Installation, Commissioning
and Technical Information
for the 0.03 - 30 L/Hr
Marine Dosing Unit
Innospec Limited
PO Box 17
Oil Sites Road
Ellesmere Port
Cheshire CH65 4EY, U.K.
tel: +44 (0)151 355 3611
fax: +44 (0)151 356 2349
The information contained in this document is provided free of charge and is based on technical data that Innospec believes to be reliable. It is intended
for use by persons having technical skill and at their own discretion and risk. Innospec accepts no liability for any loss, damage or expense arising from, or
in connection with, the use of the information. Furthermore, none of the contents of this publication should be taken as a licence to operate under any
patent, nor as a recommendation to infringe any patent.
Contents
System Specifications 3
Suction assembly 9
Functional Description 14
Commissioning Procedure 15
Spare Parts 17
Technical Information 17
System Specifications
Power Supply : 100 - 240 VAC 50/60 Hz, 0.5 Amps max
1 1
2 2
3 3
4 4
Page 9 of 50
5 5
6 6
7 7
INNOSPEC MARINE
SPECIALTIES ASSEMBLY
Name Date Title Drum plug with Low Level
Designed DM 23-01-14
Without dry break coupling
Checked BDB 23-01-14
AQ-10700021
Scale Format
8 8
- Aquality drawing nr: REV:
- 213.0700.010 0
Aquality b.v. www.aqualitybv.eu
Postbus 76, 3250 AB Scheelhoekweg 9, 3251 LZ mail: info@aqualitybv.nl
Stellendam Stellendam tel: +31-187-492541
A K J I H G F E C B A
1
AQ-10700024 1
J&R-10700012
GEH-516104VITON
GEH-22440404
2 2
GEH-46010
4 4
AQ-10700023
Page 10 of 50
5 5
6 6
J&R-10700138
7 7
TEE-21042100
INNOSPEC MARINE
SPECIALTIES ASSEMBLY
Name Date Title Drum plug with Low Level
Designed DM 23-01-14
Without dry break coupling
Checked BDB 23-01-14
-
HYD-1271983-100 Scale Format
8 8
- Aquality drawing nr: REV:
- 213.0700.011 0
Aquality b.v. www.aqualitybv.eu
Postbus 76, 3250 AB Scheelhoekweg 9, 3251 LZ mail: info@aqualitybv.nl
1 1
2 2
AQ-10700066
4 4
Page 11 of 50
5 5
6 6
7 7
INNOSPEC MARINE
SPECIALTIES ASSEMBLY
Name Date Title Dry break coupling
Designed DM 23-01-14
AQ-10700066
Checked BDB 23-01-14
-
Scale Format
8 8
- Aquality drawing nr: REV:
- 213.0700.012 0
Aquality b.v. www.aqualitybv.eu
Postbus 76, 3250 AB Scheelhoekweg 9, 3251 LZ mail: info@aqualitybv.nl
Stellendam Stellendam tel: +31-187-492541
A K J I H G F E C B A
Installation Procedure
Please refer to the P&ID on page 4. Please see Appendix A for details on how to set up the dosing system for
injecting continuously at the Purifiers.
Securely mount the dosing cabinet, using the fixing brackets supplied, to a suitable location in the vicinity of the
fuel transfer pump.
Important: The vertical distance (height) between pump unit and bottom of the product drum must
not exceed 3 meters (10 feet).
Note 1: Ensure that the Octamar™ product drum is secured tightly to the ship build so free
movement is not possible.
SECURE THE
OCTAMAR™
PRODUCT
DRUM
A. Connect the pump suction side (13) with flexible hose to the suction assembly and drum closer with suction
filter (7+8+9)
B. Suspend the suction hose with suction assembly, drum-closer, suction filter and low level switch (7+8+9) in
the product drum
C. Connect the square male plug to the female plug of the control cable (10)
D. Connect the round plug on the other side of the cable to the dosing pump socket. This is the socket on the
left bottom, below the blue plug
Note 2: Notice the positioning cam on the plug to be pointing downwards. This must not be
damaged! For further information see dosing pump manual
Note 3: Ensure that the drum-closer is screwed in completely so that the suction valve and filter will
hang 1 cm above the bottom of the drum
E. Connect the pump discharge (15) with flexible hoses (4) to the injection assembly (5) and fit the injection
nozzle in the fuel transfer pump suction line or filter
F. Connect the short air bleed hose (6) and place a small container beneath the outlet from the bleed
discharge
G. Connect a power supply cable to connection/switch box (18)
The power supply is single phase multi-voltage 100 – 240 VAC 50/60 Hz. The power supply is connected at the
left hand terminals: L; N; Earth. For further information, see electrical wiring drawing.
