SMART Digital S - DDC
up to 15 l/h
Installation and operating instructions
GRUNDFOS INSTRUCTIONS
Further languages
http://net.grundfos.com/qr/i/95726994
English (GB) Installation and operating instructions
English (GB)
Original installation and operating instructions
CONTENTS
Page
1. Safety instructions
1.1 Symbols used in this document
1.2 Qualification and training of personnel
1.3 Safety instructions for the operator/user
1.4 Safety of the system in the event of a
failure in the dosing pump
1.5 Dosing chemicals
1.6 Diaphragm breakage
2. General information
2.1 Applications
2.2 Improper operating methods
2.3 Symbols on the pump
2.4 Nameplate
2.5 Type key
2.6 Product overview
3. Technical data / Dimensions
3.1 Technical data
3.2 Dimensions
4. Assembly and installation
4.1 Pump assembly
4.1.1 Requirements 12
4.1.2 Align and install mounting plate 12
4.1.3 Engage pump in mounting plate 12
4.1.4 Adjust control cube position 12
4.2 Hydraulic connection
4.3 Electrical connection
5. Startup
5.1 Setting the menu language
5.2 Deaerating the pump
5.3 Calibrating the pump
6. Operation
6.1 Control elements
6.2 Display and symbols
6.2.1 Navigation 19
6.2.2 Operating states 19
6.2.3 Sleep mode (energy-saving mode) 19
6.2.4 Overview of display symbols 20
6.3 Main menus
6.3.1 Operation 21
6.3.2 Info 21
6.3.3 Alarm 21
6.3.4 Setup 21
6.4 Operation modes
6.4.1 Manual 22
6.4.2 Pulse 22
6.4.3 Analog 0/4-20 mA 22
6.5 SlowMode
6.6 Key lock
6.6.1 Temporary deactivation 23
6.6.2 Deactivation 23
6.7 Display Setup
6.7.1 Units 23
6.7.2 Additional display 24
6.8 Inputs/Outputs
6.8.1 Relay outputs 24
3
6.8.2 External stop 24
3
6.8.3 Empty and Low level signals 25
3
6.9
3
7. Service
7.1 Regular maintenance
3
7.2 Cleaning
4
7.3 Service system
4
7.4 Perform service
5
7.4.1 Dosing head overview 26
5
7.4.2 Dismantling the diaphragm and valves 27
5
7.4.3 Reassembling the diaphragm and valves 27
6
7.5 Resetting the service system
6
7.6 Diaphragm breakage
7
7.6.1 Dismantling in case of diaphragm
8
9
7.6.2 Dosing liquid in the pump housing 28
9
7.7 Repairs
11
8. Faults
12
8.1 List of faults
12
8.1.1 Faults with error message 30
8.1.2 General faults 31
9. Disposal
13
14
16
16
17
17
19
19
19
21
22
23
23
Basic settings
breakage
Warning
Prior to installation, read these installation
and operating instructions. Installation and
operation must comply with local
regulations and accepted codes of good
practice.
23
24
25
25
25
25
26
26
27
28
28
29
29
30
31
2
1. Safety instructions
Caution
Note
Caution
Note
Caution
These installation and operating instructions contain
general instructions that must be observed during
installation, operation and maintenance of the pump.
It must therefore be read by the installation engineer
and the relevant qualified operator prior to
installation and start-up, and must be available at the
installation location at all times.
1.1 Symbols used in this document
Warning
If these safety instructions are not
observed, it may result in personal injury.
If these safety instructions are not
observed, it may result in malfunction or
damage to the equipment.
Notes or instructions that make the job
easier and ensure safe operation.
1.2 Qualification and training of personnel
The personnel responsible for the installation,
operation and service must be appropriately
qualified for these tasks. Areas of responsibility,
levels of authority and the supervision of the
personnel must be precisely defined by the operator.
If necessary, the personnel must be trained
appropriately.
Risks of not observing the safety instructions
Non-observance of the safety instructions may have
dangerous consequences for the personnel, the
environment and the pump and may result in the loss
of any claims for damages.
It may lead to the following hazards:
• Personal injury from exposure to electrical,
mechanical and chemical influences.
• Damage to the environment and personal injury
from leakage of harmful substances.
