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Grundfos DDI209 User Manual - Industry Surplus Australia

1. o 3 SW 3 I S Lo 145 Z Fig 8 DDI 209 with Plus system Dimensions for DDI 209 with Plus system only DDI 0 4 10 DDI 5 5 10 a2 b2 c2 d2 e2 mm mm mm mm DDI 0 4 10 276 25 61 240 G 3 8 DDI 2 2 16 276 25 61 240 G 3 8 DDI 2 5 10 276 25 61 240 G 3 8 DDI 5 5 10 276 25 61 240 G 3 8 o g T 3 38 8 H Fig 9 DDI 209 with diaphragm leakage detection Dimensions for DDI 209 with diaphragm leakage detection ai b1 c1 d1 c1 HV d1 HV mm mm mm mm 8 mm mm SES DDI 0 4 10 250 34 175 5 112 G 3 8 175 5 112 G 3 8 DDI 2 2 16 250 34 175 5 112 G 3 8 207 5 176 G 5 8 DDI 2 5 10 250 34 175 5 112 G 3 8 207 5 176 G 5 8 DDI 5 5 10 250 34 175 5 112 G 3 8 207 5 176 G 5 8 DDI 13 8 4 251 40 185 133 G 5 8 185 133 G 5 8 DDI 20 3 251 40 185 133 G 5 8 185 133 G 5 8 4 5 Weight Pump type Dosing head material Weight kg DDI 0 4 10 DDI 2 5 10 PVC PP PVDF 2 3 DDI 0 4 10 DDI 2 5 10 Stainless steel DIN 1 4571 3 5 DDI 5 5 10 PVC PP PVDF 2 4 DDI 5 5 10 Stainless steel DIN 1 4571 3 6 DDI 13 8 4 DDI 20 3 PVC PP PVDF 2 6 DDI 13 8 4 DDI 20 3 Stainless steel DIN 1 4571 3 6 4 6 Materials Pump housing material Pump and control unit housing s PS FR GF 22 glass fibre reinforced polystyrene Pressure sensor Flow Monitor Sensor Aluminium oxide Al203 96 o O rings FKM EPDM or PTFE Warning Observe the manufacturer s safety i
2. Unit I h Unit Q I h and Unit gph Unit Q gal h Press the Start Stop button confirm the setting and close the service level or press the Menu Info button for a minimum of 10 seconds confirm the setting and open the pump selection Pump selection The actual pump type must always be selected to ensure error free operation of the electronic control function Otherwise the displayed pump and signals differ from the actual conditions 0 4 2 2 2 5 5 5 13 8 or 20 appears in the display Use the Up and Down buttons to switch between the pump types DDI 0 4 10 DDI 2 2 16 DDI 2 5 10 DDI 5 5 10 DDI 13 8 and DDI 20 3 Select your pump type which is indicated on the pump nameplate Press the Start Stop button and switch the power supply off then back on again confirm the setting and close the service level Caution 9 8 Resetting to default settings You can reset the first and second function levels to the default settings while the power supply is being connected The service level settings pump type Note and output settings and the values for the total dosing capacity and operating hours counter remain as they are The pump is disconnected from the power supply 1 Simultaneously press the Up and Down buttons and hold them down 2 Switch on the power supply boot appears in the display 3 Release the U
3. 1 Switch off the pump and disconnect it from the power supply 2 Depressurise the system 3 Take suitable steps to ensure that the returning dosing medium is safely collected 4 Carefully remove all lines 5 Uninstall the pump 7 3 2 Cleaning 1 Rinse all parts that have come into contact with the medium very carefully lines valves dosing head diaphragm 2 Remove any trace of chemicals from the pump housing 7 3 3 Storage Storage of the pump 1 After cleaning see above carefully dry all parts and reinstall the dosing head and valves or 2 change the valves and diaphragm See section 10 Maintenance 7 3 4 Disposal Disposal of the pump After cleaning see above dispose of the pump in accordance with the relevant regulations 31 8 Operation In the event of a diaphragm leakage the dosing liquid may leak out of the hole in the intermediate flange between the pump and the dosing head The parts inside the housing are protected from the dosing liquid for a short time depending on the type of liquid by the housing sealing It is necessary to check regularly daily if liquid is leaking out of the intermediate flange For maximum safety we recommend the pump version with diaphragm leakage detection Caution 8 1 Control and display elements M Fig 30 Display of DDI 209 TM03 6257 4506 Element Description Light emitting diode LED Lights
4. Min 10 mm TM03 6239 4506 Fig 23 Overflow and deaeration lines Dosing medium can leak from the overflow and deaeration lines Route both lines into a collection container or the tank Do not immerse the overflow line and deaeration line in the dosing medium Caution Observe the pressure limits specified in Caution p R section 1 General information 6 Electrical connections 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 AN Disconnect the power supply before connecting the power supply cable and the relay contacts Observe the local safety regulations Warning The pump housing must only be opened by personnel authorised by A Grundfos Alldos 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 Caution 6 1 Connecting the signal lines for DDI 209 flon NBS gen tonklevel A LEE 247 110 120 EK 4 1 1 b Neer E a Ley i output Jkeieieeg 5 4 2 Fig 24 DDI 209 connection diagram 6 1 1 Diaphragm leakage signal Socket 1 For diaphragm leakage signal ML
5. To protect the pump and system against excessive pressure build up install an overflow valve in the discharge line Caution The pressure sensor monitors the pressure in the dosing head If the set pressure is exceeded by 0 5 bar the pump switches off When switched on the electronics detects whether the chamber pressure control function is activated bar appears in the display TMO3 6577 4506 Fig 59 Display Pressure control 55 Pressure exceeded If after three successive strokes the cut off pressure is exceeded this is recognised as an error The pump is stopped The error signal relay switches on The LED alternately flashes red and green The last pressure value to be measured is displayed RUN ERROR and bar flash in the display TMO03 6578 4506 Fig 60 Display Pressure exceeded Pressure exceeded Pump running Pump waiting Pump restart attempts First the pump makes four attempts to restart each separated by a 2 second pause if the chamber pressure has fallen below the cut off pressure Pact lt Pset If after three successive strokes the cut off pressure is exceeded the pump is stopped again After four attempts the pump waits 10 minutes before attempting to automatically restart again The pump continuously attempts to restart if the chamber pressure decreases in this way 2 sec Fig 61 Pump restart attempts Error correction
6. 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 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 Caution 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 Caution 1 4 Applications 1 4 1 Appropriate acceptable and correct usage The DDI 209 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 Alldos 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 ifthe pump is not dismantled or incorrectly handled if repairs are carried out by authorised and qua
7. Press the Start Stop button to stop the pump and prevent it from restarting Check the discharge valve and the installation on the discharge side and correct any errors if necessary For maintenance work see section 10 Maintenance Check and correct the pressure setting if necessary Once the error has been corrected press the Start Stop button to restart the pump The pump returns to the state it was in before the error occurred Displaying the pressure that has been measured Th pu 56 e pressure that has been measured during the mp operation can be displayed at any time Press the Menu Info button twice If only pressed once the dosed quantity is displayed The pressure is displayed for approximately 10 seconds 10 min 10 min TM03 6579 4506 9 10 5 Error message broken cable or faulty sensor If the dosing controller and or the pressure control function are is switched on the missing signal is recognised and emitted as an error A faulty pressure sensor broken cable is displayed as follows The error signal relay switches on The pump is not stopped The LED flashes red ERROR flashes in the display TMO3 6580 4506 Fig 62 Display Broken cable Correct error Press the Start Stop button twice to confirm the error and to stop the pump Repair the cable break Once the error has been corrected press the Start Stop button to restart the
8. Repeatedly press the Menu Info button to navigate in the service level until you reach menu item P calibration of pressure sensor P OFF appears in the display Press the Up button to prepare the calibration P ON appears in the display When the pump is prepared for the calibration calibrate the pressure sensor 1 Press the Start Stop button P is displayed for approximately 2 seconds P CAL appears in the display The pressure sensor has been calibrated Press the Start Stop button to confirm the new settings to exit the service level to open the first function level Fit the pump back on Screw in the suction valve Warning Risk of chemical burns head connections or lines Wear protective clothing gloves and AN goggles when working on the dosing Do not allow any chemicals to leak from the pump Collect and dispose of all chemicals correctly The O rings must be correctly placed in the specified groove Caution Observe the flow direction indicated 58 by an arrow Only tighten the valve by hand TMO3 6581 4506 9 11 Batch menu batch mode In batch mode a defined batch guantity is dosed with a defined dosing flow The batch can be dosed manually or by an external contact signal Risk of dosing errors Batch dosing using contact inputs may be insufficiently or excessively triggered in the event of an error i
9. 07 22288 r 10 The DDI 209 dosing pump is delivered in a 4 Daso 40V soon cardboard box Place the pump in the packaging SC 91836593P1107120722288 S s ATM A Cer 3 3 Unpacking Made in Germany Retain the packaging for future storage or return or EE dispose of the packaging in accordance with local 7 ALLDOS regulations S 3 4 Intermediate storage Permissible storage temperature 10 C to 50 C Permissible air humidity max relative humidity Fig 1 DDI 209 nameplate Pos Description TMO3 8687 2207 92 non condensing 1 Type designation 3 5 Return 2 Model Return the pump in its original packaging or 3 Maximum capacity l h equivalent 4 Voltage V The pump must be thoroughly cleaned before it is returned or stored It is essential that there are no 5 Frequency Hz traces of toxic or hazardous media remaining on the 6 Product number pues 7 Country of origin Grundfos Alldos accepts no liability for 8 Year and week code Caution damage caused by incorrect transportation or missing or unsuitable 9 Marks of approval CE mark etc packaging of the pump 10 Maximum pressure bar Before returning the pump to Grundfos Alldos for 11 Serial number 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
10. 4 3 6 Flow Monitor for dosing control 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 Note protect the pump This function is not a substitute for the overflow valve 4 3 7 HV variant for liquids which are more viscous than water All HV variant pumps are equipped with spring loaded valves some have a larger nominal diameter and adapters Note that the HV variant pump has other dimensions and that other connection line dimensions might be required Note 4 4 Dimensional sketches R Ei DS ko SES 1 SOOM E 8 X LJ anna Dm T Lb L 3 ch 6 ER S J 1 r p l L A L 13 7 S 145 gt S a gt Z Fig 7 DDI 209 Dimensions for DDI 209 a b c d c HV d HV mm mm mm mm 8 mm mm ony DDI 0 4 10 239 23 1755 112 G 3 8 175 5 112 G 3 8 DDI 2 2 16 239 23 175 5 112 G 3 8 207 5 176 G 5 8 DDI 2 5 10 239 23 175 5 112 G 3 8 207 5 176 G 5 8 DDI 5 5 10 239 23 175 5 112 G 3 8 207 5 176 G 5 8 DDI 13 8 4 240 29 185 133 G 5 8 185 133 G 5 8 DDI 20 3 240 29 185 133 G 5 8 185 133 G 5 8 17 a2
11. Adjustment of volumetric flow proportional to the current signal displayed in I 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 thestart time for first batch setting the repeat time for subsequent batches slow mode for viscous media long suction stroke Inputs and outputs Inputs Maximum load 12 V 5 mA Minimum pulse length 10 ms Minimum pause time 20 ms Contact signal Current 0 20 mA Maximum load 22 Q 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 Q Maximum ohmic load Error sign l 50 VDC 75 VAC 0 5 A Stroke signal Contact time stroke 200 ms Maximum ohmic load Pre empty signal oo VDC 75 VAC 0 5 A 4 7 1 Interface optional PROFIBUS 19 5 Installation 5 3 Mounting 5 1 General information on installation Carefully tighten the screws otherwise Caution the plastic housing may be damaged Warning 5 3 1 Horizontal mounting Observe the specifications for the installation location and range of AN applications described in sections e 1 General information and 5 2 Installation location
12. Ban 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 e Ael i operator and appropriate precautions 7 must be taken to avoid them 113 H 105 TMO3 6222 4506 The DDI 0 4 10 not with Plus system 2 PEA Caution should be operated with flooded Fig 10 Drilling scheme suction 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 5 2 Installation location 5 2 1 Space required for operation and maintenance 5 3 2 Vertical mounting The pump must be installed ina wog Pumps with Plus system must not be Nors Position where it is easily accessible ore mounted vertically during operation and maintenance work 1 Mount the pump on a vertical surface e g a wall using four M6 screws The control elements must be easily accessible 2 Unscrew the dosing head four inner dosing head during operation screws 1q 2q Maintenance work ou the dosing head and the 3 Turn the intermediate ring 4q so that the valves must be carried out regularly discharge hole points downwards Provide sufficient space for
13. Display of total number of operating hours Fig 41 Opening exiting the second function level 1 Navigate in the second function level by repeatedly pressing the Menu Info button 2 Use the Up and Down buttons to modify the settings in the relevant menu as shown in fig 42 3 Press the Start Stop button to exit the second function level Note You can only change the parameters in the shown order When the Menu Info button is pressed again after one run the first function level opens automatically TMO3 6371 4506 39 40 Calibration Dosing controller Pressure control Memory function Weighting of current input output Batch Timer PROFIBUS Slow mode Dosing guantity counter Operating hours counter Fig 42 Second function level part 1 Press Up to start calibration see section 9 6 Calibration Flow Monitor Active only with Flow Monitor option ON OFF Press Up to switch on pressure control function For maximum counter pressure settings see section 9 10 2 Setting the Flow Monitor Saving of approx 65 000 contact signals ON OFF Weighting of current input output see section 9 9 Current signal control 0 20 mA 4 20 mA See next page TMO03 6609 4506 Setting code 111 Calibration Dosing controller Pressure control Memory function Weighting of current input output