1. Configuration No Memory.
2. Current threshold 20 %
3. Hysteresis 10 %
4. Time delay 0,3 sec
5. Start up inhibition 1 sec
H. Connect the Current transformer (11) in the starter tray of the fuel transfer pump or in the starter cabinet of
the fuel transfer pump. Disconnect one of the phases of the power supply to the fuel transfer pump and
lead this wire through the current transformer. Re-connect the wire. Note: Electrical isolation of the
2
transfer pump is required before disconnecting any phase wires. Connect a two-wire cable (2.5mm )
from the current transformer to the dosing cabinet and connect to terminal 3 and 4 in connection/switch box
(18). This cable should be no greater than 25m long to maintain the integrity of the signal. The use of a
2
shielded cable can minimise any electrical noise in the signal. The 2.5 mm wires will minimise voltage
drop for the signal.
Functional Description
The Innospec marine dosing system should always be switched ON. When the fuel transfer pump is energized,
a current will flow through the electrical cable to the transfer pump. The installed current transformer (11) will
transform that current in a ratio of 10:1.
The current will be lead to the current relay (18). Above 1 amp; the current relay will be energized. The output
contacts will be closed. The dosing pump will start pumping the Octamar™ product.
Information on how to test the dosing pump and how to bleed the system can be found in the commissioning
section on page 15 of this manual.
Commissioning Procedure
The system is designed so that the dosing pump will only operate when the fuel transfer pump is switched on.
Prior to putting the dosing unit into service, the system has to be primed and bled of air. After the dosing pump
has been primed, the correct chemical dosing rate (flow rate in L/hr) has to be set. You will be informed about
the recommended flow rate for your installation prior to commissioning.
Please follow the instructions below:-
BLEED:
1. Re-priming of the pump may be necessary after changing the product drum and/or if the pump and
hoses have been disconnected for maintenance or repair. Refer to page 15 Commissioning Procedure
2. After the electrical power is turned on, the pump might give a few strokes automatically to prime the
dosing head
3. At pump failure, over pressure and low level of the drum, the pump display will change to red colour on
alarm status. The alarms are logged and can be found by moving the display cursor to the Bell
symbol. Dosing will STOP during an alarm
4. It is very important that the pump doesn’t continue to be operated or tested if you get two successive
‘Motor Blocked’ Alarms on the display (which will change to red colour). If you get this alarm please
check that the injection line has no closed valves and that there is no blockage into the fuel line.
Continued operation of the pump in this condition will cause it to catastrophically fail
5. When the low drum level alarm activates the screen will turn red and the following symbol
will be shown on the bottom right hand corner of the display. The Octamar™ drum will need
to be replaced or topped up when this alarm is activated. The alarm will automatically clear
when Octamar™ is added to the drum or if the drum is replaced. Note that the dosing pump
won’t operate whilst this alarm is active
6. If the dosing pump automatically starts up when the fuel transfer pump starts but then stops it is likely
that the current transformer needs to be moved to a more sensitive terminal on the relay, i.e. E3 to E2
or E2 to E1 depending on which is was originally connected to. Refer to details on top of Page 14
7. In normal operation (with the dosing pump off and waiting for the transfer pump to start) the
dosing pump should display the PAUSED symbol so that when the transfer pump starts
the dosing pump kicks in automatically. Should the display show the STOP symbol the pump
won’t automatically start. To switch between the two symbols the Start/stop button should be
pressed.
Spare Parts
If spare parts are required, please contact your nearest Innospec Marine Specialties office. Address and
contact details can be found on the inside of the cabinet door.
Please quote the pump serial number, the system serial number and item(s) you require. Please also refer to
the parts listing shown in the P&ID on page 4 & 5 of this manual.
