter-pressure.
** When operating with a counter-pressure of 16 bar, the life of the dosing diaphragm will be reduced.
volume
V
3
] [l/h] [bar]* [n/min] [l/h] [US gph] [bar]* [psi]* [n/min]
[cm
Q** p max.*
50 Hz 60 Hz
Max.
stroke
rate
Q** p max.**
Max.
stroke
rate
8
6.4 Suction heights
6.4.1 Media with a viscosity similar to water
Applies to:
• counter-pressure of 1.5 to 3 bar
• non-degassing and non-abrasive media
• temperature of 20 °C
• stroke length 100 %.
50 Hz 60 Hz
Pump type
DMX 4-10 4 4 4 4 5
DMX 7-10 4 4 4 4 5
DMX 9-10 3 3 3 3 4
DMX 12-1032.532.54
DMX 17-4 1 1 1 1 2
DMX 25-3 1 1 1 1 2
DMX 7.2-16 4 3 4 3 5
DMX 8-10 4 4 4 4 5
DMX 14-1043445
DMX 18-1033334
DMX 26-1032.532.54
DMX 39-4 1 1 1 1 2
DMX 60-3 1 1 1 1 2
DMX 13.7-16 4 3 3.5 2.5 5
DMX 16-10 4 3 3.5 2.5 5
DMX 27-10 4 3 3.5 2.5 5
DMX 35-10 3 2 2.5 2 4
DMX 50-10 3 2 2.5 1.5 4
DMX 75-4 1 1 0.5 0.5 2
DMX 115-3 1 1 0.5 0.5 2
* Suction line and dosing head filled (continuous operation)
** Suction line and dosing head not filled, but dosing head and valves moistened (start-up)
Suction height*
[mWC]
Intake height**
[mWC]
Suction height*
[mWC]
Intake height**
[mWC]
Maximum length of
suction line
[m]
9
6.4.2 Suction heights for media with maximum permissible
viscosity
Applies to:
• Newtonian liquids
• non-degassing and non-abrasive media
• temperature of 20 °C.
Pump type
DMX 4-10 400 1
DMX 7-10 400 1
DMX 9-10 200 1
DMX 12-10 200 1
DMX 17-4 200 1 mWC flooded suction
DMX 25-3 200 1 mWC flooded suction
DMX 7.2-16 400 1
DMX 8-10 400 1
DMX 14-10 400 1
DMX 18-10 200 1
DMX 26-10 200 1 mWC flooded suction
DMX 39-4 100 1
DMX 60-3 100 1
DMX 13.7-16 200 1
DMX 16-10 200 1
DMX 27-10 200 1
DMX 35-10 100 1
DMX 50-10 100 1
DMX 75-4 100 1 mWC flooded suction
DMX 115-3 100 1 mWC flooded suction
Maximum
viscosity
[mPa s]
Intake height
[mWC]
6.5 Ambient and operating conditions
• Permissible ambient temperature: 0 °C to +40 °C.
• Permissible storage temperature: –20 °C to +50 °C.
• Permissible air humidity: max. relative humidity:
70 % at 40 °C, 90 % at 35 °C.
The installation site must be under cover!
Ensure that the enclosure class of motor and
Caution
• Sound pressure level: ± 55 dB(A), testing according to DIN
45635-01-KL3.
• Minimum counter-pressure: 1 bar at the pump discharge
valve.
Pay attention to the pressure losses along the way to the
injection point inclusively.
Pumps with AR control unit only
Maximum permissible mains impedance: 0.084 + j 0.084 Ω
(testing according to EN 61000-3-11).
pump are not affected by the atmospheric
conditions.
Pumps with electronics are only suitable for
indoor use! Do not install outdoors!
Warnin g
Risk of hot surfaces!
Pumps with AC motors may become hot.
Allow a minimum space of 100 mm above the fan
cover!
6.6 Dosing medium
In the event of questions regarding the material
Caution
resistance and suitability of the DMX 221 for
specific dosing media, please contact Grundfos
Alldos.
The dosing medium must have the following basic characteristics:
•liquid
• non-abrasive
• non-inflammable.
6.6.1 Permissible media temperature
Dosing head
material
PVC 0 °C to 40 °C 0 °C to 20 °C
Stainless steel,
DIN 1.4571*
Stainless steel,
DIN 2.4610*
PP 0 °C to 40 °C –
PVDF
* For SIP/CIP applications: A temperature of 145 °C at a
counter-pressure of max. 2 bar is permitted for a short period
(15 minutes).
Caution
Observe the freezing and boiling points of the
dosing medium!
–10 °C to 70 °C –10 °C to 70 °C
–10 °C to 70 °C –10 °C to 70 °C
–10 °C to 60 °C* –10 °C to 20 °C
Temperature range
p < 10 bar p < 16 bar
*70 °C at 9 bar
6.7 Electrical data
6.7.1 Enclosure class
The enclosure class depends on the motor variant selected, see
motor nameplate.
The specified enclosure class can only be ensured if the power
supply cable is connected with the same degree of protection.
Pumps with electronics: 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.
6.7.2 Motor
Version: see motor and pump nameplates.
6.8 AR control unit
Functions of pumps with electronics:
• "Continuous operation" button for function test and dosing
head deaeration
• memory function (stores a maximum of 65,000 pulses)
• two-stage tank-empty signal (e.g. via Grundfos Alldos tank
empty sensor)
• stroke signal/pre-empty signal (adjustable), e.g. as a feedback
to the control room
• dosing controller function (only with sensor – optional)
• diaphragm leakage detection (only with sensor – optional)
• access-code-protected settings
• remote on/off
• Hall sensor
• operating hours counter
• motor monitoring.
Operating modes:
• manual
Stroke frequency: manually adjustable between zero and
maximum
• contact signal control
Multiplier (1:n) and divisor (n:1)
• current signal control 0-20 mA / 4-20 mA
Adjustment of stroke frequency proportional to the current
signal.
Weighting of current input.
10
Loading...