Grundfos Control DDD Installation And Operating Instructions Manual
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Grundfos Control DDD Installation And Operating Instructions Manual

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GRUNDFOS INSTRUCTIONS
Control DDD
Demand Driven Distribution
Installation and operating instructions

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Summary of Contents for Grundfos Control DDD

  • Page 1 GRUNDFOS INSTRUCTIONS Control DDD Demand Driven Distribution Installation and operating instructions...

  • Page 2: Table Of Contents

    Type key - Action to avoid the hazard. Overview of control variants 1.2 Notes Functions The symbols and notes below may appear in Grundfos Tree of functions installation and operating instructions, safety instructions and Overview service instructions. Description of functions...

  • Page 3: Receiving The Product

    9. The system is now ready for operation. 3. Installing the product Note that Grundfos can supply hydraulic data for CR, CRI, CRE Before installing the product, check the following: and CRIE pumps where GSC files can be downloaded to CU 354.

  • Page 4: Operating Panel

    5. Operating panel 5.1 Display The operating panel in the front cover of the control cabinet features a display, a number of buttons and two indicator lights. The operating panel enables manual setting and monitoring of the performance of the system. Fig.

  • Page 5: Buttons And Indicator Lights

    See also section 5.2.7 OK (10). Control DDD consists of a control cabinet with a built-in controller, If you press [OK] before pressing [Back], the new value will be CU 354. saved. See also section 5.2.7 OK...

  • Page 6: Description Of Functions

    6.1 Description of functions Control DDD is designed for water distribution networks. At the pumping station, the controller controls the pump speed based on actual flow rate and pressure. To optimise the proportional-pressure curve used by the controller, a number of remote sensors (up to ten) are installed at critical points in the distribution network, that is where stable pressure is required.

  • Page 7: Identification

    The nameplate is fitted on the control cabinet. The main pumps of the system must be of the same type and size. Type: 6.1.2 Control variant Model: Control DDD is divided into three groups based on control variant: Mains: Control Order NO.: Description variant...

  • Page 8: Type Key

    Control range Control variants Pumps with integrated frequency converter EC: Pumps connected to a Grundfos CUE frequency converter - one per pump EF: Pumps connected to other frequency converters - one per pump Number of pumps Current range of pumps...

  • Page 9: Overview Of Control Variants

    Systems with pumps connected to frequency converters Control DDD-E Control DDD-EC Control DDD-EF EC: Control DDD with three pumps, each EF: Control DDD with three pumps, each E: Control DDD with three E-pumps. connected to a Grundfos CUE frequency connected to a frequency converter.

  • Page 10: Functions

    8. Functions 8.1 Tree of functions The functions depend on system configuration. 1. Status 2. Operation 3. Alarm Continued on page 1. Status 2. Operation 3. Alarm status Actual alarms 2.1 Further settings 3.1 Actual alarms System 2.1.1 System operating mode 3.2 Alarm log 1.2.1 Operating mode 2.1.3 Alternative setpoints...
  • Page 11 Continued from page 4. Settings Continued on page Primary controller 4.1.1 PI controller 4.1.2 Alternative setpoints 4.1.2.1 Alternative setpoints 2-7 4.1.3 External setpoint influence 4.1.3.1 Input value to be influenced by 4.1.3.2 Setting of influence function 4.1.4 Primary sensor 4.1.6 Clock program 4.1.6.1 Event 1-10 4.1.7 Proportional pressure 4.1.9 Setpoint ramp...
  • Page 12 Continued from page 4. Settings Monitoring functions 4.4.1 Dry-running protection 4.4.1.1 Pressure/level switch 4.4.1.2 Measurement, inlet pressure 4.4.1.3 Measurement, tank level 4.4.2 Min. pressure 4.4.3 Max. pressure 4.4.4 External fault 4.4.5 Limit 1 exceeded 4.4.5.1 Input value to be monitored 4.4.5.2 Delays, limit 1 exceeded 4.4.5.3 Warning, limit 1 exceeded 4.4.5.4 Alarm, limit 1 exceeded...

