Grundfos DSS User manual

GRUNDFOS INSTRUCTIONS
DSS dosing skid station
Installation and operating instructions

English (US)
2
English (US) Installation and operating instructions
Original installation and operating instructions
CONTENTS
Page
1. Limited warranty
Products manufactured by GRUNDFOS PUMPS CORPORATION
(Grundfos) are warranted to the original user only to be free of
defects in material and workmanship for a period of 24 months
from date of installation, but not more than 30 months from date
of manufacture. Grundfos' liability under this warranty shall be
limited to repairing or replacing at Grundfos' option, without
charge, FOB Grundfos' factory or authorized service station, any
product of Grundfos' manufacture. Grundfos will not be liable for
any costs of removal, installation, transportation, or any other
charges which may arise in connection with a warranty claim.
Products which are sold but not manufactured by Grundfos are
subject to the warranty provided by the manufacturer of said
products and not by Grundfos' warranty. Grundfos will not be
liable for damage or wear to products caused by abnormal
operating conditions, accident, abuse, misuse, unauthorized
alteration or repair, or if the product was not installed in
accordance with Grundfos' printed installation and operating
instructions.
To obtain service under this warranty, the defective product must
be returned to the distributor or dealer of Grundfos' products from
which it was purchased together with proof of purchase and
installation date, failure date, and supporting installation data.
Unless otherwise provided, the distributor or dealer will contact
Grundfos or an authorized service station for instructions. Any
defective product to be returned to Grundfos or a service station
must be sent freight prepaid; documentation supporting the
warranty claim and/or a Return Material Authorization must be
included if so instructed.
GRUNDFOS WILL NOT BE LIABLE FOR ANY INCIDENTAL OR
CONSEQUENTIAL DAMAGES, LOSSES, OR EXPENSES
ARISING FROM INSTALLATION, USE, OR ANY OTHER
CAUSES. THERE ARE NO EXPRESS OR IMPLIED
WARRANTIES, INCLUDING MERCHANTABILITY OR FITNESS
FOR A PARTICULAR PURPOSE, WHICH EXTEND BEYOND
THOSE WARRANTIES DESCRIBED OR REFERRED TO
ABOVE.
Some jurisdictions do not allow the exclusion or limitation of
incidental or consequential damages and some jurisdictions do
not allow limit actions on how long implied warranties may last.
Therefore, the above limitations or exclusions may not apply to
you. This warranty gives you specific legal rights and you may
also have other rights which vary from jurisdiction to jurisdiction.
2. General information
These installation and operating instructions apply to Grundfos
DSS (dosing skid station) systems equipped with Grundfos
dosing pumps.
The proper functioning of a DSS system depends on the following
points:
• correct operation
• regular maintenance
• calibration of the pump after installing the service kit and
periodic re-calibration of the pump
• installation of service kit as recommended by individual DSS
component manuals, ie manuals for dosing pumps, back
pressure and pressure relief valves.
1. Limited warranty 2
2. General information 2
2.1 Type key 3
3. Safety information 4
3.1 Target group 4
3.2 Symbols used in this document 4
3.3 Safety-related symbols on the product 4
3.4 Safety instructions for the user 4
3.5 Unauthorized changes 4
3.6 Safety of the system in the event of product failure 4
3.7 Working with chemicals 5
4. Product introduction 5
4.1 Certificates 5
4.2 Intended use 5
4.3 Improper use 5
4.4 Product overview and dimensions 5
4.5 Standard DSS pipe and instrumentation diagram for 1-,
2- and 3-pump systems 7
5. Technical data 8
6. Transport and storage 8
7. Installation 9
7.1 Electrical connection 9
8. Startup 12
8.1 Calibration 12
9. Operation 12
10. Maintenance 12
10.1 Safety instructions 12
10.2 Maintenance intervals 13
11. Long-term shutdown 13
12. Disposal 13
Warning
Prior to installation, read these installation and
operating instructions. Installation and operation
must comply with local regulations and accepted
codes of good practice.
Warning
Read the installation and operating instructions of
the DSS components (dosing pumps, back pressure
and pressure relief valves, pulsation dampers,
calibration columns and control panels)

