Grundfos DDI 222 Series Installation And Operating Instructions Manual
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Grundfos DDI 222 Series Installation And Operating Instructions Manual

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GRUNDFOS INSTRUCTIONS
DDI 222
Dosing pump
Installation and operating instructions

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Summary of Contents for Grundfos DDI 222 Series

  • Page 1 GRUNDFOS INSTRUCTIONS DDI 222 Dosing pump Installation and operating instructions...

  • Page 2: Table Of Contents

    Intermediate storage nearest Grundfos company. Return 1.2 Service documentation Technical data Identification If you have any questions, please contact the nearest Grundfos Type key company or service workshop. General description 1.3 Information about the product Safety functions Dimensional sketches 1.3.1 Pump types...
  • Page 3 1.3.3 Pump performance Performance data at maximum pump counter-pressure Normal operation Slow-mode operation Slow-mode-2 operation Pump type p max.* Max. stroke rate p max.* Max. stroke rate p max.* Max. stroke rate [l/h] [bar] [n/min] [l/h] [bar] [n/min] [l/h] [bar] [n/min] DDI 60-10 24.7...

  • Page 4: Applications

    Other applications or the operation of pumps in DDI 150-4 ambient and operating conditions, which are not approved, are considered improper and are not Standard with Flow Monitor permitted. Grundfos accepts no liability for any DDI 60-10 damage resulting from incorrect use. DDI 150-4 1.5 Warranty...

  • Page 5: Safety

    The pump housing must only be opened by personnel authorised by Grundfos! 2.2 Qualification and training of personnel The personnel responsible for the operation, maintenance, 2.7 Unauthorised modification and manufacture of...

  • Page 6: Dosing Chemicals

    Make sure that the pump cannot be put back into If Grundfos Water Treatment is requested to service the pump, it operation by accident! must be ensured that the pump is free from substances that can Dismantle the dosing head without connecting be injurious to health or toxic.

  • Page 7: Technical Data

    4. Technical data 4.1 Identification DDI 60-10 AF-PVC/T/C-S-31C5C5B 91836593 Type: DDI 222 S/N:07/22288 60 l/h, 10 bar, 0,070 kW, IP 65 100-240 V, 50/60 Hz 91836593P1107120722288 Made in Germany Fig. 1 DDI 222 nameplate Pos. Description Type designation Model Maximum capacity [l/h] Voltage [V] Frequency [Hz] Product number...

  • Page 8: Type Key

    4.2 Type key Example: AR -PP /E /G -S B2 B2 Type range Mains plug No plug Maximum flow [l/h] EU (Schuko) Maximum counter-pressure [bar] USA, Canada Control variant Australia, New Zealand Standard Switzerland AR with Flow Monitor Connection, suction/discharge AR with PROFIBUS Tube, 6/9 mm Tube, 9/12 mm...

  • Page 9: General Description

    4.3 General description 4.4 Safety functions The DDI 222 is a dosing pump with an EC motor (brushless 4.4.1 Diaphragm leakage detection (optional) DC motor) as the drive and electronic power control. The pump is Pumps with diaphragm leakage signal have a special dosing operated via the diagonal display in a user-friendly menu head with a diaphragm set and pressure switch.

  • Page 10: Dimensional Sketches

    4.4.3 Dosing control (Flow Monitor) 4.4.4 Flow compensation The pressure sensor (Flow Monitor pump option) is used as a The flow compensation is a function to keep the dosing flow dosing controller and to monitor the pressure for the whole power constant with changing system pressure.

  • Page 11: Weight

    50 VDC / 75 VAC, 0.5 A • memory function (stores a maximum of 65,000 pulses) Stroke signal Contact time/stroke: 200 ms • two-stage tank-empty signal (e.g. via Grundfos tank-empty Maximum ohmic load: sensor) Pre-empty signal 50 VDC / 75 VAC, 0.5 A •...

  • Page 12: Installation

    5. Installation 5.2.2 Permissible ambient influences Permissible ambient temperature: 0 °C to +40 °C. 5.1 General information on installation Permissible air humidity: max. relative humidity: 92 % (non-condensing). Warning Observe the specifications for the range of The installation site must be under cover! applications and installation location described Ensure that the enclosure class of motor and in sections 1.
  • Page 13 5.4.1 Installation tips • To protect the dosing pump against excessive pressure build-up, install a relief valve (6i) in the discharge line. • For non-degassing media with a viscosity similar to water, the • For degassing media: pump can be mounted on the tank (observe the permissible suction lift).

  • Page 14: Tube / Pipe Lines

    • When installing the suction line, observe the following: 5.5.2 Sizing of tube / pipe lines – Keep the suction line as short as possible. Prevent it from Warning becoming tangled. Observe the pressure stage of the used lines. – If necessary, use swept bends instead of elbows. The maximum permissible inlet pressure and the –...