  • Page 13: Overview

    8.2 Overview Section Display and display number See page 8.4 Status (1) 8.4.1 Actual alarms (3.1) 8.4.2 System (1.2) 8.4.3 Operating mode (1.2.1) 8.4.4 Setpoint (1.2.2) 8.4.5 Setpoint influence (1.2.3) 8.4.6 Measured values (1.2.4) 8.4.7 [Analog inputs (1.2.5) 8.4.8 Log graph (1.2.6) 8.4.9 Battery status (1.2.7) 8.4.10...
  • Page 14 Section Display and display number See page 8.7.32 Function of digital outputs (4.3.9.1 - 4.3.9.16) 8.7.33 Analog outputs (4.3.10) 8.7.34 Output signal (4.3.10.1 - 4.3.10.3) 8.7.35 Pilot pump curve data (4.3.18) 8.7.36 Pump curve data (4.3.19) 8.7.37 How to read the pump curve data 8.7.38 Control source (4.3.20) 8.7.39...

  • Page 15: Description Of Functions

    8.3 Description of functions The lower display half (B) shows the following: • the most recent active alarm, if any, and the fault cause with The description of functions is based on the four main menus of the fault code in brackets CU 354: •...
  • Page 16 8.4.2 System (1.2) 8.4.3 Operating mode (1.2.1) Fig. 20 System Fig. 21 Operating mode Description Description The display shows the operational state of the system. Go to The display shows the operating mode of the system and from subdisplays showing details. where it is controlled.
  • Page 17 8.4.4 Setpoint (1.2.2) 8.4.6 Measured values (1.2.4) Fig. 22 Setpoint Fig. 24 Measured values Description Description The display shows the selected setpoint and whether it comes The display gives a general status of all measured and calculated from CU 354 or an external bus. parameters.
  • Page 18 8.4.7 [Analog inputs (1.2.5) 8.4.9 Battery status (1.2.7) Fig. 25 Analog inputs Fig. 27 Battery status Description Description The display shows an overview of the analog inputs and the The display shows the status of the backup battery, if installed. measured values of each input.
  • Page 19 Description 8.4.12 Pump 1-6 (1.3 - 1.10) The display shows the different status information on the logger: Name: the name set for the sensor during commission, typically the site name.* Setpoint: the selected minimum pressure for the critical point.* Sofrel Status: •...
  • Page 20 8.5 Operation (2) 8.5.2 System operating mode (2.1.1) In this menu, you can set the basic parameters, such as setpoint, operating mode, control mode and individual pump control. 8.5.1 Operation (2) Fig. 33 System operating mode Description The system can be set to four different operating modes. Fig.
  • Page 21 8.5.3 Alternative setpoints (2.1.3) 8.5.4 Individual pump control (2.1.4) Fig. 34 Alternative setpoints Fig. 35 Individual pump control Description Description In addition to the primary setpoint 1 shown in display 2 in the You can see the status and operating mode of the pumps. "Operation"...