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English (US)
2.1 Type key
Example DSS- S2 -DDA -l/h-bar- PEF -J -B N N N -P 50 50 W
Dosing skid system Pipe connection
N = NPT
W = Weld (solvent, socket, butt, fusion)
C = Compression
F = Flange
S = Standard
C = Custom
Pumps per skid
1 = One pump
2 = Two pumps
3 = Three pumps
(N) = Any other number of pumps
Outlet pipe size
50 = 1/2"
75 = 3/4"
10 = 1"
15 = 1 1/2"
Pump model
DDA
DDC
DDE
DME
DDI
DMH
DMX
Inlet pipe size
50 = 1/2"
75 = 3/4"
10 = 1"
15 = 1 1/2"
Pump performance
flow (l/h) - pressure (bar)
Pipe material
P = PVC
C = CPVC
F = PVDF
S = Stainless steel
Base material
P = High-density polyethylene
S = Stainless steel
C = Carbon steel
Extra control cables
B = Both relay output and analog output (DDA
and DMH AR)
R = Relay output
A = Analog output (DDA and DMH AR)
S = Remote stop (DME)
T = Both relay output and remote stop (DME)
N = No extra, or none for B variant pumps
Gasket material
E = EPDM
V = Viton (FKM)
T = Teflon (PTFE)
Instrumentation
P = Pressure transducer
N = No instrumentation
Mounting
F = Floor or base mounted skid
W = Wall-mounted panel
E = Wall-mounted with enclosure
Accessories
D = Pulsation damper
N = No accessories
E = E-box
B = Both an E-box and pulsation damper
Control panel
J = Junction box (terminal strip/On Off)
C = Full control panel (Hand-Off-Auto (HOA))
P = Power plugs only
N = No control of any kind
S = Special custom panel
Back pressure or pressure relief valves
M = Multifunction valve
B = Back pressure and pressure relief valves

English (US)
4
3. Safety information
Non-observance of the safety instructions may have dangerous
consequences for the staff, the environment and the product and
may result in the loss of any claims for damages.
Should you require further information, please contact Grundfos.
3.1 Target group
These installation and operating instructions contain general
instructions that must be observed during installation, startup,
operation and maintenance of the product. The responsible staff
must read these installation and operating instructions prior to
any work at the product. These installation and operating
instructions must be available at the installation site at all times.
3.1.1 Qualification and training of staff
The staff responsible for the installation, startup, operation and
maintenance must be qualified for these tasks. Areas of
responsibility, levels of authority and the supervision of the staff
must be precisely defined by the operating company. If
necessary, the staff must be trained.
3.1.2 Obligations of the operating company
• Observe the local safety regulations.
• Instruct the operating staff.
• Provide the stipulated safety equipment and personal
protective equipment.
• Arrange regular maintenance.
3.1.3 Obligations of the user
• Read this manual thoroughly before putting the product into
operation.
• Observe the recognized health and safety regulations as well
as the accident prevention regulations.
• Wear protective equipment in accordance with national health
and safety regulations when working at the system and
handling chemicals.
3.2 Symbols used in this document
3.3 Safety-related symbols on the product
All signs and symbols on the product must be observed and kept
legible.
3.4 Safety instructions for the user
3.5 Unauthorized changes
Do not make changes of DSS systems without prior consent of or
agreement with the supplier.
Use only original accessories and original spare parts. Use of
other parts or modification of DSS systems can result in
malfunction of the product.
3.6 Safety of the system in the event of product failure
Use appropriate monitoring and control devices in order to ensure
the overall safety of the system in case the product fails.
Warning
If these safety instructions are not observed, it may
result in personal injury.
Caution
If these safety instructions are not observed, it may
result in malfunction or damage to the equipment.
Note
Note
Notes or instructions that make the job easier and
ensure safe operation.
Symbol Description
Indication of universally dangerous spot.
In case of emergency and prior to all maintenance
work and repairs, take the mains plug out of the
mains supply.
The product complies with electrical safety class II.
Connection for deaeration hose at dosing head. If the
deaeration hose is not correctly connected, danger
will arise due to possible leakage of dosing medium.
Warning
Observe the local regulations for work safety.
Observe the safety data sheets of the supplier of
chemicals.
All work on DSS systems must be carried out by
authorized and qualified staff.
Wear protective clothing when working on DSS
systems.
Warning
Danger of personal injury due to contact with
chemicals.
Make sure that leaking chemicals do not cause
personal injury or damage to property.
We recommend installation of leakage monitoring
solutions and drip trays.