TECHNICAL INFORMATION
English (GB)
Original installation and operating instructions. 6.5 Analog output 26
6.6 SlowMode 26
CONTENTS 6.7 FlowControl 27
Page 6.8 Pressure monitoring 28
6.8.1 Pressure setting ranges 28
1. Safety instructions 4
6.8.2 Calibration of pressure sensor 28
1.1 Identification of safety instructions in
6.9 Flow measurement 29
these instructions 4
6.10 AutoFlowAdapt 29
1.2 Qualification and training of personnel 4
6.11 Auto deaeration 29
1.3 Safety instructions for the operator/
user 4 6.12 Key lock 30
1.4 Safety of the system in the event of a 6.13 Display Setup 30
failure in the dosing pump 4 6.13.1 Units 30
1.5 Dosing chemicals 5 6.13.2 Additional display 30
6.14 Time/date 31
2. General 5
6.15 Bus communication 31
2.1 Applications 5
6.16 Inputs/outputs 31
2.2 Improper operating methods 5
6.16.1 Relay outputs 31
2.3 Warranty 6
6.16.2 External stop 32
2.4 Nameplate 6
6.16.3 Empty and low-level signals 32
2.5 Type key 7
6.17 Basic settings 32
2.6 Device overview 8
7. Service 33
3. Technical data / dimensions 9
7.1 Service system 33
3.1 Technical data 9
7.2 Perform service 33
3.2 Dimensions 11
7.2.1 Dosing head overview 34
4. Assembly and installation 12 7.2.2 Dismantling the diaphragm and valves 34
4.1 Pump assembly 12 7.2.3 Reassembling the diaphragm and
4.1.1 Requirements 12 valves 34
4.1.2 Align and install mounting plate 12 7.3 Resetting the service system 34
4.1.3 Engage pump in mounting plate 12 7.4 Repairs 34
4.1.4 Adjusting control cube position 12 8. Faults 35
4.2 Hydraulic connection 13 8.1 List of faults 36
4.3 Electrical connection 14 8.1.1 Faults with error message 36
5. Commissioning 16 8.1.2 General faults 38
5.1 Setting the menu language 16 9. Disposal 38
5.2 Deaerating the pump 17
5.3 Calibrating the pump 17
Warning
6. Operation 19 Prior to installation, read these
6.1 Control elements 19 installation and operating instructions.
6.2 Display and symbols 19 Installation and operation must comply
6.2.1 Navigation 19 with local regulations and accepted
6.2.2 Operating states 19 codes of good practice.
6.2.3 Sleep mode (energy-saving mode) 19
6.2.4 Overview of display symbols 20
6.3 Main menus 21
6.3.1 Operation 21
6.3.2 Info 21
6.3.3 Alarm 21
6.3.4 Setup 21
6.4 Operation modes 22
6.4.1 Manual 22
6.4.2 Pulse 22
6.4.3 Analog 0/4-20 mA 23
6.4.4 Batch (pulse-based) 24
6.4.5 Dosing timer, cycle 25
6.4.6 Dosing timer, week 25
3
1. Safety instructions
English (GB)
These installation and operating instructions contain 1.3 Safety instructions for the
general instructions that must be observed during operator/user
installation, operation and maintenance of the pump.
It must therefore be read by the installation engineer The safety instructions described in these
and the relevant qualified operator prior to instructions, existing national regulations on health
installation and start-up, and must be available at the protection, environmental protection and for accident
installation location at all times. prevention and any internal working, operating and
safety regulations of the operator must be observed.
1.1 Identification of safety instructions in Information attached to the pump must be observed.
these instructions Leakages of dangerous substances must be
The safety instructions are identified by the following disposed of in a way that is not harmful to the
symbols: personnel or the environment.
Damage caused by electrical energy must be
Warning prevented, see the regulations of the local electricity
If these safety instructions are not supply company.
observed, it may result in personal
injury! Before any work to the pump, the pump
must be in the ’Stop’ operational state
Caution
or be disconnected from the mains.
If these safety instructions are not
The system must be pressureless!
Caution observed, it may result in malfunction
or damage to the equipment! Only orginal accessories and original spare parts
should be used. Using other parts can result in
Notes or instructions that make the job exemption from liability for any resulting
Note
easier and ensure safe operation. consequences.
1.2 Qualification and training of personnel 1.4 Safety of the system in the event of a
The personnel responsible for the installation, failure in the dosing pump
operation and service must be appropriately The dosing pump was designed according to the
qualified for these tasks. Areas of responsibility, latest technologies and is carefully manufactured
levels of authority and the supervision of the and tested.
personnel must be precisely defined by the operator.