14. Note modified and saved according to the set operating mode Select the current control used 0 20 mA 4 20 mA before weighting Weighting can be set independently of the current input value that is currently set The dosing flow value I h that corresponds to the set current input value mA always appears in the display Note 1 When the pump is running or stopped press and hold down the Up button for approximately 5 seconds 0 20 mA or 4 20 mA Analog and I h flash in the display 2 Use the Up and Down buttons to increase or decrease the currently set value for the maximum flow rate L lin lout 0 20 mA 2 lin 4 20 mA lout 4 20 mA manual contact The curve for current input current output now passes as follows With 0 20 mA 4 20 mA current signal control the curve for current input and current output passes linearly through Q 0 at 0 mA 4 mA and the currently set value for the maximum flow rate Qselect max at 20 mA curves 1b and 2b The set weighting is saved in the pump The values are retained e g when the Note power supply is switched off and are also active when current weighting is called in the second function level Even for current input current output assignments that are already weighted in the second function level See curve 3a subsequent weighting can be set or weighting can be shifted here The value for the maximum
15. 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 Caution With Plus system Use the suction line with foot valve and empty signal For degassing media maintain a maximum suction lift of 1 5 m Open the isolating valve on the calibration system Maximum suction line length 5m for standard pumps or pumps with Plus system when dosing media with a viscosity similar to water 1 2 m when dosing media with a higher viscosity than water 5 6 2 Sizing of tube pipe lines Warning PVC tube DN 4 is not suitable for use as a discharge line Connect PE tube DN 4 on the discharge side 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 Pump type Standard HV variant mm mm Suction side 5 SH s Discharge side 4 DDI 2 2 16 DDI 2 5 10 4 6 DDI 5 5 10 DDI 13 8 4 6 Suction side 9 DDI 20 3 Discharge side 6 5 6 3 Connecting the suction and discharge lines Connect the suction line to the suction valve 3a Inst
16. 1 must be set to Pre empty signal See sections 6 1 Connecting the signal lines for DDI 209 and 9 7 1 Modifying the switch assignment When the contact of the corresponding float switch closes the error signal relay or pre empty signal relay switches on but the pump is not switched off The LED flashes red The empty signal symbol flashes in the display _ 1 20 l Fig 33 Display pre empty signal f Manual TMO3 6596 4506 Once the error has been corrected the error signal relay or pre empty relay switches off The pump returns to the state it was in before the error occurred Empty signal When the contact of the corresponding float switch closes the pump is switched off The error signal relay switches on The LED flashes red The empty signal symbol lights up in the display 1 20 P Manual Stop TMO3 6597 4506 K Fig 34 Display empty signal symbol Once the error has been corrected the pump starts running again if it was running before The error signal relay switches off The pump returns to the state it was in before the error occurred 9 2 4 Diaphragm leakage sensor MLS As an option the pump can be equipped with a sensor for diaphragm leakage detection The electronics automatically detects whether a sensor is connected The following appears in the display 34 Manual 1 20 Fig 35 Display MLS sensor is
17. 387 33 713290 Telefax 387 33 231795 Brazil Mark GRUNDFOS Ltda Av Humberto de Alencar Castelo Branco 630 CEP 09850 300 Sao Bernardo do Campo SP Phone 55 11 4393 5533 Telefax 55 11 4343 5015 Bulgaria GRUNDFOS Pumpen Vertrieb Representative Office Bulgaria Bulgaria 1421 Sofia Lozenetz District 105 107 Arsenalski blvd Phone 359 2963 3820 2963 5653 Telefax 359 2963 1305 Canada GRUNDFOS Canada Inc 2941 Brighton Road Oakville Ontario L6H 6C9 Phone 1 905 829 9533 Telefax 1 905 829 9512 China Grundfos Alldos Dosing amp Disinfection ALLDOS Shanghai Water Technology Co Ltd West Unit 1 Floor No 2 Building T 4 2 278 Jinhu Road Jin Qiao Export Process ing Zone Pudong New Area Shanghai 201206 Phone 86 21 5055 1012 Telefax 86 21 5032 0596 E mail alldos cn alldos com China GRUNDFOS Pumps Shanghai Co Ltd 22 Floor Xin Hua Lian Building 755 775 Huai Hai Rd M Shanghai 200020 PRC Phone 86 512 67 61 11 80 Telefax 86 512 67 61 81 67 Croatia GRUNDFOS predstavni tvo Zagreb Cebini 37 Buzin HR 10000 Zagreb Phone 385 1 6595 400 Telefax 385 1 6595 499 Czech Republic GRUNDFOS s r o Capkovsk ho 21 779 00 Olomouc Phone 420 585 716 111 Telefax 420 585 716 299 Denmark GRUNDFOS DK A S Martin Bachs Vej 3 DK 8850 Bjerringbro Tif 45 87 50 50 50 Telefax 45 87 50 51 51 E mail info_GDK grundfos com www grundfos com DK
18. Estonia GRUNDFOS Pumps Eesti OU Peterburi tee 92G 11415 Tallinn Tel 372 606 1690 Fax 372 606 1691 Finland OY GRUNDFOS Pumput AB Mestarintie 11 FIN 01730 Vantaa Phone 358 3066 5650 Telefax 358 3066 56550 France Grundfos Alldos Dosing amp Disinfection ALLDOS S A R L 7 rue Gutenberg F 67610 La Wantzenau T l 33 3 88 59 26 26 T l copie 33 3 88 59 26 00 E mail alldos fr alldos com France Pompes GRUNDFOS Distribution S A Parc d Activit s de Chesnes 57 rue de Malacombe F 38290 St Quentin Fallavier Lyon T l 33 4 74 82 15 15 T l copie 33 4 74 94 10 51 Germany Grundfos Alldos Dosing amp Disinfection ALLDOS Eichler GmbH ReetzstraRe 85 D 76327 Pfinztal S llingen Tel 49 7240 61 0 Telefax 49 7240 61 177 E mail alldos de alldos com Germany GRUNDFOS GMBH Schl terstr 33 D 40699 Erkrath Tel 49 0 211 929 69 0 Telefax 49 0 211 929 69 3799 E mail infoservice grundfos de Service in Deutschland E mail kundendienst grundfos de Greece GRUNDFOS Hellas A E B E 20th km Athinon Markopoulou Av P O Box 71 GR 19002 Peania Phone 0030 210 66 83 400 Telefax 0030 210 66 46 273 Hong Kong GRUNDFOS Pumps Hong Kong Ltd Unit 1 Ground floor Siu Wai Industrial Centre 29 33 Wing Hong Street amp 68 King Lam Street Cheung Sha Wan Kowloon Phone 852 27861706 27861741 Telefax 852 27858664 Hungary GRUNDFOS Hungaria Kft Park u
19. Socket 3 Cable Used for Stroke pulse Pin Assignment Wire colour signal pre Error signal empty signal 1 Error signal contact Brown D 2 Stroke pulse signal or White a pre empty signal contact 3 Stroke pulse signal or Blue e pre empty signal contact 4 Error signal contact Black D 26 6 1 4 Remote on off contact input current input Socket 4 For the remote on off input and contact input or current input f 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 Caution Socket 4 Cable Used for p A gt Remote on off s current Pin Assignment Wire colour input Contact input input 1 GND Brown D D 2 Current input White 3 Remote on off input Blue D A Contact input Black D 6 1 5 Empty signal only pre empty and empiy 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 Socket 5 Used for Pin Assignment Empty signal Pre empty signal 1 Empty signal 2 GND D 3 Pre empty signal D 27 6 1 6 Accessories cable and plug for DDI 209 Description Product numbers 4 pole M12 plug suitable for socket 3 with 2
20. Timer manual or Timer contact Enabling timer mode Timer manual Batch dosing with the preset pause time is triggered manually Press the Start Stop button The LED lights up green the Stop segment is turned off and Run flashes in the display The preset batch cycle is started Timer contact Batch dosing with the preset pause time is triggered by an external contact signal To activate the batch contact function press the Start Stop button The LED lights up green the Stop segment is turned off and Run appears in the display When the external contact signal is received Run flashes in the display The preset batch cycle is started During pause times The time remaining until the next dosing appears in the display To display the time already elapsed press the Down button To display the total time t4 or t2 press the Up button 61 During timer dosing The batch guantity still to be dosed appears in the display To display the batch guantity already dosed press the Down button To display the total batch guantity press the Up button Stop start of pump during timer dosing To stop the pump press the Start Stop button or actuate remote on off To restart the pump press the Start Stop button The preset batch cycle continues For the Contact timer an external contact signal must also be received Deactivating t
21. basic characteristics liquid non abrasive non inflammable Caution For degassing dosing media note the following The DDI 209 without Plus system can be used in flooded suction for moderately degassing media such as chlorine bleaching agents See section 5 Installation The DDI 209 with Plus system can be used for moderately degassing media such as chlorine bleaching agents Using the DDI 5 5 10 with Plus system at a maximum system pressure of 3 bar H202 up to a maximum of 31 can be dosed No flooded suction Maximum permissible viscosity at operating temperature Maximum viscosity Pump type Normal Slow mode Normal operation Slow mode operation P WP operation operation with Plus system with Plus system mPa s mPa s mPa s mPa s DDI 0 4 10 DDI 25 10 200 200 200 200 DDI 5 5 10 100 200 100 200 DDI 13 8 4 DDI 20 3 100 200 Pump type HV variant DDI 0 4 10 500 1000 500 500 DDI 2 2 16 DDI 2 5 10 200 1099 r z DDI 5 5 10 DDI 20 3 200 500 The stated values are approximate values and apply to Newtonian liquids Note that the viscosity increases with decreasing temperature Permissible media temperature Min Max media Dosing media temperature head tempera material ture p lt 10bar p lt 16bar C C C PVC 0 40 20 Stainless steel 10 70 70 DIN 1 4571 PP 0 40 20 PVDF 10 60 20
22. default value is 0 000 3 Use the Up and Down buttons to enter the desired value for flow rate QmA min at MAmin e g Qma min 2 I h Now enter the values for reference pair H 1 Press the Start Stop button The current value for MAmax appears in the display the default value is H 20 0 mA 2 Use the Up and Down buttons to enter the maximum current input MAmax gt MAnin e g MAmax 16 mA 3 Press the Start Stop button The current value for the MAmax assigned flow rate OmA max appears in the display the default value is Omax Set the flow rate OmA max 0 0 999 I h 1 9 9 I h 10 Qmax l h TMO3 6612 4506 Use the Up and Down buttons to enter the desired value for flow rate OmA max at MAmax e g Qma max 8 I h Press the Menu Info button confirm the setting and move on to the next menu item or press the Start Stop button confirm the setting and close the second function level 51 Result of weighting In the example the following values were entered as reference points Lg and Hg Lg MAmin 6 MA Qselect mA min 2 I h Hg MAmax 16 MA Qselect mA max 8 I h The curve for current input current output now passes through Q 0 at lt 6 mA from Q 2 I h at 6 mA to Q 8 I h at 16 mA and through Q 8 I h at gt 16 mA curve 1d In the same way it is possible to enter a current weighting with a negative gradient In order t
23. defined stroke number Red LED Red LED I 110 0 112 0 Stop ALL Input of actual ascertained calibration volume Stop CALL Value of manufacturing calibration calculated for stroke number of actual calibration TMO3 6618 4506 Fig 44 Calibration 42 9 6 1 Calibrating pumps with Plus3 system internal calibration 1 Before opening the second menu level close the isolating valve D on the calibration tube E and allow the pump to dose a couple of strokes so that the liquid level is within the scale 2 Stop the pump 3 Slowly open the isolating valve D and allow the dosing medium to rise to the top of the scale in the calibration tube Close the isolating valve D 4 Open the calibration menu OFF CAL appears in the display 1 Press the Up button ON CAL appears in the display 2 Press the Start Stop button Calibration is started The LED flashes green and Run flashes in the display 3 Press the Start Stop button to stop the calibration when the liquid level reaches the bottom of the scale The LED lights up red 4 Press the Start Stop button The current calibration value is displayed not with replacement circuit boards 5 Use the Up and Down buttons to enter the calibration value read volume in ml The pump electronics automatically calculates the calibration value based on the actual strokes performed 6 Open the isolating valve Pre
24. flow rate Qselect mA max at MAmax IS shifted curve 3b Qmax default Ocai 8 l h 6 l h K Qselect max A Uh i 2 Wh wo T 0 B 0 mA 4 mA 8 mA 12 m 16 mA 20 mA lin mA Fig 51 Current input and current output with direct weighting 49 6l h AUb A Qselect mA min a mAmi H T m Qselect mA max b MAmax 2 h H e wo he vt 0 Freck Ti FE KZ S OmA 4mA 8 mA 12 mA 16 mA 20 mA e o lin MA E Fig 52 Current input and current output with subseguent weighting 9 9 2 With calibrated pump When calibrating the pump for your application and using current signal control and or current output proceed as follows 1 Calibrate the pump 2 Determine the maximum flow rate Oca by taking a reading on the pump O a is the maximum adjustable flow rate after calibration e g in manual mode or the displayed flow rate in continuous operation press and hold down the Start Stop button for longer than 1 second 3 To set the current input current output weighting see section 9 9 3 Setting the weighting Note Note 50 For unweighted assignment curves 1a and 2a see fig 50 select the following reference points L mAmin 0 4 MA Qselect mA min 0 I h H MAmax 20 MA Qselect mA max Dest Oca is not updated automatically when the pump is re calibrated This protects the user defined value pairs After calibration new weigh