1.3 Safety instructions for the operator/user
The safety instructions described in these
instructions, existing national regulations on health
protection, environmental protection and for accident
prevention and any internal working, operating and
safety regulations of the operator must be observed.
Information attached to the pump must be observed.
Leakages of dangerous substances must be
disposed of in a way that is not harmful to the
personnel or the environment.
Damage caused by electrical energy must be
prevented, see the regulations of the local electricity
supply company.
Before starting work on the pump, the
pump must be in the "Stop" operating state
or be disconnected from the power supply.
The system must be pressureless!
The mains plug is the separator separating
the pump from the mains.
Only original accessories and original spare parts
should be used. Using other parts can result in
exemption from liability for any resulting
consequences.
1.4 Safety of the system in the event of a failure in the dosing pump
The dosing pump was designed according to the
latest technologies and is carefully manufactured
and tested.
If it fails regardless of this, the safety of the overall
system must be ensured. Use the relevant
monitoring and control functions for this.
Make sure that any chemicals that are
released from the pump or any damaged
lines do not cause damage to system parts
and buildings.
The installation of leak monitoring
solutions and drip trays is recommended.
English (GB)
3
1.5 Dosing chemicals 1.6 Diaphragm breakage
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!
A deaeration hose, which is routed into a
container, e.g. a drip tray, must be
connected to the deaeration valve.
The dosing medium must be in liquid
aggregate state!
Observe the freezing and boiling points of
the dosing medium!
The resistance of the parts that come into
contact with the dosing medium, such as
the dosing head, valve ball, gaskets and
lines, depends on the medium, media
temperature and operating pressure.
Ensure that parts in contact with the
dosing media are resistant to the dosing
medium under operating conditions, see
data booklet!
Should you have any questions regarding
the material resistance and suitability of
the pump for specific dosing media, please
contact Grundfos.
If the diaphragm leaks or is broken, dosing liquid
escapes from the drain opening (fig. 23, pos. 11) on
the dosing head. Observe section 7.6 Diaphragm
breakage.
Warning
Danger of explosion, if dosing liquid has
entered the pump housing!
Operation with damaged diaphragm can
lead to dosing liquid entering the pump
housing.
In case of diaphragm breakage,
immediately separate the pump from the
power supply!
Make sure the pump cannot be put back
into operation by accident!
Dismantle the dosing head without
connecting the pump to the power supply
and make sure no dosing liquid has
entered the pump housing. Proceed as
described in section 7.6.1 Dismantling in
case of diaphragm breakage.
To avoid any danger resulting from diaphragm
breakage, observe the following:
• Perform regular maintenance. See section
7.1 Regular maintenance.
• Never operate the pump with blocked or soiled
drain opening.
– If the drain opening is blocked or
soiled, proceed as described in
section 7.6.1 Dismantling in case of
diaphragm breakage.
• Never attach a hose to the drain opening. If a
hose is attached to the drain opening, it is
impossible to recognise escaping dosing liquid.
• Take suitable precautions to prevent harm to
health and damage to property from escaping
dosing liquid.
• Never operate the pump with damaged or loose
dosing head screws.
4
2. General information
Caution
The DDC dosing pump is a self-priming
diaphragm pump. It consists of a housing
with stepper motor and electronics,
a dosing head with diaphragm and valves and the
control cube.
Excellent dosing features of the pump:
• Optimal intake even with degassing media, as
the pump always works at full suction stroke
volume.
• Continuous dosing, as the medium is sucked up
with a short suction stroke, regardless of the
current dosing flow, and dosed with the longest
possible dosing stroke.
2.1 Applications
The pump is suitable for liquid, non-abrasive,
non-flammable and non-combustible media strictly in
accordance with the instructions in these installation
and operating instructions.
Areas of application
• Drinking water treatment
• Wastewater treatment
• Swimming pool water treatment
• Boiler water treatment
• CIP (Clean-In-Place)
• Cooling water treatment
• Process water treatment
• Wash plants
• Chemical industry
• Ultrafiltration processes and reverse osmosis
• Irrigation
• Paper and pulp industry
• Food and beverage industries
2.2 Improper operating methods
The operational safety of the pump is only
guaranteed if it is used in accordance with
section 2.1 Applications.