If necessary, the personnel must be trained If it fails regardless of this, the safety of the overall
appropriately. system must be ensured. Use the relevant
monitoring and control functions for this.
Risks of not observing the safety instructions
Non-observance of the safety instructions may have Make sure that any chemicals that are
dangerous consequences for the personnel, the released from the pump or any
environment and the pump and may result in the loss damaged lines do not cause damage to
of any claims for damages. Caution system parts and buildings.
It may lead to the following hazards: The installation of leak monitoring
solutions and drip trays is
• Personal injury from exposure to electrical,
recommended.
mechanical and chemical influences.
• Damage to the environment and personal injury
from leakage of harmful substances.
4
1.5 Dosing chemicals 2. General
English (GB)
The DDA dosing pump is a self-priming
Warning
diaphragm pump. It consists of a housing
Before switching the supply voltage with stepper motor and electronics, a
back on, the dosing lines must be dosing head with diaphragm and valves and the
connected in such a way that any control cube.
chemicals in the dosing head cannot
Excellent dosing features of the pump:
spray out and put people at risk.
• Optimal intake even with degassing media, as
The dosing medium is pressurised and
the pump always works at full suction stroke
can be harmful to health and the
volume.
environment.
• Continuous dosing, as the medium is sucked up
Warning with a short suction stroke, regardless of the
current dosing flow, and dosed with the longest
When working with chemicals, the possible dosing stroke.
accident prevention regulations
applicable at the installation site 2.1 Applications
should be applied (e. g. wearing
protective clothing). The pump is suitable for liquid, non-abrasive, non-
flammable and non-combustible media strictly in
Observe the chemical manufacturer's
accordance with the instructions in these installation
safety data sheets and safety
and operating instructions.
instructions when handling chemicals!
Areas of application
Warning • Drinking water treatment
If the diaphragm leaks or is broken, • Wastewater treatment
dosing liquid will escape from the • Swimming pool water treatment
discharge opening on the dosing head
(see fig. 3). • Boiler water treatment
Take suitable precautions to prevent • CIP (Clean-In-Place)
harm to health and damage to property • Cooling water treatment
from escaping dosing liquid! • Process water treatment
Check daily whether liquid is escaping • Wash plants
from the discharge opening! • Chemical industry
Changing the diaphragm, see section • Ultrafiltration processes and reverse osmosis
7. Service.
• Irrigation
A deaeration hose, which is routed into • Paper and pulp industry
Caution a container, e. g. a drip tray, must be • Food and beverage industries
connected to the deaeration valve.
2.2 Improper operating methods
The dosing medium must be in liquid The operational safety of the pump is only
aggregate state! guaranteed if it is used in accordance with section
Caution
Observe the freezing and boiling points 2.1 Applications.
of the dosing medium!
Warning
The resistance of the parts that come Other applications or the operation of
into contact with the dosing medium, pumps in ambient and operating
such as the dosing head, valve ball, conditions, which are not approved,
gaskets and lines, depends on the are considered improper and are not
medium, media temperature and permitted. Grundfos cannot be held
operating pressure. liable for any damage resulting from
Ensure that parts in contact with the incorrect use.
Caution dosing media are resistant to the
dosing medium under operating Warning
conditions, see data booklet! The pump is NOT approved for
Should you have any questions operation in potentially explosive
regarding the material resistance and areas!
suitability of the pump for specific
dosing media, please contact Warning
Grundfos. A sunscreen is required for outdoor
installation!
5
2.5 Type key
English (GB)
The type key is used to identify the precise pump and is not used for configuration purposes.
Pump type
Max. flow [l/h]
Max. pressure [bar]
Control variant
AR Standard
FC AR with FlowControl
FCM FC with integrated flow measurement
Gasket material
E EPDM
V FKM
T PTFE
Voltage
3 1 x 100-240 V, 50/60 Hz
Valve type
1 Standard
2 Spring-loaded (HV version)
Power plug
F EU (Schuko)
B USA, Canada
G UK
I Australia, New Zealand, Taiwan
E Switzerland
J Japan
L Argentina
Design
G Grundfos Alldos
*) including: 2 pump connections, foot valve, injection unit, 6 m PE discharge hose, 2 m PVC suction hose,
2 m PVC deaeration hose (4/6 mm)
7
2.6 Device overview
English (GB)
Control cube
Graphic LC display
(Sect. 6.2.2)
Deaeration valve
8
3. Technical data / dimensions
English (GB)
3.1 Technical data
9
DDA pump type
English (GB)
Data
7.5 - 16 12-10 17-7 30-4
Sound
pressure Max. sound pressure level [dB(A)] 60
level
1)
The maximum stroke frequency varies depending on calibration
2)
Data is based on measurements with water
3)
Maximum suction lift: 1 m, dosing flow reduced (approx. 30 %)
4)
Length of suction line: 1.5 m / length of discharge line: 10 m (at max. viscosity)
5) With E-Box.