25. in the event of a failure in the dosing system Transport and intermediate storage Transport Delivery Unpacking Intermediate storage Return Technical data Identification Type key General description Dimensional sketches Weight Materials Control unit Installation General information on installation Installation location Mounting Installation examples Installation tips Tube pipe lines Electrical connections Connecting the signal lines for DDI 209 Connecting the power supply cable Start up shutdown Initial start up subsequent start up Operating the pump Shutdown Operation Control and display elements Switching on off 10 10 10 10 10 10 10 11 11 11 11 11 11 11 11 12 13 17 19 19 19 20 20 20 20 21 22 23 24 25 28 28 28 31 31 32 32 32 Checking the dosing flow with Plus system 32 Deaeration Changing the tank with Plus system How to use the control unit Menu levels General functions of the control unit Signal outputs First function level Second function level 33 33 33 33 33 35 36 38 9 6 Calibration 41 9 7 Service level 44 9 8 Resetting to default settings 47 9 9 Current signal control 0 20 mA 4 20 mA 47 9 10 Flow Monitor 54 9 11 Batch menu batch mode 59 9 12 Timer menu timer mode 60 9 13 Creating a master slave application 62 9 14 Hotkeys info keys 63 10 Maintenance 64 10 1 General notes 64 10 2 Maintenance inter
26. m signal cable 96609017 321 206 4 pole M12 plug suitable for socket 3 with 5 m signal cable 96609019 321 208 4 pole M12 plug suitable for socket 4 with 2 m signal cable 96609014 321 205 4 pole M12 plug suitable for socket 4 with 5 m signal cable 96609016 321 207 5 pole M12 plug set suitable for socket 2 with coupling for pressure sensor 96645265 321 327 Flow Monitor and 2 m of signal cable for the current output 5 pole M12 plug suitable for sockets 1 2 and 4 screwed without cable with double cable entry 96609030 321 210 5 pole M12 plug suitable for sockets 1 2 and 4 screwed without cable with single cable entry 96609031 321 217 Extension cable 5 m with 5 pole coupling for M12 plug 6 2 Connecting the power supply cable 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 Caution 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 Caution Do not switch on the power supply until you are ready to start the pump 6 2 1 Versions without mains pl
27. pump The pump returns to the state it was in before the error occurred If the cable is broken the dosing controller and pressure control pressure display functions are not active When the Menu Info button is pressed twice to display the chamber pressure only is displayed Note If the sensor fault cannot be corrected immediately and if the pump is to continue to run without a sensor Switch off the dosing controller flow OFF and pressure control function P OFF Note 9 10 6 Changing the number of permissible error strokes To change the number of permissible error strokes during the start up operation and during normal dosing operation Permissible error strokes during start up operation Number of error strokes until the error message is triggered ERROR Fig 63 Permissible error strokes 1 Open the service level 2 Repeatedly press the Menu Info button to navigate in the service level until you reach menu item St 60 error stroke during start up operation The display shows St and the number of currently defined error strokes that are permissible during the start up operation 3 Use the Up and Down buttons to set the number of permissible error strokes during the start up operation in the range between 1 and 99 4 Press the Start Stop button Confirm the setting and go to menu item FE 7 The display shows FE and
28. removing the dosing 4 Turn the dosing head 90 so that the suction head and the valves valve is at the bottom and the discharge valve is 5 2 2 Permissible ambient influences at the top dosing always flows upwards Permissible ambient temperature 0 C to 40 C 5 Cross tighten the screws using a torque wrench teat ditty A ity Maximum torque Permissible air humidity max relative humidity S 92 non condensing DDI 0 4 DDI 5 5 2 1 Nm DDI 13 8 DDI 20 2 5 Nm 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 Caution 5 2 3 Mounting surface The pump must be mounted on a flat surface TM03 6223 4506 Fig 11 Vertical mounting 5 3 3 Diaphragm leakage detection With diaphragm leakage detection Screw the sensor from the bottom into the opening in the dosing head flange 20 5 4 Installation examples Ab i T l Fig 12 Installation example of pump with manual deaeration Pos Components 1i Dosing tank 2i Electric agitator 3i Extraction device D Dosing pump 6i Relief valve 7i Pressure loading valve 9i Calibration tube 10i Injection unit 15i Filter For pumps wit
29. the number of currently defined error strokes that are permissible during normal dosing operation 5 Use the Up and Down buttons to set the number of error strokes until the error message is triggered during normal dosing operation in the range between 3 and 99 6 Press the Start Stop button to confirm the new settings to exit the service level to open the first function level Service level Use the Up and Down buttons to set the number of permissible error strokes during the start up operation in the range between 1 and 99 Use the Up and Down buttons to set the number of error strokes until the error message is triggered during normal dosing operation in the range between 3 and 99 TMO3 6575 4506 9 10 7 Calibrating the sensor after the sensor has been replaced Once a sensor has been replaced the new sensor must be calibrated to the ambient pressure Prepare the pump for the calibration 1 Before screwing in the sensor check that no dosing liquid is left in the place where the pressure sensor will be screwed in 2 Screw in the new sensor with the correctly fitting O ring 3 Screw the sensor plug into socket 2 4 Unscrew the suction valve 57 Calibration of sensor 3 Service level Calibration of pressure sensor Prepare the pump first 0 is P CAL Wait approximately 2 seconds Fig 64 Calibration of pressure sensor Open the service level
30. toxic the pump will be classified as contaminated Caution If Grundfos Alldos is reguested 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 Alldos 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 Alldos service workshop Caution 4 2 Type key Example DDI 2 16 ARPVC V G F 31 3B1 B Type range Mains plug DDI X No plug Maximum flow l h F EU Schuko Maximum counter pressure bar B USA Canada Control variant l Australia New Zealand Taiwan AR Standard E Switzerland AF AR with Flow Monitor Connection suction discharge AP AR with PROFIBUS B6 Pipe 4 6 mm AR with Flow Monitor and APF PROFIBUS 3 Tube 4 6 mm Dosing head variant A5 Tube 5 8 mm PP Polypropylene 4 Tube 6 9 mm PV PVDF polyvinylidene Tube 9 12 mm fluoride PVC Polyvinyl chloride C4 Tube 1 8 1 4 SS Stainless steel DIN 1 4401 R Tube 1 4 3 8 PP P3 PP with Plus
31. up red when the pump is stopped Lights up green when the pump is started and briefly goes out during a suction stroke Lights up yellow when the pump is switched off remotely Flashes red if an error signal is present Goes out when the pump is in menu mode Start Stop Use this button to start or stop the pump Error signals can be acknowledged by pressing the Start Stop button Use the Menu Info button to switch between the operating modes Use the Down and Up buttons to change values in the display oe 32 8 1 1 Display test A display test is automatically performed when the pump is switched on All the segments of the LCD are switched on for 3 seconds and the software version number is then displayed for 2 seconds 8 2 Switching on off Before switching on the pump check that it is installed correctly See sections 5 Installation and 7 1 Initial start up subsequent start up Caution To start the pump switch on the power supply To stop the pump switch off the power supply 8 3 Checking the dosing flow with Plus system For pumps with Plus system the current dosing flow can be checked during operation Warning A Do not let the calibration tube E run empty Re open the isolating valve D in due time 1 Close the isolating valve D at the calibration tube E 2 The supply from the priming chamber F is shut off and the calibra
32. when the pump is stopped or when it is running Manual 1 20 Fig 39 Display manual control TMO3 6601 4506 The maximum displayed adjustable flow rate is automatically set according to the selected pump type and the calibrated stroke volume Input range for the flow rate Gmin Pump type Resolution of flow rate l h DDI 0 4 10 0 004 1 ml h DDI 2 2 16 0 025 5 ml h for Q lt 1 I h DDI 2 5 10 0025 10 ml h for Q gt 1 Wh DDI 5 5 10 0 055 DDI 13 8 4 0 140 20ml h for Q lt 10 I h DDI 20 3 0 200 100 ml h for Q gt 10 I h For counter pressures lower than 3 bar Qmin continuously increases from 0 004 I h to 0 006 I h 9 4 3 Contact signal control The pump must be started first in this Note operating mode LED lights up green and Run appears in the display Use the Start Stop button to start or stop the pump For continuous dosing in a process For each signal received at the contact input of the pump e g from a water meter with reed contact output the pump doses the set dosing capacity The dosing is continuously distributed between the incoming contacts via a controller The maximum dosing capacity must not be exceeded Input range for the dosing capacity per contact Za ZS SS aS 28 ac 2 EK ZS E H E os 2 29 SZ Pump type g 25 g 78 ZS o Sei EE 6 o alt alt ml ml ml DDI 0 4 10 0 07 0 001 0 28 DDI 2 2 16 0
33. 11 0 Repl 15 720074 V10 0 91834768 0708 Repl 91834768 0108 E www grundfosalldos com GRUNDFOS 714 ALLDOS
34. 22 0 004 0 86 DDI 2 5 10 0 22 0 004 0 88 DDI 5 5 10 0 55 0 011 2 20 DDI 13 8 4 1 24 0 025 4 96 DDI 20 3 1 92 0 039 7 86 Even if the pump receives more contact signals than it can process at the maximum flow rate it only runs in continuous operation with a maximum stroke frequency of 180 min 120 min in slow mode Contact ml N 1 75 Fig 40 Display contact signal control TMO3 6602 4506 Use the Up and Down buttons in the first function level to set the dosing volume for each contact signal 1 When the pump is stopped LED lights up red press the Menu Info button The first function level is opened 2 Use the Up and Down buttons in the contact signal control menu to set the dosing volume per contact signal 3 Press the Start Stop button to confirm the settings and to exit the first function level The pump is running LED lights up green 9 4 4 Current signal control 0 20 mA 4 20 mA For current signal control see section 9 9 Current signal control 0 20 mA 4 20 mA 37 9 5 Second function level 9 5 1 Opening exiting the second function level Open the second function level to set the access code to enable or disable functions such as Flow Monitor or memory to enter settings for operating modes such as batch mode to display the total number of operating hours and total dosing capacity to carry out a calibration or to modify the assignment
35. 8 H 2045 T r kb lint Phone 36 23 511 110 Telefax 36 23 511 111 India GRUNDFOS Pumps India Private Limited 118 Old Mahabalipuram Road Thoraipakkam Chennai 600 096 Phone 91 44 2496 6800 Indonesia PT GRUNDFOS Pompa JI Rawa Sumur III Blok III CC 1 Kawasan Industri Pulogadung Jakarta 13930 Phone 62 21 460 6909 Telefax 62 21 460 6910 460 6901 Ireland GRUNDFOS Ireland Ltd Unit A Merrywell Business Park Ballymount Road Lower Dublin 12 Phone 353 1 4089 800 Telefax 353 1 4089 830 Italy GRUNDFOS Pompe Italia S r l Via Gran Sasso 4 I 20060 Truccazzano Milano Tel 39 02 95838112 Telefax 39 02 95309290 95838461 Japan GRUNDFOS Pumps K K Gotanda Metalion Bldg 5F 5 21 15 Higashi gotanda Shiagawa ku Tokyo 141 0022 Japan Phone 81 35 448 1391 Telefax 81 35 448 9619 Korea GRUNDFOS Pumps Korea Ltd 6th Floor Aju Building 679 5 Yeoksam dong Kangnam ku 135 916 Seoul Korea Phone 82 2 5317 600 Telefax 82 2 5633 725 Latvia SIA GRUNDFOS Pumps Latvia Deglava biznesa centrs Augusta Deglava iela 60 LV 1035 Riga Talr 371 714 9640 7 149 641 Fakss 371 914 9646 Lithuania GRUNDFOS Pumps UAB Smolensko g 6 LT 03201 Vilnius Tel 370 52 395 430 Fax 370 52 395 431 Malaysia GRUNDFOS Pumps Sdn Bhd 7 Jalan Peguam U1 25 Glenmarie Industrial Park 40150 Shah Alam Selangor Phone 60 3 5569 2922 Telefax 60 3 5569 2866 M xico Bomba
36. Batch on off ON OFF Batch OFF a Adjustment of batch quantity and Les dosing rate for batch operation see section 9 6 5 Batch menu batch mode Timer on off Timer 4 ON OFF OFF A Adjustment of batch quantity E t dosing rate and times for Timer see section 9 6 6 Timer menu B timer mode OFF Bus address indication See previous page 6 PROFIBUS only with PROFIBUS Slow mode on off ON OFF To set the slow mode factor see section 9 6 8 Slow mode Display of total dosing quantity I resettable Dosing quantity 1 0 000 9 999 counter 9999 10 00 99 99 100 0 999 9 1000 9999 Slow mode anti cavitation J o Operating hours n Display of operating time of drive Q counter 1 L 1 10 h to 9999 99 990 h B 2 8 py E Fig 43 Second function level part 2 9 6 Calibration The dosed volume must be gauged in The dosing flow display is set by default for an litres during calibration e g by drawing operating counter pressure of 3 bar Calibration can the dosing medium from a gauged tank be used to set the pump flow to the actual operating Note For an alternative for pumps with Plus conditions system see section 9 6 1 Calibrating Calibrate the pump under normal operating pumps with Plus system internal conditions with the discharge line connected and at calibration operating counter p
37. Fig 68 Priming chamber valve 10 3 3 Unscrewing suction and discharge valves cleaning valves 1 Unscrew the suction and discharge valves 2 Dismantle the inner valve parts Standard DN 4 DN 8 valve Carefully push out the inner valve part using a thin wire nail or paper clip in the flow direction see arrow on the valve body Dismantle the inner parts seat 4r O ring 1r balls 3r ball cages 2r TMO3 6265 4506 Fig 69 Standard DN 4 DN 8 valve Spring loaded DN 4 DN 8 valve Unscrew the valve cover Dismantle the inner parts as shown in fig 70 DN 8 2 0 Qo oo comm GO Fig 70 Spring loaded DN 4 valve spring loaded DN 8 valve 3 Clean all parts If faulty parts are detected proceed as follows Replace the valve for stainless steel valves inner valve parts For contents and product numbers of the spare parts kits contact Grundfos Alldos 4 Re assemble and refit the valve 5 Remove the deaeration cartridge 1p 2p 3p under the discharge valve from the dosing head using a pair of tweezers Dismantle the cartridge Clean the cartridge If faulty parts are detected proceed as follows Replace the deaeration cartridge For contents and product numbers of the spare parts kits contact Grundfos Alldos Re assemble the cartridge 6 Refit all parts Fig 71 Standard DN 4 DN 8 valve TMO03 6267 4506 TMO3 6268 4506 The O rings must