Warning
Other applications or the operation of
pumps in ambient and operating
conditions, which are not approved, are
considered improper and are not
permitted. Grundfos cannot be held liable
for any damage resulting from incorrect
use.
Warning
The pump is NOT approved for operation
in potentially explosive areas!
Warning
A sunscreen is required for outdoor
installation!
Frequent disengagement from the mains
voltage, e.g. via a relay, can result in
damage to the pump electronics and in the
breakdown of the pump. The dosing
accuracy is also reduced as a result of
internal start procedures.
Do not control the pump via the mains
voltage for dosing purposes!
Only use the "External stop" function to
start and stop the pump!
English (GB)
5
2.3 Symbols on the pump
P
QU
Type
Model
f
P
max
Imax
97694877
Made in France
N20683
NEMA 4X
psi
gphA l/h
Bar
W IP 65
GWT, 76327 PĮŶnjtal, Germany
English (GB)
Symbol Description
Indication of universally dangerous spot.
In case of emergency and prior to all maintenance work and repairs, take the mains plug out
of the mains supply!
The device complies with electrical safety class II.
Connection for deaeration hose at dosing head. If the deaeration hose is not correctly
connected, danger will arise due to possible leakage of dosing liquid!
2.4 Nameplate
Fig. 1 Nameplate
Pos. Description Pos. Description
1 Type designation 6 Enclosure class
2 Voltage 7 Mark of approval, CE mark, etc.
3 Frequency 8 Country of origin
4 Power consumption 9 Max. operating pressure
5 Max. dosing flow 10 Model
TM04 8144 1716
6
2.5 Type key
The type key is used to identify the precise pump and is not used for configuration purposes.
Code Example DDC 6- 10 AR- PP/ V/ C- F- 3 1 U2U2 F G
Pump type
Max. flow [l/h]
Max. pressure [bar]
Control variant
A
Standard
AR
A with alarm relay and analog input
Dosing head material
PP
Polypropylene
PVC
PVC (polyvinyl chloride, only up to 10 bar)
PV
PVDF (polyvinylidene fluoride)
SS
Stainless steel DIN 1.4401
Gasket material
E
EPDM
V
FKM
T
PTFE
Valve ball material
C
Ceramic
SS
Stainless steel DIN 1.4401
Control cube position
F
Front-mounted (can be changed to the right or left)
Voltage
3
1 x 100-240 V, 50/60 Hz
Valve type
1
Standard
2
Spring-loaded (HV version)
Suction/discharge side connection
Hose, 4/6 mm, 6/9 mm, 6/12 mm, 9/12 mm
U2U2
Hose, 0.17" x 1/4"; 1/4" x 3/8"; 3/8" x 1/2"
U7U7
Threaded Rp 1/4", female (stainless steel)
AA
Threaded 1/4" NPT, female (stainless steel)
VV
No connection
XX
Installation set*
Hose, 4/6 mm (up to 7.5 l/h, 13 bar)
I001
Hose, 9/12 mm (up to 60 l/h, 9 bar)
I002
Hose, 0.17" x 1/4" (up to 7.5 l/h, 13 bar)
I003
Hose, 3/8" x 1/2" (up to 60 l/h, 10 bar)
I004
Mains plug
EU
F
USA, Canada
B
UK
G
Australia, New Zealand, Taiwan
I
Switzerland
E
Japan
J
Argentina
L
Design
G
Grundfos
* Including: 2 pump connections, foot valve, injection unit, 6 m PE discharge hose, 2 m PVC suction hose,
2 m PVC deaeration hose (4/6 mm).