10
4.3 Electrical connection
English (GB)
Warning
The enclosure class (IP65 / Nema 4X) is only guaranteed if plugs or protective caps are
correctly installed!
Warning
The pump can start automatically when the mains voltage is switched on!
Do not manipulate mains plug or cable!
The rated voltage of the pump, see section 2.4 Nameplate, must conform to local conditions.
Signal connections
2 1 2 1
3 4 3 4
4 3 2 1
5
1 2 3 4
14
Analog, external stop and pulse input
English (GB)
Pins
Function Plug type
1/brown 2/white 3/blue 4/black
Pins
Function Plug type
1/brown 2/white 3/blue 4/black
Pins
Function Plug type
5/yellow/
1/brown 2/white 3/blue 4/black
green
Relay outputs
Pins
Function Plug type
1/brown 2/white 3/blue 4/black
Relay 1 X X Pulse
Relay 2 X X Pulse
Sensor
TM04 1158 0110
15
5. Commissioning
English (GB)
Operation
2. Press the click wheel to open the ’Setup’ menu.
7.50 l/h
Manual
Setup
3. Turn the click wheel to highlight the ’Language’ Language English >
menu. Operation mode Manual >
Analog output Actual flow
SlowMode Off
FlowControl active ❑
Setup
4. Press the click wheel to open the ’Language’ Language English >
menu. Operation mode Manual >
Analog output Actual flow
SlowMode Off
FlowControl active ❑
Setup
5. Turn the click wheel to highlight the desired English
language. Deutsch ❑
Francais ❑
Espanol ❑
Italiano ❑
Setup
6. Press the click wheel to select the highlighted English
Deutsch ❑
language.
Francais ❑
Espanol ❑
Italiano ❑
Setup
7. Press the click wheel again to confirm the
TM04 1184 1110
16
5.2 Deaerating the pump
English (GB)
Warning
The deaeration hose must be
connected correctly and inserted into a
suitable tank!
17
Calibration process - example for DDA 7.5 - 16
English (GB)
Calibration
4. Start the calibration process in the ’Setup >
Calibration’ menu.
Strokes
200 START
STOP
Calibration
5. The pump executes 200 dosing strokes and
200
displays the factory calibration value
(e. g. 125 ml). Strokes
Vd = V1 - V2 = 130 ml
7. From V1 and V2 , calculate the actual dosed
volume Vd = V1-V2
(e. g. 300 ml - 170 ml = 130 ml).
Calibration
Strokes START
200
8. Set and apply Vd in the calibration menu.
– The pump is calibrated. STOP
TM04 1154 1110
18
6. Operation 6.2 Display and symbols
English (GB)
6.2.1 Navigation
6.1 Control elements
In the ’Info’, ’Alarm’ and ’Setup’ main menus, the
The pump control panel includes a display options and submenus are displayed in the rows
and the following control elements. below. Use the ’Back’ symbol to return to the higher
menu level. The scroll bar at the right edge of the
display indicates that there are further menu items
which are not shown.
Graphical LC
Operation
display The active symbol (current cursor position) flashes.
7.50 l/h Press the click wheel to confirm your selection and
Manual 7.49 l/h open the next menu level. The active main menu is
Click wheel displayed as text, the other main menus are
displayed as symbols. The position of the cursor is
100% highlighted in black in the sub-menus.
When you position the cursor on a value and press
the click wheel, a value is selected. Turning the
clickwheel clockwise increases the value, turning the
19
6.2.4 Overview of display symbols
The following display symbols may appear in the menus.
English (GB)
Operation
7.48 l/h
Manual 7.48l/h
100% Deaerating
Diaphragm position 'out’ (Sect. 7.)
Diaphragm position ’in’ (Sect. 7.)
20
6.3 Main menus 6.3.3 Alarm
You can view errors in the ’Alarm’ main menu.