38. GRUNDFOS ALLDOS INSTRUCTIONS DDI 209 Dosing pump Installation and operating instructions E BE THINK gt INNOVATE gt GRUNDFOS 74 ALLDOS Declaration of Conformity We Grundfos Alldos declare under our sole responsibility that the products DDI 209 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 July 2008 Geht h W Schwald Ulrich Stemick Managing Director Technical Director CONTENTS NN AA A A A sch onw DON Rw NNN Noa General information Introduction Service documentation Information about the product Applications Warranty Safety Identification of safety instructions in this manual Marking at the pump Qualification and training of personnel Risks when safety instructions are not observed Safety conscious working Safety instructions for the operator user Safety instructions for maintenance inspection and installation work Unauthorised modification and manufacture of spare parts Improper operating methods Safety of the system
39. MA Fig 55 Diagram for current input current output TMO3 6614 4506 53 9 10 Flow Monitor 9 10 1 Application notes Dosing of degassing media H202 chlorine bleaching agents Fora robust operation set the number of permissible error strokes to a value higher than 10 Dosing of antiscalent viscosity higher than 20 mPa s in particular for DDI 0 4 10 with Plus Use spring loaded valves for high viscosity media Dosing of viscous media For media with a viscosity higher than 20 mPa s spring loaded suction and discharge valves are recommended Dosing media with a viscosity higher than 100 mPa s on request For batch or timer operation Set the number of permissible error strokes to a value lower than the number of working strokes If while the pump is stopped the pressure in the discharge line falls below the minimum pressure of 2 bar e g in the event of a leak in the pressure loading valve increase the number of permissible error strokes so as to prevent unnecessary error messages Ensuring the counter pressure by a pressure loading valve Check the counter pressure 2 to 3 weeks after start up If it is below 2 bar the pressure loading valve has to be re adjusted If the volume flow is not constant as for example in the case of contact or analog control even small volume flows should not fall below the minimum pressure or minimum pressure difference of 2 bar Set cut of
40. OS Thailand Ltd 92 Chaloem Phrakiat Rama 9 Road Dokmai Pravej Bangkok 10250 Phone 66 2 725 8999 Telefax 66 2 725 8998 Turkey GRUNDFOS POMPA San ve Tic Ltd Sti Gebze Organize Sanayi B lgesi Ihsan dede Caddesi 2 yol 200 Sokak No 204 41490 Gebze Kocaeli Phone 90 262 679 7979 Telefax 90 262 679 7905 E mail satis grundfos com Ukraine TOB FPYHQOC YKPAIHA 01010 Kuis Byn Mockoscbka 86 Ten 38 044 390 40 50 Qax 38 044 390 40 59 E mail ukraine grundfos com United Arab Emirates GRUNDFOS Gulf Distribution P O Box 16768 Jebel Ali Free Zone Dubai Phone 971 4 8815 166 Telefax 971 4 8815 136 United Kingdom Grundfos Alldos Dosing amp Disinfection ALLDOS Ltd 39 Gravelly Industrial Park Tyburn Road Birmingham B24 8TG Phone 44 121 3283336 Telefax 44 121 3284332 E mail alldos uk alldos com United Kingdom GRUNDFOS Pumps Ltd Grovebury Road Leighton Buzzard Beds LU7 8TL Phone 44 1525 850000 Telefax 44 1525 850011 U S A GRUNDFOS Pumps Corporation 17100 West 118th Terrace Olathe Kansas 66061 Phone 1 913 227 3400 Telefax 1 913 227 3500 Usbekistan NpegctasutenbctBo TPYH GOC B TaiukeHTe 700000 TawkeHT yn Ycmana Hocupa 1 7 Tynuk 5 TenecboH 3712 55 68 15 ac 3712 53 36 35 Addresses revised 17 03 2008 Being responsible is our foundation BESTHINKSINNOVATES Thinking ahead makes it possible Innovation is the essence 15 720074 v
41. S The diaphragm leakage signal is pre assembled with an M12 plug for socket 1 Connect the cables according to the table below Used for wire colours TMO3 6595 4506 Socket 1 Diaphragm leakage signal MLS Pin Assignment Cable 0 8 m Cable 3 m without plug 1 12V 2 MLS GND White White 3 MLS supply Blue Yellow 5 MLS output Green yellow Green MLS is an abbreviation of the function in German language Membranleckagesignalisierung diaphragm leakage signalling 25 6 1 2 Current output Flow Monitor Socket 2 For pressure sensor for Flow Monitor option The pressure sensor is supplied ready made with M12 plug for socket 2 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 Socket 2 Cable Used for 5 V i current k Pin Assignment Wire colour output Flow Monitor 1 5V Brown Brown 3 Pressure sensor input Blue Blue 4 Current output Black 5 GND Green yellow Grey Pressure sensor Flow Monitor If socket 2 is also used for current Note output the plug set product number 96645265 has to be applied as described in section 6 1 6 Accessories cable and plug for DDI 209 6 1 3 Stroke pulse signal pre empty signal error signal Socket 3 Electrically isolated output for stroke pulse signal or pre empty signal and error signal
42. The settings for the operating modes of the slave pumps are implemented independently of settings for the master pump Note Unused pulse inputs from the master pump are forwarded to the slave pumps Caution when output signal pulse input is set They are processed on the slave pumps according to the slave pump settings 9 14 Hotkeys info keys The following important displays and functions of the DDI 209 can be accessed guickly using button combinations hotkeys Service functions Operating state of the Activate function Deactivate function Function pump display display Run Press the Start Stop F Deaerate In Run Stop or button for at least Release the Start Stop Menu Info mode 1 second button Move back the diaphragm for servicing The pump must be in Stop mode Simultaneously press the Up and Down buttons The pump is disconnected from the power supply Boot function Simultaneously press the Up and Down buttons while switching on the power supply Delete the total dosing In Run mode capacity Display functions in batch and timer operation Operating state of the Display function pump Press the Menu Info button for 5 seconds Activate function display Deactivate function display Display the batch quantity already dosed During the batch dosing since start of the batch jn batch
43. Up and Down buttons to switch between 1 OFF Relay function stroke signal 1 min flashes in the display and 1 O0N Relay function pre empty signal empty signal symbol flashes in the display and 1 1 1 Relay function pulse input n 1 flashes in the display Press the Menu Info button confirm the setting and move on to the next menu item or press the Start Stop button confirm the setting and close the service level Relay output NO NC stroke pre empty pulse 2 NO or 2 NC appears in the display 1 min and empty signal symbol flash in the display 3 Use the Up and Down buttons to switch between 2 NO Stroke pre empty signal pulse input relay normally open contact and 2 NC Stroke pre empty signal pulse input relay normally closed contact Press the Menu Info button confirm the setting and move on to the next menu item or press the Start Stop button confirm the setting and close the service level Pre empty signal NO NC input 3 NO or 3 NC appears in the display empty signal symbol flashes in the display 4 Use the Up and Down buttons to switch between 3 NO Pre empty signal normally open contact and 3 NC Pre empty signal normally closed contact Press the Menu Info button confirm the setting and move on to the next menu item or press the Start Stop button confirm the setting a
44. a 3a a h paag Fig 2 DDI 209 with manual deaeration Pos Components 3a Suction valve 3b Discharge valve 2a Dosing head with manual deaeration l Connection for deaeration line Vv Deaeration screw for manual deaeration Option The pump can also be equipped with the following Flow Monitor interface for PROFIBUS The functions are described but only apply to the relevant pump version TMO3 6589 4506 13 4 3 2 DDI 209 Plus system with priming and calibration system for moderately degassing liquids L Fig 3 DDI 209 Plus system Pos Components 3a Suction valve 3b Discharge valve 2c Dosing head Plus system l Connection for deaeration line V Deaeration screw A Suction line from tank Ae Line from calibration tube E to dosing head 2c D Isolating valve at calibration tube E E Calibration tube F Priming chamber G Connection for overflow line H H Overflow line to tank PVC tube 8 11 J Deaeration line to tank K Discharge line L Cover M Adhesive label N Deaeration hole chlorine bleaching agents only for DDI 209 0 4 10 to DDI 209 5 5 10 4 3 3 Functional principle of the Plus system Plus system in operation The priming chamber F is filled with the dosing medium via the suction valve 3a The calibration tube E is filled from the priming chamber Unused dosi
45. all 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 TMO3 6235 4506 Fig 20 Connecting the suction and discharge lines Pos Components 3a Suction valve 3b Discharge valve Cc Pipe connection D Tube connection 23 5 6 4 Connecting the overflow and deaeration lines Warning Observe chemical resistance HV variant pumps have an assisting suction In this case prepare cut the deaeration line but do not connect it yet Note The pump has a deaeration line PVC 4 6 Connect the deaeration line J to the connection for the deaeration line I i K TMO3 6237 4506 Fig 21 Connection for the deaeration line For pumps with Plus system The pump has a deaeration line PVC 4 6 Connect the deaeration line J to the connection for the deaeration line I Connect the overflow line H PVC tube 8 11 to the connection G TMO3 6238 4506 Fig 22 Plus system 24 5 6 5 Installing the overflow and deaeration lines Shorten the overflow line H and deaeration line J to at least 10 mm above the maximum tank level Insert the overflow line H and deaeration line J downwards into the dosing tank or collection container Avoid loops
46. ally saved approximately every 10 minutes and remain as they are even after the power supply has been switched off 9 2 General functions of the control unit 9 2 1 Deaeration and suction If the Start Stop button is pressed for longer than 1 second the pump switches to continuous operation for as long as the button is held down e g for suction or deaeration This happens regardless of the selected operating mode In batch or timer mode the pump has to be stopped first 9 2 2 Locking run The pump can be locked to avoid manual stopping When activating this function service level the pump starts running with the present settings and cannot be stopped using the Start Stop button It is still possible to acknowledge error messages using the Start Stop button Stopping the pump when the locking run is activated If remote on off is connected use remote off Disconnect the pump from the power supply For Batch manual the Run button Note should not be locked as the pump then runs in continuous operation 9 2 3 Two stage tank empty signal This function is used to provide a warning when the tank is almost empty and to switch off the pump when the tank is empty To use the pre empty signal ensure that the suction line is equipped with two float switches 33 Pre empty signal The pre empty signal can be an error signal or a pre empty signal at socket 3 For a pre empty signal relay
47. alve 14i in the suction line Di P12 1bar p P2 P1 7i TMO03 6230 4506 d 7 Fig 16 Installation to avoid the siphon effect To protect the dosing pump against excessive pressure build up install a relief valve 6i in the discharge line For degassing media Flooded suction not with Plus system Install a filter 15i in the suction line to prevent the valves being contaminated p lt Oi 15i 5 ET TMO03 6231 4506 Fig 17 Installation with relief valve and filter When installing the suction line observe the following 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 TMO3 6232 4506 Fig 18 Installation of suction line Inthe case of long discharge lines install a non return valve 12i in the discharge line 6i 1 ez J A Fig 19 Installation with non return valve TMO03 6233 4506 5 6 Tube pipe lines 5 6 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
48. appears in the display The batch function is deactivated 9 12 Timer menu timer mode In timer mode a defined batch quantity is dosed with a defined dosing flow The first dosing starts after the start time t4 has elapsed Batch dosing is then repeated after the repetition time tg has elapsed until the user stops the process by pressing the Start Stop button or with remote off Input range for the batch quantity 0 0 999 9 ml 1 00 99 99 I Input range for the times t4 and to 1 min lt t4 lt 999 h 1 min lt t2 lt 999 h Input hh mm Dosing Batch 1 Start time t4 Repetition time t gt Fig 66 Timer mode Risk of dosing errors If repetition time tz is not long enough to dose the batch quantity at the set dosing flow within this time the pump continues dosing until the current batch quantity is finished The pump is then stopped and the next batch dosing Caution is triggered after the next repetition time Batch dosing in timer mode may be insufficiently or excessively triggered in the event of an error if the pump system is not monitored The system must be protected redundantly Timer mode is controlled at the first and second function levels The batch quantity and times t4 and t are set in the second function level Timer mode is enabled in the first function level 60 Dosing Batch 2 Dosing Batchn Repeti
49. be correctly placed in the specified groove Caution Observe the flow direction indicated by an arrow Only tighten the valve by hand 10 4 Replacing the diaphragm Warning Risk of chemical burns Wear protective clothing gloves and goggles when working on the dosing head connections or lines Do not allow any chemicals to leak from the pump Collect and dispose of all chemicals correctly If possible rinse the dosing head Note e g by supplying it with water 10 4 1 Resetting the diaphragm When replacing the diaphragm it must be at the back dead point end of suction stroke As the stroke usually ends at the front dead point reset the diaphragm as follows With the pump stopped LED lights up red press the Up and Down buttons simultaneously The diaphragm is reset 10 4 2 Switching off the pump uf Switch off the pump and disconnect it from the power supply 2 Depressurise the system ow Take suitable steps to ensure that the returning dosing medium is safely collected 10 4 3 Replacing the diaphragm See fig 72 or 73 T 2 Unscrew the diaphragm Q counter clockwise Loosen the four screws 1q 2q on the dosing head 2 Remove the dosing head 2 For pumps without Plus system Replace the sealing diaphragm 3q intermediate ring 4q and support disk 5q Screw in the new diaphragm Q Replace the dosing head 2 and c