English (GB)
7
2.6 Product overview
[Start/stop] key
(section 6.1)
Mains connection
Control cube
Graphic LC display
(section 6.2.2)
Click wheel (section 6.1)
[100 %] key (section 6.1)
Signal inputs/outputs
(section 4.3)
Mounting plate
Deaeration valve
Dosing head
Valve, suction side
Connection, deaeration
hose
Valve, discharge side
Control cube assembly
screws
Drain opening in case of
diaphragm breakage
English (GB)
Fig. 2 Front view of the pump
TM04 1173 3117
Fig. 3 Rear view of the pump
8
TM04 1175 3510
3. Technical data / Dimensions
3.1 Technical data
Data 6-10 9-7 15-4
Turn-down ratio (setting range) [1:X] 1000 1000 1000
[l/h] 6.0 9.0 15.0
[gph] 1.5 2.4 4.0
[l/h] 3.00 4.50 7.50
[gph] 0.75 1.20 2.00
[l/h] 1.50 2.25 3.75
[gph] 0.38 0.60 1.00
[l/h] 0.0060 0.0090 0.0150
[gph] 0.0015 0.0024 0.0040
[bar] 10 7 4
[psi] 150 100 60
[strokes/
min]
140 200 180
[m] 6
[m]223
[bar] 1
[mPas]
(= cP)
[mPas]
(= cP)
[mPas]
(= cP)
[mPas]
(= cP)
2500 2000 2000
1800 1300 1300
600 500 500
50 50 300
[mm]466
[mm] 9
Mechanical
data
Max. dosing capacity
Max. dosing capacity with SlowMode 50 %
Max. dosing capacity with SlowMode 25 %
Min. dosing capacity
Max. operating pressure
Max. stroke frequency
1)
Stroke volume [ml] 0.81 0.84 1.58
Accuracy of repeatability [%] ± 1
Max. suction lift during operation
Max. suction lift when priming with wet valves
Min. pressure difference between suction and
discharge side
2)
2)
Max. inlet pressure, suction side [bar] 2
Max. viscosity in SlowMode 25 % with spring-loaded
3)
valves
Max. viscosity in SlowMode 50 % with spring-loaded
3)
valves
Max. viscosity without SlowMode with spring-loaded
3)
valves
Max. viscosity without spring-loaded valves
Min. internal hose/pipe diameter suction/discharge
2), 4)
side
Min. internal hose/pipe diameter suction/discharge side
(high viscosity)
4)
3)
Min./Max. liquid temperature [°C] -10/45
Min./Max. ambient temperature [°C] 0/45
Min./Max. storage temperature [°C] -20/70
Max. relative humidity (non-condensing) [%] 96
Max. altitude above sea level [m] 2000
English (GB)
9
English (GB)
Data 6-10 9-7 15-4
Voltage [V]
100-240 V, - 10 %/+ 10 %,
50/60 Hz
Length of mains cable [m] 1.5
Max. inrush current for 2 ms (100 V) [A] 8
Electrical
data
Max. inrush current for 2 ms (230 V) [A] 25
Max. power consumption P
1
[W] 22
Enclosure class IP65, Nema 4X
Electrical safety class II
Pollution degree 2
Max. load for level input 12 V, 5 mA
Max. load for pulse input 12 V, 5 mA
Max. load for External stop input 12 V, 5 mA
Signal
input
Min. pulse length [ms] 5
Max. pulse frequency [Hz] 100
Impedance at 0/4-20 mA analog input [Ω]15
Accuracy of analog input (full-scale value) [%] ± 1.5
Min. resolution of analog input [mA] 0.05
Max. resistance in level/pulse circuit [Ω] 1000
Signal
output
Max. ohmic load on relay output [A] 0.5
Max. voltage on relay output [V] 30 VDC / 30 VAC
Weight (PVC, PP, PVDF) [kg] 2.4
Weight/size
Weight (stainless steel) [kg] 3.2
Diaphragm diameter [mm] 44 50
Sound
pressure
Max. sound pressure level [dB(A)] 60
Approvals CE, CB, CSA-US, NSF61, EAC, ACS, RCM
1)
The maximum stroke frequency varies depending on calibration
2)
Data is based on measurements with water
3)
Maximum suction lift: 1 m, dosing capacity reduced (approx. 30 %)
4)
Length of suction line: 1.5 m, length of discharge line: 10 m (at max. viscosity)
10
3.2 Dimensions
161
17
D
B
C
A1
G 5/8"
A
200.8
110
4 x Ø6
105
120
17.5
168
Fig. 4 Dimensional sketch
Pump type A [mm] A1 [mm] B [mm] C [mm] D [mm]
DDC 6-10 280 251 196 46.5 24
DDC 9-7 280 251 196 46.5 24
DDC 15-4 280 251 200.5 39.5 24
English (GB)
TM04 8169 3117
11
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