  • Page 22: Alarm

    8.5.5 Pump 1-6 (2.1.4.1 - 2.1.4.6) 8.6 Alarm (3) This menu gives an overview of alarms and warnings. You can reset alarms. 8.6.1 Alarm status (3) Fig. 36 Pump 1-6 Description The display is shown for the individual pumps and it allows you to set an operating mode.
  • Page 23 Warning Auto Water leakage Overload, pump Warning Auto Pumps outside duty Warning Man/auto range Warning Auto Fault, non-return valve Overload Warning Auto Alarm Underload Warning Pressure high Stop Man/auto Dry running Warning Warning Man/auto Low flow rate Warning Pressure low Alarm Stop Man/auto...
  • Page 24 8.6.2 Actual alarms (3.1) 8.6.3 Alarm log (3.2) The alarm log can store up to 24 warnings and alarms. Fig. 38 Actual alarms Fig. 39 Alarm log Description This submenu shows the following: Description • Warnings caused by faults that still exist. The display shows warnings and alarms.
  • Page 25 8.7 Settings (4) 8.7.1 Primary controller (4.1) Fig. 42 Primary controller Fig. 41 Settings Description In this menu, you can set the following functions: You can set the functions related to the primary controller. It is • Primary controller only necessary to make settings in this menu if the functionality is PI controller, Alternative setpoints, External setpoint influence, to be expanded with one of following functions: Primary sensor, Clock program, Proportional pressure,...
  • Page 26 8.7.2 PI controller (4.1.1) Description The function allows you to select up to six setpoints (2 to 7) as alternatives to the primary setpoint (1). The primary setpoint (1) is set in the "Operation" menu. Every alternative setpoint can be addressed manually to a separate digital input (DI).
  • Page 27 8.7.5 External setpoint influence (4.1.3) 8.7.6 Setting of influence function (4.1.3.2) Fig. 46 External setpoint influence Fig. 47 Setting of influence function Description Description The function allows you to adapt the setpoint by letting measuring You can select the relation between the measuring parameter parameters influence the setpoint.
  • Page 28 8.7.7 Primary sensor (4.1.4) 8.7.8 Clock program (4.1.6) Fig. 49 Primary sensor Fig. 50 Clock program Description Description You can select the control parameter of the system and set the With this function, you can adjust the setpoint, and day and time sensor to measure the value.
  • Page 29 Setting range 8.7.9 Proportional pressure (4.1.7) • Activation and setting of event. Fig. 52 Proportional pressure Fig. 51 Event 1 Description Setting via operating panel With this function the setpoint is automatically adapted to the actual flow rate to compensate for flow-dependent dynamic •...
  • Page 30 Fig. 56 Proportional pressure, manual adaptation Pos. Description Fig. 54 Automatic adaptation of proportional-pressure curve Pressure at 0 flow. Starting point of proportional- pressure control (influence at 0 flow = x % of setpoint) Pos. Description Qpmax Setpoint Pressure at 0 flow. Starting point of proportional- pressure control.
  • Page 31 8.7.10 Setpoint ramp (4.1.9) 8.7.11 Tank filling (4.1.10) Fig. 57 Setpoint ramp Fig. 58 Tank filling Description Description When this function is enabled, setpoint changes are affected by This function makes it possible to use intelligent level control for the setpoint ramp, and the setpoint changes gradually over a tank filling applications.
  • Page 32 Setting via the operating panel Setting via operating panel • Settings > Primary controller > Tank filling. Settings > Pump cascade control > Min. time between start/stop. 1. Select: Enable. Factory setting 2. Set Tank height, which corresponds to the height of the tank. The setting is done in the startup wizard and depends on the 3.
  • Page 33 8.7.14 Min. time and max. number of starts (4.2.1) 8.7.15 Standby pumps (4.2.3) Fig. 62 Min. time and max. number of starts Fig. 63 Standby pumps Description Description The function limits the number of pump starts and stops per hour The function makes it possible to limit the maximum performance for the complete system.
  • Page 34 8.7.16 Forced pump changeover (4.2.4) 8.7.17 Pump test run (4.2.5) Fig. 64 Forced pump changeover Fig. 65 Pump test run Description Description The function ensures that the pumps run for the same number of The function is primarily used in situations where the forced pump operating hours.
  • Page 35 8.7.18 Pump stop attempt (4.2.7) 8.7.19 Pump start and stop speed (4.2.8) Fig. 66 Pump stop attempt Fig. 67 Pump start and stop speed Description Description The function makes it possible to set automatic stop attempts of a The function controls the starting and stopping of pumps. pump when several pumps are running.
  • Page 36 8.7.22 Stop function (4.3.1) The function is not used for DDD systems. 8.7.21 Secondary functions (4.3) Fig. 70 Stop function Description The function is used to stop the last pump if there is no or a very small consumption. Fig. 69 Secondary functions Purpose of the function: •...
  • Page 37 5. Press x 2. A: Normal operation 6. Set: Start/stop band. B: Pressure boosting 7. Set: Stop limit C: Stop By default, there is a 10-second detection hysteresis. Stop 8.7.23 Pilot pump (4.3.2) Start Stop: Hset + 0.5 x start/stop band Start: Hset - 0.5 x start/stop band Fig.
  • Page 38 Factory setting • Filling pressure The function is disabled. • Max. time. 2. Select: Warning or Alarm + stop. 8.7.24 Soft pressure build-up (4.3.3) 3. Set: Ramp time. 4. Select: Enabled. Factory setting The function is disabled. 8.7.25 Emergency run (4.3.5) Fig.
  • Page 39 8.7.26 Digital inputs (4.3.7) 8.7.27 Functions of digital inputs (4.3.7.1) Fig. 77 Digital inputs Fig. 78 Functions of digital inputs Description Description In the menu, you can set the digital inputs of CU 354 and IO A function can be related to the digital inputs. 351B.
  • Page 40 8.7.28 Analog inputs (4.3.8) 8.7.29 Analog inputs (4.3.8.1 - 4.3.8.7) Fig. 79 Analog inputs Fig. 80 Analog inputs Description Description Each analog input of CU 354 and IO 351B can be activated and In the menu, you can set analog inputs. Each display is divided related to a certain function.