English (GB)
The main menus are displayed as symbols at the top
of the display. The currently active main menu is
displayed as text.
Alarm
6.3.1 Operation 1 12.02.2010 12:34
Status information such as the dosing flow, Empty
selected operation mode and operating state
is displayed in the ’Operation’ main menu. 2 12.02.2010 12:34
Low level
21
6.4 Operation modes 6.4.2 Pulse
In this operation mode, the pump doses the
English (GB)
6.4.1 Manual
In this operation mode, the pump constantly Operation
doses the dosing flow set with the click wheel.
3.40 l/h the click wheel. The setting range for the dosing
volume depends on the pump type:
Manual 3.40l/h
Type Setting range [ml/pulse]
DDA 7.5 - 16 0.0013 - 12.8
Fig. 15 Manual mode
DDA 12-10 0.0026 - 25.8
The setting range depends on the pump type: DDA 17-7 0.0027 - 26.8
Setting range* DDA 30-4 0.0058 - 58.4
Type
l/h gph The frequencyof incoming pulses is multiplied by the
DDA 7.5 - 16 0.0025 - 7.5 0.0007 - 2.0 set dosing volume. If the pump receives more pulses
than it can process at the maximum dosing flow, it
DDA 12-10 0.012 - 12 0.0031 - 3.1 runs at the maximum stroke frequency in continuous
DDA 17-7 0.017 - 17 0.0045 - 4.5 operation. Excess pulses will be ignored if the
memory function is not enabled.
DDA 30-4 0.03 - 30 0.0080 - 8.0
Memory function
* When the SlowMode function is active, the maximum When the ’Setup > Pulse memory’ function is
dosing flow is reduced, see section 3.1 Technical enabled, up to 65,000 unprocessed pulses can be
data. saved for subsequent processing.
22
6.4.3 Analog 0/4-20 mA Set analog scaling
In this operation mode, the pump doses Analog scaling refers to the assignment of the
English (GB)
according to the external analog signal. The current input value to the dosing flow.
dosing volume is proportional to the signal input Analog scaling passes through the two reference
value in mA. points (I 1 / Q1) and (I 2 / Q2), which are set in the
’Setup > Analog scaling’ menu. The dosing flow is
Operation controlled according to this setting.
Input value Dosing flow
mode
Example 1 (DDA 7.5 - 16)
≤ 4.1 mA 0% Analog scaling with positive gradient:
4 - 20 mA
≥ 19.8 mA 100 %
Q [l/h]
≤ 0.1 mA 0% (I 2 / Q 2)
0 - 20 mA 7.5
≥ 19.8 mA 100 %
Q [%]
Fig. 19 Analog scaling with pos. gradient
100
In example 1, the reference points I1 = 6 mA,
80
mA Q 1 = 1.5 l/h and I 2 = 16 mA, Q 2 = 7.5 l/h have been
20
60 0- set.
TM04 1120 2010
6.5
TM04 1127 1110
(I 1 / Q1)
ml/h 7,5
0-20 mA 17.14 mA
0
0 2 16 20 I [mA]
23
Set analog scaling in the ’Operation’ menu The batch volume (e. g. 75 ml) is set in the ’Setup >
Analog scaling can also be modified after a security Batch volume’ menu. The minimum dosing time
English (GB)
prompt directly in the ’Operation’ menu. This is how required for this (e. g. 32 seconds) is displayed and
the dosing flow is directly modified for the current can be increased.
flow input value.
t1 t1
(e. g. 75 ml) and the remaining batch volume still to
Time be dosed (e. g. 43 ml) are shown in the display.
Pulse Pulse
24
6.4.5 Dosing timer, cycle The total batch volume (e. g. 125 ml) and the
In this operation mode, the pump doses the remaining batch volume still to be dosed are
English (GB)
set batch volume in regular cycles. Dosing displayed in the ’Operation’ menu. During breaks in
starts when the pump is started after a singular start dosing, the time until the next dosing process
delay. The setting range for the batch volume (e. g. 1:21) is displayed.
corresponds to the values in section 6.4.4 Batch
(pulse-based).
Operation
125
t1 t1
Timer Note
If several procedures overlap, the
process with the higher dosing flow has
TM04 1137 1110
Procedure 1
Batch volume 80.5 ml
Dosing time [mm:ss] 0:34
Start time [hh:mm] 05:00
M❑ T W❑ T F❑ S❑ S
25
The batch volume (e. g. 80.5 ml) is set in the ’Setup Wiring diagram see section 4.3 Electrical
> Dos. Timer Week’ menu. The minimum dosing time connection.