50. between the current input output and dosing rate This function level can only be opened when the pump is stopped LED lights up red 9 5 2 Setting the access code The access code is used to protect the pump against unintentional unauthorised access to pump settings The default setting is 111 Code 111 gives access to all settings described in sections 9 4 First function level and 9 5 Second function level The Start Stop button for stopping Nog the pump is active with any code 1 Press the Start Stop button while the pump is running LED lights up green The pump is stopped LED lights up red 2 Press and hold down the Menu Info button for 3 seconds The second function level is opened The input arrow appears in the display C 111 default setting is 111 or a user defined code appears in the display 3 Use the Up and Down buttons to set the code in the range between 1 and 999 Code 111 is required to open the second function level 38 Pump running LED lights up green 6 SN Pump not running LED lights up red 16 Keep pressed for 3 seconds SN Setting code 111 6 Calibration Flow on off Active only with Flow Monitor option D Memory function on off Weighting of current input output Batch mode Second function level Timer mode PROFIBUS Slow mode Display or resetting of total dosing capacity
51. ce Beware of caustic liquids Risk of causticisation by the dosing medium If the pump is filled keep the cover ZA closed and do not touch inside the priming chamber Before dismantling and transporting the pump empty the priming chamber completely and clean it if necessary 2 3 Gualification and training of personnel The personnel responsible for the operation maintenance inspection and installation must be appropriately gualified 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 4 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 infl
52. connected MBS TMO3 6598 4506 When a diaphragm leakage is detected by the sensor the pump is switched off The error signal relay switches on The LED flashes red MBS MLS and ERROR flash in the display 1 20 Fig 36 Display diaphragm leakage detected TMO3 6599 4506 Once the error has been corrected the contact is no longer closed press the Start Stop button to acknowledge the error The pump starts running again if it was running before The error signal relay switches off The pump returns to the state it was in before the error occurred 9 2 5 Hall sensor motor monitoring If the pump has existing strokes to process the Hall sensor checks whether the drive is turning If the drive motor is blocked e g due to excess counter pressure in the dosing system this is detected and indicated by the integrated motor monitoring function The error signal relay switches on 1 min bar and ERROR flash in the display TMO3 6360 4506 Fig 37 Display motor monitoring The pump is stopped The red LED flashes For possible errors and their correction see section 11 Fault finding chart Once the error has been corrected press the Start Stop button to acknowledge the error 9 2 6 Remote on off The pump can be switched off remotely e g from a control room If switched off remotely the pump does not respond to any inpu
53. declare that this product is free from hazardous chemicals biological and radioactive substances Product type Model number No media or water A chemical solution name see pump nameplate Fault description Please make a circle around the damaged part In the case of an electrical or functional fault please mark the cabinet GrA3494 Please give a short description of the fault Date and signature Company stamp 69 Argentina Bombas GRUNDFOS de Argentina S A Ruta Panamericana km 37 500 Lote 34A 1619 Garin Pcia de Buenos Aires Phone 54 3327 414 444 Telefax 54 3327 411 111 Australia Grundfos Alldos Dosing amp Disinfection ALLDOS Oceania Pty Ltd Unit 3 74 Murdoch Circuit Acacia Ridge QLD 4100 Phone 61 0 7 3712 6888 Telefax 61 0 7 3272 5188 E mail alldos au alldos com Australia GRUNDFOS Pumps Pty Ltd P O Box 2040 Regency Park South Australia 5942 Phone 61 8 8461 4611 Telefax 61 8 8340 0155 Austria GRUNDFOS Pumpen Vertrieb Ges m b H GrundfosstraRe 2 A 5082 Gr dig Salzburg Tel 43 6246 883 0 Telefax 43 6246 883 30 Belgium N V GRUNDFOS Bellux S A Boomsesteenweg 81 83 B 2630 Aartselaar T l 32 3 870 7300 T l copie 32 3 870 7301 Belorussia NpegctasutenbctBo FPYH AOC B Muncke 220090 Muuck yn Onewesa 14 Tenecbou 8632 62 40 49 axc 8632 62 40 49 Bosnia Herzegovina GRUNDFOS Sarajevo Paromlinska br 16 BiH 71000 Sarajevo Phone
54. eaeration line from the empty tank The dosing medium is then supplied from the tank F 2 Insert the suction line overflow line and deaeration line into the new tank 3 Do not immerse the overflow line and deaeration line in the dosing medium Route the lines downwards and without loops There is only a limited amount of time available to change the tank depending on the pump type and dosing flow e g 30 seconds at a dosing flow of 6 I h If air has been sucked in briefly increase the stroke setting to 100 and switch the pump to continuous operation Note 9 How to use the control unit First see sections 5 Installation 7 Start up shutdown and Note 7 2 Operating the pump Only the additional functions are described in this section 9 1 Menu levels Menu levels used in the control unit First function level for selecting and setting the operating modes of the pump Manual Contact Analog performing the batch and timer functions and starting the pump Second function level for setting and viewing additional functions selecting and setting the batch and timer functions and setting the access code to protect the pump against unintentional or unauthorised access to pump settings Service level for setting the pump type and the unit of display for the dosing flow I h or gal h and setting the inputs and outputs Saving user settings The pump settings are automatic
55. f pressure 9 10 2 Setting the Flow Monitor In order for the pressure sensor if installed to function as a dosing controller the dosing controller must be switched on To allow the pump to switch off in the event of overpressure and to set the cut off pressure of the pump the pressure control function must be switched on and set If no pressure sensor is connected the pump determines the pressure from the motor current For applications with high requirements in terms of precision the pressure control function must be used with a pressure sensor Note Switching on dosing controller Menu item flow is open flow OFF appears in the display 1 Press the Up button flow ON appears in the display The dosing controller is activated Switching on pressure control function This menu item only appears if the Note pressure sensor has already been detected once 1 Press the Menu Info button Menu item P is open P OFF appears in the display 2 Press the Up button P ON appears in the display The pressure control function is activated 60 P OFF barl sn as Second function level Fig 56 Set cut off pressure 54 TMO03 6680 4506 P ON in the display 1 Press the Start Stop button The currently defined cut off pressure is shown in the display The default value is the ma
56. f the pump system is not monitored The system must be protected redundantly Caution Setting batch dosing Batch mode is controlled at the first and second function levels The batch quantity is set in the second function level The batch function is enabled in the first function level Input range for the batch quantity 0 0 999 9 ml 1 00 99 99 I E S 3 1 05 L w g OFF 4 S L B CT f Input of dosing rate Input of batch quantity S e i Bi with Up Down with Up Down lo Sen mee 5 G g CP E Fig 65 Setting batch dosing In the second function level OFF B appears in the display 1 Press the Up button ON B appears in the display 2 Press the Start Stop button The currently defined flow rate appears in the display 3 Use the Up and Down buttons to enter the desired flow rate 4 Press the Start Stop button The currently defined batch quantity appears in the display 5 Use the Up and Down buttons to enter the desired batch guantity Press the Menu Info button confirm the setting and move on to the next menu item or press the Start Stop button confirm the setting close the second function level and enable batch dosing in the first function level Performing batch dosing Inthe first function level only the batch function is displayed with the Batch manual and Batch contact menu items Stop a
57. gt Display L Pump running LED lights up green Set the dosing rate to approx 1 to 100 of max dosing rate l h per stroke ml rate signal Continuous operation max dosing rate Pump stops Dosing rate proportional to current signal Fault signal switches on ERROR LED flashes red TMO3 6600 4506 You can modify the assignment between the current input and the flow rate See section 9 9 Current signal control 0 20 mA 4 20 mA 9 4 1 Setting the operating modes The operating modes are selected in the first function level and settings can be made for the modes This function level can only be opened when the pump is stopped 12 36 When the pump is stopped LED lights up red press the Menu Info button The first function level is opened Navigate in the first function level by repeatedly pressing the Menu Info button Use the Up and Down buttons to modify the settings in the relevant menu as shown in fig 38 Press the Start Stop button to confirm the settings and to exit the first function level The pump is running LED lights up green 9 4 2 Manual control Dosing with manual on off and manually adjustable dosing flow In this operating mode all the settings are entered on the pump by the operator Use the Start Stop button to start or stop the pump Use the Up and Down buttons to increase or decrease the flow rate This can be done
58. h Plus system No flooded suction Minimum injection pressure on the discharge side The pressure at the discharge valve must be at least 1 bar higher than the pressure at the suction valve wm L lt 1 5m Approx 5 10 mm TMO03 6225 4506 TMO3 6226 4506 Fig 13 Installation example of pump with Plus system 21 5 5 Installation tips 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 not possible with Plus system 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 Su lt 1 5 m 13i 7 Approx 15i 4 5 10 mm Fig 14 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 7i p21 bar i amp Fig 15 Installation with pressure loading valve 22 TMO3 6227 4506 TM03 6229 4506 To avoid the siphon effect install a pressure loading valve 7i in the discharge line and if necessary a solenoid v
59. he timer function 1 Open the second function level 2 Repeatedly press the Menu Info button ON t appears in the display 3 Press the Up button OFF t appears in the display The timer function is deactivated 9 13 Creating a master slave application You can connect several secondary pumps and control the secondary pumps slaves via the first pump master 9 13 1 Master All operating modes are available for the master pump Manual Contact Batch dosing with manual contact start Timer mode with manual contact start Current control Select the output signal of the master pump in the service level relay 1 output socket 3 Stroke signal emits one output signal per stroke must be used for manual or current control of the master pump or pulse input emits one output signal per contact input signal must be used for contact control of the master pump 62 Alternatively select the current output output socket 2 for current control of the slave pump Please note that the current output can differ from the current input e g when Note the pump is stopped and please observe the modified current output values with weighted current control 9 13 2 Slave The following operating modes are available for slave pumps in contact or current control input socket 4 Contact Batch dosing with contact start Timer mode with contact start Current control
60. ion level constant f Siphon effect inlet pressure higher Install a pressure loading valve than counter pressure g Leaking or porous suction line or Replace the suction line or discharge discharge line line h Parts in contact with the medium are Replace with resistant materials not resistant to it i Dosing diaphragm worn incipient Replace the diaphragm Also observe tears the maintenance instructions j Variation of the dosing medium Check the concentration Use an density viscosity agitator if necessary 5 Loud piercing a At dosing capacities lower than 10 The resonance noise of the stepper noises of the maximum dosing capacity of the pump resonance noises may temporarily occur at the stepper motor motor does not indicate an error 6 Liquid leaks out of a the hole in the intermediate flange between the pump and the dosing head Note 12 Disposal A diaphragm leakage has occurred This product or parts of it must be disposed of in an environmentally sound way 1 Use appropriate waste collection services 2 If this is not possible contact the nearest Grundfos or Grundfos Alldos company or service workshop 68 Replace the diaphragm For further error signals for the control unit refer to the relevant section Subject to alterations Safety declaration Please copy fill in and sign this sheet and attach it to the pump returned for service We hereby
61. lified personnel if original spare parts are used for repairs 2 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 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 Caution observed it may result in malfunction or damage to the equipment Note Notes or instructions that make the job easier and ensure safe operation Information provided directly on the pump e g abelling of fluid connections must be observed and must be maintained in a readable condition at all times 2 2 Marking at the pump The pumps with Plus system are provided with the following danger noti