  • Page 41 8.7.30 Analog inputs and measured value (4.3.8.1.1 - 8.7.31 Digital outputs (4.3.9) 4.3.8.7.1) Fig. 82 Digital outputs Fig. 81 Analog inputs and measured value Description Description Each digital output can be activated and related to a certain A function can be related to the individual analog inputs. function.
  • Page 42 Setting range 8.7.34 Output signal (4.3.10.1 - 4.3.10.3) You can select one function in each display: • No function • Operation, system • Alarm, system • Warning, system • Ready, system • Water shortage • Min. pressure • Max. pressure •...
  • Page 43 Grundfos Product Center at www.grundfos.com. See figs examples in figs 88 to 91. to 91. If you cannot access Grundfos Product Center, try bringing a If you cannot access Grundfos Product Center, try bringing a pump into the three duty points: pump into the three duty points: •...
  • Page 44 Power, Q0, 50 % speed • Rated power Pnom. Fig. 89 Reading of power, Q0, 100 % speed (Grundfos Product Center) Duty point, Q0, 50 % speed Power, Q0, 50 % speed Fig. 90 Reading of power, Q0, 50 % speed (Grundfos Product Center)
  • Page 45 8.7.38 Control source (4.3.20) 8.7.40 Flow estimation (4.3.23) Fig. 92 Control source Fig. 94 Flow estimation Description The system can be remote-controlled via an external bus The function is not used for DDD systems. connection (option). See section 8.8.2 GENIbus. See also section 8.8 Data communication.
  • Page 46 8.7.42 Remote sensors (4.3.25) 8.7.43 Remote sensor 1-10 (4.3.25.1) Fig. 96 Remote sensors Fig. 97 Sofrel logger Description Description The function allows you to enter the phone number for CU 354. The function allows you to enable the remote sensor and select The number must start with the country code (e.g.
  • Page 47 Setting range XiLog sensor Factory setting • Setting the remote sensor to enabled. The function is disabled as the following has been set: – Select the sensor type Number of pumps in operation during user-defined duty: • Entering a unique name for the remote sensor. 8.7.45 Tank filling parameters (4.3.27) •...
  • Page 48 8.7.46 Measurement supervision (4.3.28) 8.7.47 Supervision 1 to Supervision 6 (4.3.28.1 - 6) Fig. 100Measurement supervision Fig. 101Supervision 1 to Supervision 6 Description Description The function is designed to monitor up to six different input values Each Supervision parameters must be defined. and let them influence or limit the setpoint.
  • Page 49 8.7.48 Monitoring functions (4.4) 8.7.49 Dry-running protection (4.4.1) Fig. 102Monitoring functions Fig. 103Dry-running protection Description Description The system has a series of functions that constantly monitor the Dry-running protection is one of the most important monitoring operation of the system. functions, as bearings and shaft seal may be damaged if the pumps run dry.
  • Page 50 8.7.50 Pressure/level switch (4.4.1.1) 8.7.51 Measurement, inlet pressure (4.4.1.2) Fig. 104Pressure/level switch Fig. 105Measurement, inlet pressure Description Description Dry-running protection can take place by means of a pressure Dry-running protection can take place by means of a pressure switch on the inlet manifold or a level switch in a tank on the inlet transmitter measuring the inlet pressure.
  • Page 51 8.7.52 Measurement, tank level (4.4.1.3) 8.7.53 Min. pressure (4.4.2) Fig. 106Measurement, tank level Fig. 107Min. pressure Description Description Dry-running protection can take place by means of a level The outlet pressure will be monitored if the function is enabled. transmitter measuring the level in a tank on the inlet side. CU 354 will react if the pressure becomes lower than a set minimum level for an adjustable time.
  • Page 52 8.7.54 Max. pressure (4.4.3) 8.7.55 External fault (4.4.4) Fig. 108Max. pressure Fig. 109External fault Description Description The outlet pressure will be monitored if the function is enabled. The function is used when CU 354 is to be able to receive a fault CU 354 will react if the pressure becomes higher than a set signal from an external contact.
  • Page 53 8.7.56 Limit 1 exceeded (4.4.5 - 4.4.6) Setting via the operating panel Analog inputs must be correctly set before the function is enabled. See section 8.7.28 Analog inputs (4.3.8). • Settings > Monitoring functions > Limit 1 exceeded / Limit 2 exceeded >...
  • Page 54 8.7.57 Pumps outside duty range (4.4.7) 8.7.58 Log values (4.4.9) Fig. 111 Pumps outside duty range Fig. 112Log values Description Description The function gives a warning if the duty point of the pumps moves Select the values to be logged and the number of samples per outside the defined range.
  • Page 55 8.7.59 Fault, primary sensor (4.4.10) 8.7.60 Night flow monitoring (4.4.11) Fig. 113Fault, primary sensor Fig. 114Night flow monitoring Description Description You can set how the system reacts if the primary sensor fails. You can set the system to monitor the flow at night (default setting is between 2:00 AM and 4:00 AM).
  • Page 56 8.7.61 Functions, CU 354 (4.5) 8.7.62 Display language (4.5.1) Fig. 115Functions, CU 354 Fig. 116Display language Description Description Make the basic settings of CU 354 in this submenu. Here you select the language for the CU 354 display. CU 354 comes with most of these settings, or they are made at Setting range startup and normally not to be changed.
  • Page 57 Setting range 8.7.64 Date and time (4.5.3) Basic setting Parameter Possible units Imperial kPa, MPa, mbar, Pressure bar, m, psi kPa, MPa, mbar, Differential pressure bar, m, psi Head m, cm, ft, in Level m, cm, ft, cm /s, m /h, l/s, Flow rate gpm, yd...
  • Page 58 (option). See also fig. and section 8.8.2 GENIbus. Communication is carried out according to the Grundfos bus protocol, GENIbus, and enables connection to a building management system or another external control system. Operating parameters, such as setpoint and operating mode, can be set via the bus signal.
  • Page 59 CIM 270 can establish communication with a GSM configuration files (GSC) read into the unit are shown. You can network. also upgrade the software version. Contact Grundfos for further information. Change the PIN code by inserting the SIM card into a mobile phone.