English (GB)
Output = Input
Actual flow ❑
Backpressure
Bus control
❑
❑
SlowMode
Control
Description variant
Setting
Analog output signal
FCM
AR
FC
English (GB)
FC/FCM control variant.
parameters ’Sensitivity’ and ’Delay’ in the ’Setup >
This function is used to monitor the dosing process.
FlowControl’ menu.
Although the pump is running, various influences
e. g. air bubbles, can cause a reduced flow or even Sensitivity
stop the dosing process. In order to guarantee In 'Sensitivity’ the deviation in stroke volume, which
optimum process safety, the enabled FlowControl will result in an error message, is set in percent.
function directly detects and indicates the following
errors and deviations: Sensitivity Deviation
• Overpressure
Low approx. 70 %
• Damaged discharge line
Medium approx. 50 %
• Air in the dosing chamber
• Cavitation High approx. 30 %
• Suction valve leakage
Delay
• Discharge valve leakage.
The ’Delay’ parameter is used to define the time
The occurrence of a fault is indicated by the 'eye' period until an error message is generated: ’short’,
symbol flashing. The faults are displayed in the ’medium’ or ’long’. The delay depends on the set
’Alarm’ menu (see section 8. Faults). dosing flow and therefore cannot be measured in
FlowControl works with a maintenance-free sensor strokes or time.
in the dosing head. During the dosing process, the
sensor measures the current pressure and
continuously sends the measured value to the
microprocessor in the pump. An internal indicator
diagram is created from the current measured values
and the current diaphragm position (stroke length).
Causes for deviations can be identified immediately
by aligning the current indicator diagram with a
calculated optimum indicator diagram. Air bubbles in
the dosing head reduce e. g. the discharge phase
and consequently the stroke volume (see fig. 33).
Pressure
Trouble-free dosing
Faulty dosing stroke: Air
stroke
bubbles in the dosing
head
1
3
TM04 1610 1710
Stroke
length
1 Compression phase
2 Discharge phase
3 Expansion phase
4 Suction phase
27
6.8 Pressure monitoring 4. Proceed as described below to calibrate:
English (GB)
Type
Fixed min. Settable max. Sensor not calibrated.
pressure (bar) pressure [bar]
Calibration error
DDA 7.5 - 16 <2 3 ... 17
OK
DDA 12-10 <2 3 ... 11
Message: Message:
DDA 17-7 <2 3 ... 8 ’Sensor calib. OK ’Sensor calib. failed!
DDA 30-4 <2 3 ... 5 Current pressure: X bar’
’Repeat?’
28
6.9 Flow measurement Examples of ’AutoFlowAdapt’
English (GB)
FCM control variant Pressure fluctuations
The pump accurately measures the actual flow and The dosing volume decreases as backpressure
displays it. Via the 0/4 - 20 mA analog output, the increases and conversely the dosing volume
actual flow signal can easily be integrated into an increases as the backpressure decreases.
external process control without additional The ’AutoFlowAdapt’ function identifies pressure
measuring equipment (see section 6.5 Analog fluctuations and responds by adjusting the stroke
output). frequency. The actual flow is thus maintained at a
The flow measurement is based on the indicator constant level.
diagram as described in section 6.7 FlowControl. Air bubbles
The accumulated length of the discharge phase The ’AutoFlowAdapt’ function identifies air bubbles.
multiplied by the stroke frequency produces the The pump responds with a special indicator diagram
displayed actual flow. Faults e. g. air bubbles or due to which the air bubbles are removed as a top
backpressure that is too low result in a smaller or priority (deaeration).
larger actual flow. When the ’ AutoFlowAdapt’
If the air bubbles have not been eliminated after a
function is activated (see section
maximum of 60 strokes, the pump switches to the
6.10 AutoFlowAdapt), the pump compensates for
’Air bubble’ warning status and returns to the normal
these influences by correction of the stroke
indicator diagram.
frequency.
29
6.12 Key lock 6.13.2 Additional display
Additional display provides additional information
English (GB)
Operation mode/
Metric units US units
function
30
6.14 Time/date 6.16 Inputs/outputs
English (GB)
The time and date can be set in the ’Setup > In the ’Setup > Inputs/outputs’ menu, you can
Time+date’ menu. configure the two outputs ’Relay 1+2’ and the signal
inputs ’External stop’, ’Empty signal’ and ’Low level
The conversion between summer and signal’.