62. n the power supply The LED alternately flashes red and green 3 Release the Menu Info and Down buttons Press the Start Stop button 5 Press the Up button The LED lights up yellow Func appears in the display 6 Press the Menu Info button The service level is opened Pump not connected to power supply Keep pressed when switching on v LED alternately flashes red and green oO LED lights up yellow Service level 1 Relay function stroke pre empty pulse selection 2 Relay output NO NC stroke pre empty pulse 3 Pre empty signal NO NC input 4 Empty signal NO NC input 5 Error signal NO NC output 6 Remote off NO NC input 7 Locking run on off P CAL on off St 60 unit l h gph Keep pressed for approx 10 seconds Pump type Fig 46 Opening exiting the service level Navigate in the service level by repeatedly pressing the Menu Info button Use the Up and Down buttons to modify the switch assignment in the relevant menu Press the Menu Info button for 10 seconds to open the pump type selection Press the Start Stop button to confirm the new settings to exit the service level to open the first function level TMO03 6620 4506 45 4 2 Relay function stroke pre empty pulse selection OFF 1 0N or 1 1 1 appears in the display Use the
63. nd close the service level Empty signal NO NC input 4 NO or 4 NC appears in the display empty signal symbol lights up in the display 46 Use the Up and Down buttons to switch between 4 NO Empty signal normally open contact and 4 NC Empty signal normally closed contact Press the Menu Info button confirm the setting and move on to the next menu item or press the Start Stop button confirm the setting and close the service level 5 Error signal NO NC output 5 NO or 5 NC appears in the display ERROR flashes in the display 6 Use the Up and Down buttons to switch between 5 NO Error signal relay normally open contact and 5 NC Error signal relay normally closed contact Press the Menu Info button confirm the setting and move on to the next menu item or press the Start Stop button confirm the setting and close the service level Remote off NO NC input 6 NO or 6 NC appears in the display Run and Stop flash in the display T Use the Up and Down buttons to switch between 6 NO Remote off normally open contact and 6 NC Remote off normally closed contact Press the Menu Info button confirm the setting and move on to the next menu item or press the Start Stop button confirm the setting and close the service level Locking run on off The locking of the Start Stop b
64. nd the preset batch quantity appear in the display The LED lights up red Use the Menu Info button to select Batch manual or Batch contact Enabling batch mode Batch manual Batch dosing is triggered manually Press the Start Stop button The LED and the Stop segment are turned off and Run flashes in the display The preset batch quantity is dosed Batch contact Batch dosing is triggered by an external contact signal To activate the batch contact function press the Start Stop button The LED lights up green the Stop segment is turned off and Run appears in the display When the external contact signal is received Run flashes in the display The preset batch quantity is dosed During batch dosing The batch quantity still to be dosed appears in the display To display the batch quantity already dosed press the Down button To display the total batch quantity press the Up button 59 Stop start of pump during batch dosing To stop the pump press the Start Stop button or actuate remote on off To restart the pump press the Start Stop button The preset batch cycle continues For the Contact timer an external contact signal must also be received Deactivating the batch function 1 Open the second function level 2 Repeatedly press the Menu Info button ON B appears in the display 3 Press the Up button OFF B
65. next menu item or press the Start Stop button confirm the setting and close the second function level 9 6 4 Weighting of current input output In current input output operation the dosing capacity is controlled via the current signal The pump emits a current signal as a feedback for control rooms or master slave applications For weighting of current input output Note see also 9 9 Current signal control 0 20 mA 4 20 mA 9 6 5 Batch menu batch mode In batch mode a defined batch quantity is dosed with a defined dosing flow See section 9 11 Batch menu batch mode 9 6 6 Timer menu timer mode In timer mode a defined batch quantity is dosed with a defined dosing flow and a defined start time See section 9 12 Timer menu timer mode 9 6 7 PROFIBUS menu The PROFIBUS menu item is only displayed for pumps with PROFIBUS interfaces The PROFIBUS interface is activated deactivated in this menu and the bus address is specified 9 6 8 Slow mode Activating the slow mode function lengthens slows down the suction stroke For example cavitation is thus reduced with viscous media Slow mode can be activated in any operating mode The maximum flow rate of the pump decreases The time for the suction stroke increases The maximum stroke rate in slow mode is 120 1 min Note 44 9 6 9 Display resetting of total dosing capacity The total capacity dosed since the value was last rese
66. ng medium flows back into the tank via the overflow line H The dosing medium flows from the calibration tube E to the discharge valve 3b via the small dosing diaphragm Note The isolating valve D must be open during operation TMO3 6590 4506 TMO3 6214 4506 Fig 4 Functional principle of the Plus system 4 3 4 DDI 209 with diaphragm leakage detection Fig 5 DDI 209 with diaphragm leakage detection Pos Components 3a Suction valve 3b Discharge valve Dosing head with flange for diaphragm 2b leakage detection l Connection for deaeration line Vv Deaeration screw for manual deaeration O Opto sensor P M12 plug for socket 1 TMO3 6591 4506 4 3 5 Functional principle of diaphragm leakage detection Pumps with diaphragm leakage detection MLS have a special dosing head flange for an optoelectronic sensor The pump is supplied with the diaphragm leakage sensor MLS already installed The optoelectronic sensor contains infrared transmitter infrared receiver TMO3 6216 4506 Fig 6 Diaphragm leakage sensor MLS If the diaphragm leaks the liquid enters the dosing head flange the light refraction changes the sensor emits a signal The electronics operates two contacts which can be used for example to trigger an alarm signal or to switch off the pump
67. nstructions when handling chemicals The resistance of the parts that come into contact with the media depends on the media media temperature and Caution operating pressure Ensure that parts in contact with the medium are chemically resistant to the dosing medium under operating conditions Further information on resistance with Note and operating pressure is available on request 4 7 Control unit Functions of pumps with control unit 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 dosing controller function only with sensor optional diaphragm leakage detection only with sensor optional access code protected settings remote on off Hall sensor for motor monitoring calibration adjust the pump to local operating conditions dosing capacity display can be reset operating hours counter cannot be reset interface PROFIBUS optional regard to the media media temperature Operating modes manual input display of the dosing flow in I 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
68. ntil the dosed medium is free of air bubbles and for the Plus system until the calibration tube is full Leave the pump DDI 0 4 10 running in continuous operation for approximately 5 min 5 Carefully close the deaeration valve The pump is now ready for operation 7 1 6 After initial start up of pumps with Plus system After initial start up remove the adhesive label M from the cover L see figs 3 and 29 Nach Inbetriebnahme Aufkleber entfernen TMO3 6247 4506 Fig 29 Adhesive label 7 1 7 Tightening 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 torgue wrench Maximum torgue DDI 0 4 DDI 5 5 2 1 Nm DDI 13 8 DDI 20 2 5 Nm Caution 7 2 Operating the pump To operate the pump see sections 8 Operation and 10 Maintenance and if necessary section 11 Fault finding chart Note 7 3 Shutdown Warning Risk of chemical burns Wear protective clothing gloves and goggles when working on the dosing head connections or lines Do not allow any chemicals to leak from the pump Collect and dispose of all chemicals correctly If possible rinse the dosing head Note before shutting down the pump e g by supplying it with water 7 3 1 Switching off uninstalling
69. o do this the value pair for reference point L must first be entered with the smaller mA value followed by reference point H Qselect mA min e om 10 Vh 8 l h 6 l h Alb Qselect mA min d 2 Wh Fig 54 Result of weighting The maximum flow rate of the pump N ole must not be exceeded 52 4mA 8 mA In the example the following values were entered as reference points Lg and He Le MAmin 2 MA Qselect mA min 12 l h He MAmax 16 MA Qselect mA max 2 l h The curve for current input current output now passes through Q 0 at lt 2 mA from G 12 I h at 2 mA to Q 2 I h at 16 mA and through Q 2 I h at gt 16 mA curve 1e Qselect mA max d 12 mA TMO3 6613 4506 Note down the set current weighting in the following diagram for current input current output 1 Label the Q I h axis for your working area 2 Mark your reference points with the value pairs L mAmin Qselect mA min and H mAmax Qselect mA max in the diagram 3 Draw the curve as a line from L to H vertically from Qselect mA min to the mA axis and horizontally from Qselect mA max to the edge of the diagram L Qselect mA min J MAmin H Qselect mA max J mAmax E si A a i S aaa ra Na A PEE a a Q l h 0 Stokoe tet al bP tt L 1 2 al 0 mA 4mA 8 mA 12 mA 16 mA 20 mA lin out
70. on before an error signal is emitted After a further 7 error strokes a dosing error is signalled Default values see also section 9 7 1 Modifying the switch assignment The start up operation is triggered as follows By switching on the power voltage Deaeration operation continuously pressing the Start Stop button The start up operation is completed after 60 strokes after the first valid stroke signalled by the dosing controller after short switching on and off the pump by pressing the Start Stop button The number of permissible error strokes can be increased or decreased since depending on pump type for example 60 strokes may take a considerable time during the start up operation Dosing error after start up operation If after seven successive strokes or after the number of strokes which have been defined by the user the dosing controller does not emit a signal this is recognised as an error The error signal relay switches on but the pump is not switched off The LED flashes red flow and ERROR flash in the display Manual 1 210 ERROR flow TMO3 6576 4506 Fig 58 Display Dosing error Once the error has been corrected and seven valid strokes have been measured or the Start Stop button has been pressed the error signal relay switches off The pump returns to the state it was in before the error occurred 9 10 4 Pressure control function
71. on line correctly Check for damage f Crystalline deposits in the valves Clean the valves g Diaphragm broken or diaphragm tappet torn out Replace the diaphragm h Empty dosing tank Fill the dosing tank 3 Dosing pump does not dose a Air in the suction line and dosing head Fill the dosing head and suction line b Viscosity or density of medium too high Check the installation c Crystalline deposits in the valves Clean the valves e Valves not correctly assembled Assemble the inner valve parts in the right order and check or possibly correct the flow direction e Injection unit blocked Check and possibly correct the flow direction or remove the obstruction f Incorrect installation of lines and peripheral eguipment Check the lines for free passage and correct installation g Empty dosing tank Fill the dosing tank 5 Sealing elements not chemically resistant Replace sealing elements 67 Fault Cause Remedy 4 Dosing flow of the a Dosing head not fully deaerated Repeat the deaeration pump is inaccurate b Degassing medium Check the installation c Parts of the valves covered in dirt or Clean the valves incrusted d Counter pressure fluctuations Install a pressure loading valve and a pulsation damper if necessary e Suction lift fluctuations Keep the suct
72. onnected 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 input power 20 W including all sensors reduced input power according to pump type and connected sensors 24 V DC power supply Supply voltage 24 V Deviation from the rated value 15 Quality of the DC voltage smoothed ripple below 3 6 V Maximum input power 20 W including all sensors reduced input power according to pump type and connected sensors The power supply must be electrically Note isolated from the signal inputs and outputs 1 3 9 Ambient and operating conditions 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 209 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 Caution 1 3 10 Dosing medium In the event of guestions regarding the material resistance and suitability of the pump for specific dosing media please contact Grundfos Alldos The dosing medium must have the following
73. or timer operation Display total batch quantity Press the Down button Release the Down button Press the Up button Release the Up button Display the time that has already elapsed During pause times in timer operation Display the total time Other display functions Operating state of the Display function pump Press the Down button Release the Down button Press the Up button Activate function display Release the Up button Deactivate function display Display the total dosing In Run mode capacity Press the Menu Info button Display the input current In Analog mode 0 20 mA 4 20 mA Press the Down button Display automatically jumps back after 5 seconds 63 10 Maintenance 10 1 General notes Warning When dosing dangerous media observe the corresponding safety precautions Risk of chemical burns AN Wear protective clothing gloves and goggles when working on the dosing head connections or lines Do not allow any chemicals to leak from the pump Collect and dispose of all chemicals correctly Warning The pump housing must only be opened by personnel authorised by Grundfos Alldos Repairs must only be carried out by authorised and qualified personnel Switch off the pump and disconnect it from the power supply before carrying out maintenance work and repairs 10 2 Maintenance inter