5
English (US)
3.7 Working with chemicals
4. Product introduction
DSS systems consist of one or more dosing pumps mounted on a
base together with optional equipment. See section 4.4 Product
overview and dimensions.
Standard DSS systems are designed according to the variants
available in the type key. Customized systems are designed as
customer-specified products.
4.1 Certificates
Depending on the DSS model, certificates and approvals will
differ. Please refer to the pump and control panel installation and
operating instructions specific to the installed DSS system.
4.2 Intended use
• DSS systems are intended for media that are compatible with
the DSS materials of construction.
• The operating safety of DSS systems is only ensured, if they
are used for the specified application and media, and in
accordance with the values mentioned in section 5. Technical
data. The specified limit values must not be exceeded.
• DSS systems may only be operated by technical staff in
accordance with the installation and operating instructions.
• Modifications to DSS systems are only permitted with the
consent of the manufacturer. Original spare parts and
accessories approved by the manufacturer are safe to use.
4.3 Improper use
• DSS systems are not intended for dosing explosive, gaseous,
highly viscous, solid media, or media containing abrasive or
long-fibred particles.
• DSS systems are not intended for operation in other
conditions than specified in the agreement with the customer
or described in section 5. Technical data.
The operational safety of the product is only guaranteed, if it is
used in accordance with section 4.2 Intended use.
• The product must not be used for media that are not specified
in the agreement between Grundfos and the customer.
• The product must not be used in potentially explosive areas.
• The product must not be used in food-processing systems.
• The product must not be used if it is damaged.
• The product must not be used after improper repair.
• The product must not be used after unauthorized modification.
4.4 Product overview and dimensions
Fig. 1 DSS mounting holes
Warning
Danger of personal injury due to contact with
chemicals.
Wear the stipulated personal protective equipment
(protective clothing, goggles, respirator etc.) when
handling chemicals.
Observe the chemicals manufacturer's safety data
sheets and safety instructions of the chemicals used.
Caution
Make sure that parts in contact with the chemicals
are resistant to the chemicals under the specific
operating conditions.
Should you have questions regarding the material of
construction of the Grundfos equipment, please
contact Grundfos.
Warning
Any usage other than that described here is not
intended. Grundfos accepts no liability for any
injuries or damage resulting from improper use.
Warning
Any improper use can lead to personal injury and
damage to the equipment.
Note
Note
Observe the freezing and boiling points of the dosing
medium at operating pressure. Observe the
temperatures specified.
TM06 5552 1215
Typical for all standard skids

English (US)
6
Fig. 2 Example of a DSS system
TM06 5481 1115
Pos. Description
1 Inlet isolating valve
2 Y strainer
3 Isolating valve
4 Calibration column
5 Inlet isolating valve
6 Dosing pump
7 Pressure relief valve
8 Outlet isolating valve
9 Inlet isolating valve
10 Dosing pump
11 Pressure relief valve
12 Outlet isolating valve
13 Sample valve or bleed valve
14 Pressure gauge with diaphragm gauge guard
15 Back pressure valve
16 Outlet isolating valve
17 Nameplate
18 Junction box or Hand-Off-Auto panel (HOA) (optional)
19 Calibration column overflow accessory
Height
Depth
Width
DSS system dimensions
Height
[inches] Width [inches] Depth [inches]
Simplex 43 24 23.5
Duplex 43 34 23.5
Triplex 43 46 23.5

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English (US)
4.5 Standard DSS pipe and instrumentation diagram for 1-, 2- and 3-pump systems
Fig. 3 Simplex DSS with junction box, see pos. 18 in fig. 2
Fig. 4 Duplex DSS with junction box, see pos. 18 in fig. 2
TM06 6241 0216
Back
pressure
valve
Junction
box
160 psi pressure
gauge with isolator
PI
Outlet
valve
1/2" pipe
Pump IO
HS
Stop-analog in.
1/2" tube
Power
250-500 mL
calibration column
Inlet valve
Y strainer
1/2" pipe
1/2" tube
Grundfos
Smart Digital
pump
1/2" tube
Pressure
relief valve
TM06 6242 0216
Back
pressure
valve
Outlet
valve
Pressure
relief valve
1/2" tube
1/2" tube
160 psi
pressure
gauge with
isolator
1/2" pipe
PI
Sample
or bleed
valve
1/2" tube
Junction
box
HS
1/2" pipe
Grundfos
Smart
Digital pump
250-500 mL
calibration column
Inlet valve
Y strainer
Pump IO
Stop-analog in.
Stop-analog in.
Power

English (US)
8
Fig. 5 Triplex DSS with junction box, see pos. 18 in fig. 2
5. Technical data
Refer to the installation and operating instructions of the dosing
pump and characteristic of the dosing medium.
6. Transport and storage
• Check the DSS system for transportation damage or missing
parts.
• Store the DSS system in a sheltered place at temperatures
between 41 and 113 °F (5 and 45 °C).
TM06 6243 0216
Outlet
valve
Back
pressure
valve
160 psi
pressure
gauge with
isolator
PI
1/2" tube
1/2" tube
1/2" pipe
1/2" tube
Pressure
relief
valve
Sample or
bleed valve,
or relief valve
PI
1/2" pipe
Grundfos
SmartDigital
pump
Y strainer
Inlet valve
250/500 mL
calibration column
Junction
box
Caution
The values stated in the technical data of the
components must be observed.
For the entire system, the value of the component
with the most limited value applies.
Caution
The dosing medium must be in liquid state. Observe
the freezing point of your dosing medium.
Caution
Transport the DSS system carefully and only at
temperatures above 41 °F (5 °C).
Risk of breakage.
Note
Note
The DSS system is tested for tightness in the factory.
Some residual water may still be present in the
fittings and pipes.