Caution winter time does not take place
automatically!
In/Output
6.15 Bus communication
Relay 1 Relay 2
Description
Fig. 35 ’Setup > Bus’ menu signal signal
* Factory setting
31
Timer, cycle (relay 2) 6.16.3 Empty and low-level signals
For the ’Relay 2 > Timer cycle’ function, set the In order to monitor the filling level in the
English (GB)
32
7. Service The service requirement signals when the
replacement of wearing parts is due and displays the
English (GB)
In order to ensure a long service life and number of the service kit. Press the click wheel to
dosing accuracy, wearing parts such as temporarily hide the service prompt.
diaphragms and valves must be regularly checked
for signs of wear. Where necessary, replace worn When the ’Service now’ message appears (displayed
parts with original spare parts made from suitable daily), the pump must be serviced immediately. To
materials. signalise in the ’Operation’ menu, the symbol
appears in the ’Signal/error display’ area of the
Should you have any questions, please contact your display.
service partner.
The number of the service kit required is also
Warning displayed in the ’Info’ menu.
If the diaphragm leaks or is broken, For media which result in increased wear, the service
dosing liquid will escape from the interval must be shortened.
discharge opening on the dosing head
(see fig. 3). 7.2 Perform service
Take suitable precautions to prevent Only spare parts and accessories from Grundfos
harm to health and damage to property should be used for maintenance. The usage of non-
caused by escaping dosing liquid! original spare parts and accessories renders any
Check daily whether liquid is escaping liability for resulting damages null and void.
from the discharge opening! Information about carrying out maintenance can be
found in the service kit catalog on our homepage
7.1 Service system (www.grundfosalldos.com).
According to the motor runtime or after a defined Warning
period of operation, service requirements will
When dosing dangerous media,
appear. Service requirements appear regardless of
observe the corresponding precautions
the current operational state of the pump and do not
in the safety data sheets!
affect the dosing process.
Risk of chemical burns!
Motor Wear protective clothing (gloves and
Time interval goggles) when working on the dosing
Service requirement runtime
[months]* head, connections or lines!
[h]*
Do not allow any chemicals to leak
’Service soon’ 7500 23 from the pump. Collect and dispose of
’Service now’ 8000 24 all chemicals correctly!
* Since the last service system reset Before any work to the pump, the pump
must be in the ’Stop’ operational state
Caution
or be disconnected from the mains.
The system must be pressureless!
TM04 1131 1110
Service soon!
Please exchange
diaphragm and valves!
Service kit:
97xxxxxx
Service now!
Please exchange
diaphragm and valves!
Service kit:
97xxxxxx
33
7.2.1 Dosing head overview 7.2.3 Reassembling the diaphragm and valves
1. Attach flange (2) correctly and screw on new
English (GB)
34
8. Faults
English (GB)
In the event of faults in the dosing pump, a
warning or an alarm is triggered. The
corresponding fault symbol flashes in the
’Operation’ menu, see section 8.1 List of faults. The
cursor jumps to the ’Alarm’ main menu symbol.
Press the click wheel to open the ’Alarm’ menu and,
where necessary, faults to be acknowledged will be
acknowledged.
A yellow display indicates a warning and the pump
continues running.
A red display indicates an alarm and the pump is
stopped.
The last 10 faults are stored in the ’Alarm’ main
menu. When a new fault occurs, the oldest fault is
deleted.
The two most recent faults are shown in the display,
you can scroll through all the other faults. The time
and cause of the fault are displayed.
Alarm
1 12.02.2010 12:34
Empty
2 12.02.2010 12:34
Low level
TM04 1109 1010
Delete alarm
messages ❑
35
8.1 List of faults
English (GB)
Display in the
Possible cause Possible remedy
’Alarm’ menu
36
Display in the
English (GB)
Possible cause Possible remedy
’Alarm’ menu
* Depending on setting
37
8.1.2 General faults
English (GB)
9. Disposal
This product and all its associated parts must
be disposed of in an environmentally friendly
manner. Use appropriate waste collection
services. If there is no such facility or the facility
refuses to accept thse materials used in the product,
the product can be sent to the nearest Grundfos
company or Grundfos service centre.
Subject to alterations.
38