  • Page 15: Electrical Connections

    Warning Make sure that the pump is suitable for the electricity supply on The pump housing must only be opened by which it will be used. personnel authorised by Grundfos! Warning Warning Electrical connections must only be carried out Protect the cable connections and plugs against by qualified personnel! corrosion and humidity.
  • Page 16 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. Socket 3 Cable Used for Stroke/pulse signal / Assignment Wire colour Error signal pre-empty signal Error signal contact Brown Stroke/pulse signal or pre-empty signal contact White...

  • Page 17: Connecting The Power Supply Cable

    The printed circuit board may only be replaced 2. Depressurise the system on the discharge side of the pump: by service personnel authorised by Grundfos. – Open the system deaeration and evacuation valve. 3. Let the pump run in continuous operation: –...

  • Page 18: Operating The Pump

    7.2 Operating the pump 8. Operation To operate the pump, see sections 8. Operation, In the event of a diaphragm leakage, the dosing 9. How to use the control unit and liquid may leak out of the hole in the intermediate Note 10.

  • Page 19: How To Use The Control Unit

    9. How to use the control unit 9.2.3 Two-stage tank-empty signal This function is used to provide a warning when the tank is almost First see sections 5. Installation, empty and to switch off the pump when the tank is empty. To use 7.
  • Page 20 9.2.4 Diaphragm leakage sensor (MBS) 9.2.6 Power off As an option, the pump can be equipped with a sensor for If the power consumption of the drive motor is too high, e.g. due diaphragm leakage detection. to excess counter-pressure in the dosing system, this is detected and indicated by the power monitoring function.

  • Page 21: Signal Outputs

    9.2.9 Flow Monitor The pump can be equipped with a pressure sensor (Flow Monitor pump 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.

  • Page 22: First Function Level

    9.4 First function level Pump not running (LED lights up red) Menu Pump running (LED lights up green) Info Manual 1.20 Set the dosing rate to approx. Stop Down Manual control 0.125 % to 100 % of max. dosing Start rate [l/h] Menu Info...

  • Page 23: Second Function Level

    9.4.1 Setting the operating modes 9.4.3 Contact signal control The operating modes are selected in the first function level, and The pump must be started first in this operating settings can be made for the modes. mode (LED lights up green and "Run" appears in Note This function level can only be opened when the pump is the display).
  • Page 24 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 .
  • Page 25 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 figs 28 and 29. 3. Press the "Start/Stop" button to exit the second function level. You can only change the parameters in the shown order.
  • Page 26 Setting code 111 Calibration Dosing controller Pressure control See previous page Memory function Weighting of current input/output Stop Menu Start Info Batch on/off Stop Down Batch ON/OFF Start Adjustment of batch quantity and dosing rate for batch operation, see Menu section 9.11 Batch menu / batch mode Info Timer on/off...

  • Page 27: Calibration

    9.6 Calibration 3. Press the "Start/Stop" button. – Calibration is started. The LED flashes green and "Run" The dosing flow display is set by default for an operating flashes in the display. counter-pressure of 3 bar. Calibration can be used to set the pump flow to the actual operating conditions.
  • Page 28 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: •...

  • Page 29: Service Level

    9.6.7 PROFIBUS menu 9.7 Service level The "PROFIBUS" menu item is only displayed for pumps with Open the service level PROFIBUS interfaces. The PROFIBUS interface is • to modify the switch assignments of the electronics, activated/deactivated in this menu and the bus address is •...
  • Page 30 Pump not connected to power supply Menu Down Info Keep pressed when switching on LED flashes up red and green alternating Stop Start Stop LED lights up yellow Start Menu Info Service level 1. Relay function (stroke / pre-empty / pulse selection) 2.
  • Page 31 1. Relay function (stroke / pre-empty / pulse selection) 7. Locking "run" on/off "1:OFF", "1:ON" or "1:1:1" appears in the display. The locking of the "Start/Stop" button to prevent manual stopping of the pump can be enabled and disabled. • Use the "Up"...

  • Page 32: Resetting To Default Settings

    9.8 Resetting to default settings 4-20 mA current signal control If the current input signal falls below 2 mA, the error relay is You can reset the first and second function levels to the default switched, as an error has probably occurred at the signal source settings when the power supply is being connected.
  • Page 33 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 Q ) at 20 mA (curve 1a). max.
  • Page 34 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 flow rate Q select mA max. is shifted (curve 3b).
  • Page 35 9.9.3 Setting the weighting 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.