74. p and Down buttons All modified settings at the first and second function levels are reset to the default settings unit of display for the dosing flow input 9 9 Current signal control 0 20 mA 4 20 mA For controlling the dosing pump via an external current signal of 0 20 mA 4 20 mA WE Analog N 8 0 Ih D T o 3 Run o o Vi Ba Fig 47 Display 0 20 mA current signal control Anal 4 20 iy 8 ream Uh B T L 3 Run o o o F Fig 48 Display 4 20 mA current signal control The flow rate is proportional to a current input signal of 0 20 mA 4 20 mA Above 19 5 mA the pump runs in continuous operation at maximum dosing flow Omax Below 0 2 4 2 mA the pump switches off Default setting for Omax is the dosing flow up to 3 bar default calibration value Once the pump has been Note calibrated the current signals must be weighted See sections 9 9 2 With calibrated pump and 9 9 3 Setting the weighting The pump must be started first in this Note operating mode LED lights up green and Run appears in the display Use the Start Stop button to start or stop the pump 4 20 mA current signal control If the current input signal falls below 2 mA the error relay is switched as an error has probably occurred at the signal source or on the cable The error signal relay switches on The LED flashes red 4 20 mA and ERROR flash in
75. quent 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 Alldos 2 8 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 9 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 10 Safety of the system in the event of a failure in the dosing system DDI 209 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 3 Transport and intermediate storage 4 Technical data 3 1 Transport 4 1 Identification Caution Do not throw or drop the pump DDI 60 10 AF PVC T C S 31C5C5B 11 2 222 600 10261 3 2 Delivery 3 S N
76. rated in the range between 1 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 Yo 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 E 2 s S O S S Pump type 8 2 ei 2 S 2 S a 2 5 bar bar bar No flooded DDI 0 4 10 2 2 suction no DDI 5 5 10 positive inlet pressure DDI 13 8 4 2 2 DDI 20 3 1 5 1 5 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 0 4 10 1 DDI 20 3 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 pres
77. ressure Due to the small stroke volume of the DDI 0 4 10 calibration is essential for a precise dosing flow Note Before calibrating the DDI 0 4 10 deaerate the pump and then let it run for 15 minutes at operating counter pressure with full stroke rate 41 OFF CAL appears in the display 4 Use the Up and Down buttons to enter the 1 Press the Up button calibration value gauged volume in ml ON CAL appears in the display Press the Menu Info button confirm the setting 2 Press the Start Stop button and move on to the next menu item or Calibration is started The LED flashes green press the Start Stop button confirm the setting and Run flashes in the display and close the second function level 200 strokes are performed by default The The calibration process does not number of strokes performed appears in the change the setting for the assignment display weighting of the current input and Press Start Stop to stop at any stroke value Note OUtPUI for the flow rate The LED lights up red If a current input or output is used 3 Press the Start Stop button check after calibration to determine i S li whether a new current weighting is The current calibration value is displayed required not with replacement circuit boards Green LED flashing Process 200 strokes 99 200 Run CALL Stop CALL Flashing 87 Stop CALL Manual stop at user
78. ross tighten the screws 1q 2q Maximum torque DDI 0 4 DDI 5 5 2 1 Nm DDI 13 8 DDI 20 2 5 Nm Vent and start up the dosing pump 65 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 torgue wrench Caution Maximum torgue DDI 0 4 DDI 5 5 2 1 Nm DDI 13 8 DDI 20 2 5 Nm 3q 4q 8 wo T g 8 8 Fig 72 Replacing diaphragm without Plus system o 3 T Y o va d 8 e 8 2 S 1q Fig 73 Replacing diaphragm with Plus system 66 11 Fault finding chart Fault Cause Remedy 1 Dosing pump does not run a Not connected to the mains Connect the power supply cable o Incorrect mains voltage Switch off the pump Check voltage and motor If the motor is faulty return the pump for repair c Electrical failure Return the pump for repair 2 Dosing pump does not suck in D Leaking suction line Replace or seal the suction line Cross section of the suction line too small or suction line too long S Check with Grundfos Alldos specification c Clogged suction line Rinse or replace the suction line d Foot valve covered by sediment Suspend the suction line from a higher position e Buckled suction line Install the sucti
79. rundfos moscow grundfos com Serbia GRUNDFOS Predstavni tvo Beograd Dr Milutina Ivkovi a 2a 29 YU 11000 Beograd Phone 381 11 26 47 877 11 26 47 496 Telefax 381 11 26 48 340 Singapore GRUNDFOS Singapore Pte Ltd 24 Tuas West Road Jurong Town Singapore 638381 Phone 65 6865 1222 Telefax 65 6861 8402 Slovenia GRUNDFOS PUMPEN VERTRIEB Ges m b H Podru nica Ljubljana Blatnica 1 SI 1236 Trzin Phone 386 1 563 5338 Telefax 386 1 563 2098 E mail slovenia grundfos si South Africa Grundfos Alldos Dosing amp Disinfection ALLDOS Pty LTD 98 Matroosberg Road Waterkloof Park P O Box 36505 Menlo Park 0102 0181 ZA Pretoria E mail alldos za alldos com Spain Bombas GRUNDFOS Espa a S A Camino de la Fuentecilla s n E 28110 Algete Madrid Tel 34 91 848 8800 Telefax 34 91 628 0465 Sweden GRUNDFOS AB Box 333 Lunnagardsgatan 6 431 24 M lndal Tel 46 0 771 32 23 00 Telefax 46 0 31 331 94 60 Switzerland Grundfos Alldos Dosing amp Disinfection ALLDOS International AG Sch nmattstrake 4 CH 4153 Reinach Tel 41 61 717 5555 Telefax 41 61 717 5500 E mail alldos ch alldos com Switzerland GRUNDFOS Pumpen AG Bruggacherstrasse 10 CH 8117 Fallanden ZH Tel 41 1 806 8111 Telefax 41 1 806 8115 Taiwan GRUNDFOS Pumps Taiwan Ltd 7 Floor 219 Min Chuan Road Taichung Taiwan R O C Phone 886 4 2305 0868 Telefax 886 4 2305 0878 Thailand GRUNDF
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81. ss the Menu Info button confirm the setting and move on to the next menu item or press the Start Stop button confirm the setting and close the second function level Adjusting the operating counter pressure without gauging the dosed volume during calibration If you do not gauge the dosed volume you can determine the calibration value from the following dosing capacity curves in order to adjust your pump to the operating counter pressure The curves represent 200 strokes Dosing medium with a viscosity similar to water Pumps without Plus system 450 Vear ml 400 350 300 250 200 150 100 50 0 DDI 20 3 DDI 13 8 4 DDI 5 5 10 DDI 2 5 10 DDI 2 2 16 DDI 0 4 10 9 10 11 12 13 14 15 16 p bar TMO03 6619 4506 Fig 45 Dosing capacity curves Values are approximate values and do not take into consideration deviations due to construction tolerance according to VDMA 24284 Note 43 9 6 2 Flow Monitor In order for the pressure sensor if installed to function as a dosing controller the dosing controller must be switched on see section 9 10 Flow Monitor 9 6 3 Memory function The memory function is used to store excess contact signals for processing later see section 9 2 7 Memory function Switch the memory function on off with Up Down Press the Menu Info button confirm the setting and move on to the
82. sure difference Maximum suction lift start up for media with a viscosity similar to water Operating conditions version Pump type Pl A ae operation with Plus system m m DDI 0 4 10 Flooded suction AP DDI 2 2 16 1 5 Se DDI 2 5 10 1 5 me DDI 5 5 10 2 0 p DDI 13 8 4 2 8 DDI 20 3 2 8 Deaeration valve open Pumps with Plus system are delivered with a special start up device Maximum suction lift continuous operation for non degassing media with a viscosity similar to water Operating conditions version k Slow mode Pump type Normal operation Secher Ke polls ack hi beste i m m m m DDI 0 4 10 Flooded suction Flooded suction 1 5 1 5 DDI 2 2 16 4 6 1 5 1 5 DDI 2 5 10 4 6 1 5 1 5 DDI 5 5 10 4 6 1 5 1 5 DDI 13 8 4 3 3 DDI 20 3 3 3 Dosing head and valves moistened 1 3 6 Sound pressure level 45 dB A testing according to DIN 45635 01 KL3 At dosing capacities up to 10 of the maximum dosing capacity of the pump resonance noise may temporarily occur at the stepper motor Note 1 3 7 Enclosure class 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 Caution Pump with mains plug IP65 Pump without mains plug IP65 can only be ensured if the power supply cable is c
83. system S Tube 3 8 1 2 PVC P3 PVC with Plus system A Threaded Rp 1 4 female DE PP integrated diaphragm V Threaded 1 4 NPT female leakage detection pvel PX integrated diaphragm AQ Threaded 1 2 NPT male leakage detection PVC integrated diaphragm Tube 6 12 mm PVC L B1 leakage detection cementing d 12 mm SS L SS integrated diaphragm B2 Tube 13 20 mm leakage detection cementing d 25 mm Gasket material Valve type E EPDM 1 Standard X ERNI Spring loaded T PTFE 2 0 05 bar suction opening pressure Valve ball material 0 05 bar discharge opening pressure c Ceramics Spring loaded G Glass 3 0 05 bar suction opening pressure T PTFE 0 8 bar discharge opening pressure ss Stainless steel DIN 1 4401 Control panel position 4 Spring loaded discharge side only 0 8 bar opening pressure F Front mounted T Top mounted Supply voltage 3 1 x 100 240 V 50 60 Hz l 24 V DC 4 3 General description The DDI 209 is a dosing pump with a stepper motor and electronic power control The pump is operated via the diagonal or horizontal display in a user friendly menu structure The DDI 209 is available in various versions See also section 1 General information In the general description a distinction is made between pumps with dosing heads with the following features manual deaeration standard Plus system diaphragm leakage detection 4 3 1 DDI 209 with manual deaeration V 2
84. t is displayed The maximum value that can be displayed is 9999 I If this value is exceeded the counting starts again at zero Note To reset the value 1 press the Up button dEL appears in the display 2 Press the Start Stop button The total dosing capacity is deleted Press the Menu Info button confirm the setting and move on to the next menu item or press the Start Stop button confirm the setting and close the second function level 9 6 10 Display of total number of operating hours The operating hours counter indicates the operating time of the drive e g to check maintenance intervals The maximum number of operating hours that can be displayed is 99 990 h display 9999 The operating hours counter cannot be reset Multiply the number displayed by 10 to Note determine the number of operating hours 9 7 Service level Open the service level to modify the switch assignments of the control unit to set the pump type or to select the unit of measurement for the dosing flow I h or gal h that will be displayed 9 7 1 Modifying the switch assignment You are modifying the default settings Note of your control unit They will therefore differ from the technical data The service level can only be accessed when the power supply is switched on 1 Simultaneously press the Menu Info and Down buttons and hold them down 2 Switch o
85. t signals or to operator input Exception The pump can still be stopped and deaerated manually Stop lights up in the display The yellow LED lights up When switched on remotely the pump returns to the state it was in before it was switched off If for example the pump was previously in Stop mode it returns to this mode once it is switched on 9 2 7 Memory function Contact signals which cannot be processed immediately can be stored and subsequently made available to the pump for processing A maximum of 65 000 contact signals can be stored Without memory If the pump is running when a contact signal is received the signal is ignored The pump performs the current dosing then it is again ready to receive new contact signals i e it rejects excess contacts With memory If the pump is running when a contact signal is received the signal is stored in the memory First the pump performs the current dosing then it processes the contact signals from the memory The contents of the memory are deleted by switching off the power supply by switching the operating mode The contents of the memory are not deleted by actuating the remote on off contact by pressing the Start Stop button by continuous operation The memory function can be enabled Note and disabled in the second function level 9 2 8 Flow Monitor The pump can be equipped with a pressure sensor Flow Monitor p
86. ten if necessary Check that all electrical connections are correct With Plus system Open the isolating valve D at the calibration tube 7 1 2 Assisting suction for Plus system Pumps with Plus system have an assisting suction Fit the syringe and the piece of hose TMO3 6242 4506 Fig 25 Assisting suction for Plus system Warning Ensure that the pump is stopped Sucking in dosing medium using the assisting suction for Plus system Fig 26 Sucking in the dosing medium 1 Remove the cover from the priming chamber o Push the hose as far as it will go into the valve tube Draw up the syringe in order to create a perceptible low pressure and hold the syringe in this position Dosing medium rises in the suction line through the valve tube to the suction hose Relieve the syringe Remove the syringe and hose and empty Close the cover For HV variant pumps see section 7 1 3 Assisting suction for HV variant Pump without HV variant can now be started see section 7 1 5 Starting the pump 7 1 3 Assisting suction for HV variant HV variant pumps have an assisting suction Fit the syringe and the piece of hose Fig 27 Assisting suction for HV variant A Warning Ensure that the pump is stopped TMO3 6243 4506 TMO3 6244 4506 29 Sucking in dosing medium using
87. the assisting suction Fig 28 Sucking in the dosing medium 1 Attach the hose to the connection for the deaeration line 2 Open the deaeration screw 1 or 2 turns 3 Draw up the syringe in order to create a perceptible low pressure and hold the syringe in this position 4 Dosing medium rises in the suction line up to the suction hose 5 Relieve the syringe 6 Carefully remove the syringe with the suction hose 7 Empty the syringe into the dosing tank 8 Tighten the deaeration screw 9 Attach the deaeration line to the connection for the deaeration line Observe the instructions in section 5 6 4 Connecting the overflow and deaeration lines The pump can now be started see section 7 1 5 Starting the pump 30 TMO3 6245 4506 7 1 4 Assisting suction for systems without Plus system 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 5 Starting the pump 1 Open the suction and discharge isolating valves if installed 2 Open the deaeration valve of the dosing head by approximately 1 turn 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 u