  • Page 60: Data Communication

    8.8 Data communication CU 354 is equipped with a hardware enabling communication with external units, such as a computer, via an external GENIbus or Ethernet connection. Grundfos CIU 250 GSM communication interface including SCADA/ a CIM 040 module* BMS system...
  • Page 61 8.8.1 Ethernet This is the first display shown when connecting to CU 354. Ethernet is the most widely used standard for local networks (LAN). The standardisation of this technology has created some of the easiest and cheapest ways of creating communication between electric units, for instance between computers or between computers and control units.
  • Page 62 ACCESS: changed to <access Grundfos for further information. option> The gateway may be a Grundfos CIU or a third-party gateway. The access will be changed to LIST and you can proceed. For further information on the CIU, see Grundfos Product Center, or contact Grundfos.

  • Page 63: Measuring Parameters

    9. Measuring parameters Command Description 9.1 Transmitter types With this configuration command, you can add a number to the CIM 250 phone number list. The number The transmitter types in the table below can be used for the must be of international format with "+" followed by the measurement of values in the system.

  • Page 64: Servicing The Product

    Repair or replace the cable. c) The power supply is disconnected. Connect the power supply. d) CU 354 is defective. Contact Grundfos. e) The power supply is disconnected. Connect the power supply. The main switch is switched off. Switch on the main switch.

  • Page 65: Technical Data

    24 VDC 1. Use the public or private waste collection service. Closed-circuit current: 5 mA, DC 2. If this is not possible, contact the nearest Grundfos company Frequency range: 0-4 Hz or service workshop. The crossed-out wheelie bin symbol on a product...
  • Page 67 Telefax: +64-9-415 3250 GRUNDFOS Pumps (Hong Kong) Ltd. Turkey Norway Brazil Unit 1, Ground floor GRUNDFOS POMPA San. ve Tic. Ltd. Sti. Siu Wai Industrial Centre GRUNDFOS Pumper A/S BOMBAS GRUNDFOS DO BRASIL Gebze Organize Sanayi Bölgesi 29-33 Wing Hong Street &...
  • Page 68 98509352 06.2020 ECM: 1282948 www.grundfos.com...

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