  • Page 36: Flow Monitor

    Result of weighting 9.10 Flow Monitor In the example, the following values were entered as reference 9.10.1 Application notes points L and H Dosing of degassing media (H , chlorine bleaching : mA = 6 mA, Q = 10 l/h min.
  • Page 37 Menu Info P:on Stop 10.0 Stop Start Start Down P:OFF Down P:OFF Menu Second function level Info Menu Info Fig. 42 Set cut-off pressure "P:ON" in the display: Suppression of dosing control function during start-up operation 1. Press the "Start/Stop" button. 60 error strokes* are permitted during the start-up operation, –...
  • Page 38 9.10.4 Pressure control function To protect the pump and system against Caution excessive pressure build-up, install an overflow valve in the discharge line. 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.
  • Page 39 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: •...
  • Page 40 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.

  • Page 41: Batch Menu / Batch Mode

    9.11 Batch menu / batch mode In batch mode, a defined batch quantity 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 Caution event of an error if the pump/system is not...

  • Page 42: Timer Menu / Timer Mode

    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 t elapsed. Batch dosing is then repeated after the repetition time t has elapsed until the user stops the process by pressing the "Start/Stop"...

  • Page 43: Creating A Master/Slave Application

    Selecting "Manual" or "Contact" timer mode 9.13 Creating a master/slave application • When the pump is running (LED lights up green), press the You can connect several secondary pumps and control the "Start/Stop" button. secondary pumps (slaves) via the first pump (master). –...

  • Page 44: Hotkeys / Info Keys

    9.14 Hotkeys / info keys The following important displays and functions of the DDI 222 can be accessed quickly using button combinations (hotkeys). Service functions Function Operating state of the pump Activate function / display Deactivate function / display In "Run", "Stop" or "Menu/Info" Press the "Start/Stop"...

  • Page 45: Pump Safety Functions

    9.15 Pump safety functions The DDI 222 pump is equipped with various safety functions as standard, which are indicated by the following indicators and behaviour of the pump. Safety functions Behaviour after error Designation Error Pump behaviour LED/display/relay removal The LED flashes red/green.

  • Page 46: Maintenance

    Collect and dispose of all chemicals correctly! Warning The pump housing must only be opened by personnel authorised by Grundfos! Repair must only be carried out by authorised and qualified personnel! Switch off the pump and disconnect it from the...

  • Page 47: Diaphragm Breakage

    10.4 Resetting the diaphragm 10.6 Replacing the diaphragm Warning Warning Danger of explosion, if dosing liquid has entered Risk of chemical burns! the pump housing! Wear protective clothing (gloves and goggles) If the diaphragm is possibly damaged, don’t when working on the dosing head, connections connect the pump to the power supply! or lines! Do not allow any chemicals to leak from the...

  • Page 48: Repair

    Observe section 10.5 Diaphragm breakage. If the above requirements are not met, Grundfos may refuse to accept delivery of the pump. The shipping costs will be charged to the sender. Fig. 57 Replacing the diaphragm for DDI 150-4 Pos.

  • Page 49: Fault Finding Chart

    Leaking suction line. Replace or seal the suction line. not suck in. b) Cross-section of the suction line too small or Check with Grundfos specification. suction line too long. c) Clogged suction line. Rinse or replace the suction line.

  • Page 50: Disposal

    12. Disposal This product or parts of it must be disposed of in an environmentally sound way. Use appropriate waste collection services. If this is not possible, contact the nearest Grundfos company or service workshop. Subject to alterations.
  • Page 51 Appendix Safety declaration Please copy, fill in and sign this sheet and attach it to the pump returned for service. Note Fill in this document using english or german language. Product type (nameplate) Model number (nameplate) Dosing medium Fault description Please make a circle around the damaged parts.

  • Page 52: Declaration Of Conformity

    RO: Declaraţie de conformitate CE Мы, компания Grundfos, со всей ответственностью заявляем, что Noi, Grundfos, declarăm pe propria răspundere că produsele DDI 222, la изделия DDI 222, к которым относится настоящая декларация, care se referă această declaraţie, sunt în conformitate cu aceste соответствуют...
  • Page 55 Phone: +852-27861706 / 27861741 Telefax: +47-22 32 21 50 Canada Telefax: +852-27858664 Turkey Poland GRUNDFOS Canada Inc. GRUNDFOS POMPA San. ve Tic. Ltd. Sti. Hungary 2941 Brighton Road GRUNDFOS Pompy Sp. z o.o. Gebze Organize Sanayi Bölgesi Oakville, Ontario GRUNDFOS Hungária Kft.

  • Page 56: Www.grundfos.com

    96690281 0514 ECM: 1126779 www.grundfos.com...

This manual is also suitable for:

Ddi 222 60-10Ddi 222 150-4Ddi 150-4Ddi 60-10

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