88. the display TMO3 6605 4506 Fig 49 Display 4 20 mA current signal control 47 The assignment between the current signal and flow rate is linear With 0 20 mA current signal control the curve for current input and current output passes through Q 0 at 0 mA and the value pair Qmax Ocai at 20 mA curve 1a With 4 20 mA current signal control the curve for current input and current output passes through Q 0 at 4 mA and the value pair Qmax eat at 20 mA curve 2a With manual or contact control the curve for current output passes through Q 0 at 4 mA and the value pair Qmax Oca at 20 mA curve 2a The default setting for Omax is the maximum dosing flow at default calibration at 3 bar EE Omax default Qca Q l h lin lout 0 20 mA i 10 Vh lin 4 20 mA i lout 4 20 mA manual i Su contact i 6 I h i A Uh i 2 I h 0 FH FFF ee eg 0 mA 4 mA 8mA 12 mA 16 mA 20 mA lin mA Fig 50 Current input and current output with default setting 48 TMO03 6606 4506 9 9 1 Direct weighting of the current signal input and output Weighting while the pump is running can be carried out in the first function level The currently set value increases or decreases for the maximum flow rate Omax eat or with weighting set value Qselect mA max Setting the weighting The parameters for 0 20 mA and for 4 20 mA are independent of one another The weighting parameters are
89. ting may be reguired 9 9 3 Setting the weighting Note The setting options for weighting depend on the selected current signal control The parameters for 0 20 mA and for 4 20 mA are independent of one another The weighting parameters are modified and saved according to the set operating mode Select the current control operating mode used later 0 20 mA 4 20 mA manually or via contact signal before weighting Weighting of the control output for manual control mode or contact signal control is the same as current weighting 4 20 mA 0 20 mA Analog 6 mA Le 0 20 mA Analog 0 000 7 Select value for current input MAnin 0 20 mA 0 20 mA Analog 16 7 Set the flow rate Qma min 0 0 999 I h 1 9 9 I h 10 Qmax l h 0 20 mA Analog 11 00 7 Flashing Select value for current input mAmax gt MAmin Fig 53 Setting the weighting In the second function level first enter the values for reference pair L The current value for MAmin appears in the display the default value is L 0 0 mA L 4 0 mA Analog and 0 20 mA 4 20 mA are flashing 1 Use the Up and Down buttons to enter the minimum current input MAmin between 0 mA 4 mA and 20 mA e g mAmin 6 MA 2 Press the Start Stop button The current value for the mMAmin assigned flow rate OmA min appears in the display the
90. tion time tz TMO3 6616 4506 Fig 67 Setting timer mode OFF t appears in the display 1 Press the Up button ON t appears in the display 2 Press the Start Stop button 3 Use the Up and Down buttons to enter the desired dosing flow The selected dosing flow appears in the display 4 Press the Start Stop button 5 Use the Up and Down buttons to enter the desired batch guantity The selected batch guantity appears in the display 6 Press the Start Stop button t4 appears in the display 7 Use the Up and Down buttons to enter start time ty 8 Press the Start Stop button t2 appears in the display 9 Use the Up and Down buttons to enter repetition time tp Press the Menu Info button confirm the setting and move on to the next menu item or press the Start Stop button confirm the setting close the second function level and enable timer mode in the first function level Selecting Manual or Contact timer mode When the pump is running LED lights up green press the Start Stop button Stop and the preset start time t4 appear in the display The LED lights up red Manual or Contact appears in the display Manual is default setting TMO3 6617 4506 In the first function level only the timer function is displayed with the Timer manual and Timer contact menu items Use the Menu Info button to select
91. tion tube E is slowly emptied 3 Using a stop watch measure the time t in seconds it takes to dose 3 or 10 ml of dosing medium depending on pump type 4 Re open the isolating valve D at the calibration tube E 5 Calculate the dosing flow 3ml D I v Bai 87 D TMO3 6262 4506 4 Fig 31 Calculation of the dosing flow 8 4 Deaeration TMO3 6263 4506 Fig 32 Manual deaeration of the dosing head while the pump is running 1 Open the deaeration valve V of the dosing head by approximately 1 turn 2 turns with Plus system 2 Press the Start Stop button and keep it pressed The pump switches to continuous operation 3 Leave the pump running until the medium flowing from the deaeration line J is free of air bubbles 4 Carefully close the deaeration valve 8 5 Changing the tank with Plus system For pumps with Plus system the tank can also be changed during operation by using the supply of dosing medium in the priming chamber Warning The dosing medium is constantly supplied from the overflow line while the pump is running Take suitable steps to ensure that the dosing medium is safely collected Warning Risk of chemical burns Wear protective clothing gloves and goggles when working on the dosing head connections or lines Do not let the calibration tube E run Caution empty Changing the tank 1 Remove the suction line overflow line and d
92. uences damage to the environment from leakage of harmful substances 2 5 Safety conscious working The safety instructions in this manual applicable national health and safety regulations and any operator internal working operating and safety regulations must be observed 2 6 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 7 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 subse
93. ug 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 Pump in 24 V version Connect the power supply cable according to the table below Assignment Wire colour Brown O Blue Green yellow 28 96609032 321 223 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 7 Start up shutdown 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 Maximum torque DDI 0 4 DDI 5 5 2 1 Nm DDI 13 8 DDI 20 2 5 Nm Caution 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 tigh
94. ump option Based on the pressure measured by the sensor and on the motor position an indicator diagram is created Possible dosing faults or the exceeding of the permissible counter pressure are detected reliably and indicated by the display or the error message output The following errors are recognised Pressure exceeded the pump is stopped and restarts automatically when the pressure decreases Dosing error the pump doses 30 to 100 less due to a leaking discharge valve or suction valve a clogged suction line or an air bubble in the dos ing head Depending on the operating conditions it may be impossible to detect dosing errors which are caused by leaking suction valves Caution The dosing controller and dosing control functions can be switched on and off independently of each other It is always possibly to display the pressure that has been measured during operation whenever the pressure sensor is connected For information about operating the Note pump with the Flow Monitor see section 9 10 Flow Monitor 9 3 Signal outputs The control unit has the following signal outputs e g in order to return a signal to the control room 9 3 1 Current signal output To use the control signal output see Note section 9 9 Current signal control 0 20 mA 4 20 mA The current flow rate of the pump is output as a current signal Current output 0 20 mA in the follo
95. uration 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 Note 1 3 2 Connection size Pump type Connection size HV variant DDI 0 4 10 DN 4 DN 4 DDI 2 2 16 DN 4 DN 8 DDI 2 5 10 DN 4 DN 8 DDI 5 5 10 DN 4 DN 8 DDI 13 8 4 DN 8 10 DN 8 DDI 20 3 DN 8 10 DN 8 1 3 3 Pump performance Performance data at maximum pump counter pressure Normal operation Slow mode operation a Max Max Pump type With p max stroke With p max stroke Standard Plus rate Standard Plus rate system system l h l h bar n min l h l h bar n min DDI 0 4 10 0 4 0 4 10 180 0 26 0 26 10 120 DDI 2 2 16 2 2 1 9 16 180 1 5 1 2 16 120 DDI 2 5 10 2 5 2 2 10 180 1 7 1 4 10 120 DDI 5 5 10 5 5 4 9 10 180 3 7 3 2 10 120 DDI 13 8 4 13 8 4 180 9 2 4 120 DDI 20 3 20 3 180 13 3 3 120 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 At counter pressures lower than 10 bar the maximum dosing flow of the DDI 0 4 10 gradually increases to up to 1 I h Note Note The pump can be ope
96. utton to prevent manual stopping of the pump can be enabled and disabled The display indicates ONT or 7 0FF the Run symbol is displayed P Use the Up and Down buttons to switch between DONT Locking run on and 7 OFF Locking run off Press the Menu Info button confirm the setting and move on to the next menu item or press the Start Stop button confirm the setting and close the service level CAL on off only for Flow Monitor CAL ON or CAL OFF appears in the display CAL appears Use the Up and Down buttons to switch between CAL ON Calibration of the pressure sensor for the Flow Monitor enabled and CAL OFF Calibration of the pressure sensor for the Flow Monitor disabled For calibration see section Note 9 10 7 Calibrating the sensor after the sensor has been replaced St e g 60 only for Flow Monitor Use the Up and Down buttons to set the number of error strokes permitted when starting If the number of error strokes is exceeded the Flow error error message appears FE e g 7 only for Flow Monitor Use the Up and Down buttons to set the number of error strokes permitted during operation If the number of error strokes is exceeded the Flow error error message appears Selection of unit display Unit I h or Unit gph appears in the display Use the Up and Down buttons to switch between
97. vals In the event of a diaphragm leakage the dosing liquid may leak out of the hole in the intermediate flange between the pump and the dosing head The parts inside the housing are protected from the dosing liquid for a short time depending on the type of liquid by the housing sealing It is necessary to check regularly daily if liquid is leaking out of the intermediate flange For maximum safety we recommend the pump version with diaphragm leakage detection Caution Atleast every 12 months or after 4 000 operating hours When dosing crystallising liquids more frequently In the event of a fault 10 2 1 Cleaning the valves and diaphragm Clean the diaphragm and valves and replace if necessary for stainless steel valves inner valve parts 64 10 3 Cleaning suction and discharge valves If possible rinse the dosing head Note e g by supplying it with water 10 3 1 Switching off the pump 1 Switch off the pump and disconnect it from the power supply 2 Depressurise the system 3 Take suitable steps to ensure that the returning dosing medium is safely collected 10 3 2 Unscrewing the priming chamber valve Plus system When using the Plus system unscrew the priming chamber valve 3c as follows 1 Remove the cover L from the priming chamber 2 Remove the valve tube R with the valve 3c 3 Unscrew the valve 3c from the valve tube TMO03 6264 4506
98. vals 64 10 3 Cleaning suction and discharge valves 64 10 4 Replacing the diaphragm 65 11 Fault finding chart 67 12 Disposal 68 Warning 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 information 1 1 Introduction These installation and operating instructions contain all the information required for starting up and handling the DDI 209 diaphragm 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 1 3 Information about the product 1 3 1 Pump types The DDI 209 dosing pump is available for a variety of performance ranges in various sizes Pump types DDI 0 4 10 DDI 2 2 16 DDI 2 5 10 DDI 5 5 10 DDI 13 8 4 DDI 20 3 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 config
99. wing mode Current control 0 20 mA Current output 4 20 mA in the following modes Current control 4 20 mA Manual Contact Batch dosing with manual contact start Timer with manual contact start The current output is linear between 4 0 mA at flow rate 0 and 20 mA at Note maximum flow rate Omax default setting or the corresponding weighting value pair 9 3 2 Error signal Used to return various error states to the control room 9 3 3 Stroke signal pre empty signal pulse input Depending on the relay setting the contact output receives a signal in these cases for each complete stroke of the pump or apre empty signal input or each pulse input at the pump To set the relay see section 9 7 1 Modifying the switch assignment 35 9 4 First function level Pump not running LED lights up red Manual Manual control Contact signal Contact ml control 0 20 mA Analog Current signal Vh control 0 20 mA Fig 38 First function level Set the dosing quantity signal 1 15 gt to 2 to 400 of the volume ooo Dosing rate proportional to current signal 220 mA Continuous operation max dosing 0 000 A 0 2 mA Pump stops 0 2 20 mA Dosing rate proportional to current Dosing rate proportional to current signal 220 mA lt 0 2 mA Current signal R control 0 2 20 mA 4 20 mA lt 2mA
100. ximum counter pressure of the pump type 1 bar pumps lt 10 bar or 2 bar pumps from 10 bar and up 2 Use the Up and Down buttons to enter the desired cut off pressure You can set the cut off pressure at which the pump is to be stopped at around 2 bar up to the default value Press the Menu Info button confirm the setting and move on to the next menu item or press the Start Stop button confirm the setting and close the second function level The actual cut off pressure Dout op iS Note higher than the set pressure Deet Pcut off Pset 0 5 bar When you are setting the cut off pressure be aware that the pressure measured in the dosing head is higher than the system pressure It is advisable to display the measured pressure first see section Displaying the pressure that has been measured The set cut off pressure should be higher than the measured pressure in the dosing head Caution 9 10 3 Dosing controller function The pump software monitors the dosing process and emits a pulse for each dosing stroke For each stroke the flow display is momentarily turned off When switched on the electronics detects whether the dosing controller is activated flow appears in the display TMO3 6574 4506 Fig 57 Display Dosing controller Suppression of dosing control function during start up operation 60 error strokes are permitted during the start up operati

Grundfos DDI209 User Manual - Industry Surplus Australia

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