9
English (US)
7. Installation
• During installation refer to Plant Engineering Drawings,
Construction Drawings, Engineering Documentation, System -
General Arrangement, P&ID and Electrical Drawings if
included in the scope of delivery.
All DSS system pipes are supported within DSS. Make sure to
adequately support all pipes outside DSS, including inlet,
outlet, drain or vent pipes, to the site floor, wall or ceiling. Do
not use the DSS pipes for support.
• Allow for clearance around the DSS system for regular
maintenance to be safely carried out.
• Allow provisions to drain the system pipes for maintenance
and repair.
• Depending on the vapor pressure of the dosing medium, you
may need to mount the inlet line with a continuous upward
slope from the supply tank to reduce gas locking, especially in
volatile media.
1. Mount the DSS system to the wall if it is a wall-mounted
system or on the floor if it is a floor-mounted system.
2. Position DSS on an even, solid surface that is flat, hard,
vibration free and leveled (i.e. a concrete floor or foundation).
3. Install the on-site inlet, outlet and drain or vent pipes to the
DSS termination point for the system inlet (1), outlet (16) and
drain or vent pipe (13) in fig. 2. Make sure that the inlet
conditions do not exceed the maximum suction lift capability
of the dosing pump as described in the pump installation and
operating instructions.
4. Check that O-rings are installed in all unions.
5. Check the tightness of all threaded connections.
6. If required, install the pulsation dampers on DSS according to
the pulsation damper connection instructions received with
the DSS system.
7. If required, fit the calibration column into the 1/2" NPT
connection on DSS in pos. 3 in fig. 2on page 6.
8. A calibration column overflow accessory that can be fitted on
top of the calibration column, is shipped separately. Install the
calibration column overflow accessory with an appropriate
length of 1/2" OD flexible tubing directed back to the dosing
tank.
7.1 Electrical connection
• DSS systems installed outdoors must be sheltered to allow
trouble-free operation.
– Exceptions are DSS systems equipped with an IP65 outdoor
cabinet with integrated heating.
Caution
Pipes, components and equipment connections may
become loose during transport or storage.
Note
Note
The pulsation dampers may have been removed
from DSS to prevent damage during transport.
Caution
Keep the minimum diameter of the inlet and outlet
lines. Too small diameters may cause damage to the
DSS system and the dosing pump.
Depending on the viscosity and density of the dosing
medium, the number of valves and fittings, and the
length of the pipes, you may have to increase the
pipe diameter.
The diameter and length of the outlet and inlet pipe
or tube must be dimensioned in such a way that
pressure peaks do not exceed the pressure limit
during the dosing stroke and the minimum pressure
does not fall below the vapor pressure of the dosing
medium during the suction stroke.
Warning
Make sure that the room where the DSS system is
installed has sufficient ventilation.
Warning
Protect the DSS system against unauthorized
access.
Caution
The dosing medium must be in liquid state. Observe
the freezing point of your dosing medium.
Note
Note
Keep the DSS system freely accessible for operation
and maintenance.
Provide sufficient lighting.
Warning
The electrical work must be carried out by an
authorized individual. Read manuals for all electrical
components supplied with the DSS system or
supplied separately. Make sure that the system is
suitable for the power supply to which it is to be
connected. The power supply, equipment and
components (if included in the scope of delivery)
must be installed, connected and tested by an
authorized electrician in accordance with local codes
and regulations and any wiring drawings supplied.

English (US)
10
Fig. 6 Junction box wiring diagram
TM06 6496 0416
Cable 1:
Analog external
stop pulse
Cable 2:
Level input Cable 3: GENIbus analog
output
Cable 4:
Relay output
GND
Brown Blue GND
Brown White
White BUSBUS
GND
Green
Blue Brown Black White Blue
115 VAC
power
distribution
On Off
PE
PE
N1
N2
N3
P1
P2
P3
GND/PE
GND/PE
P1 Neutral
P2 Neutral
P3 Neutral
P1 Line
P2 Line
Analog in-mA
Analog in-mA
External stop
Level low
Level empty
Level ground
Analog out-mA
Relay 1A
Relay 1B
Relay 2A
Relay 2B
Analog in-mA
Analog in-mA
External stop
Level low
Level empty
Level ground
Analog out-mA
Analog out-mA
Relay 1A
Relay 1B
Relay 2A
Relay 2B
Analog in-mA
Analog in-mA
External stop
Level low
Level empty
Level ground
Analog out-mA
Analog out-mA
Relay 1A
Relay 1B
Relay 2A
Relay 2B
Pump 2
IO
Pump 3
IO
Pump 1
IO
Not to scale
Dimensions are in inches unless otherwise noted
Analog out-mA
P3 Line
CB 10A

11
English (US)
Fig. 7 Hand-Off-Auto control panel (HOA) wiring diagram
TM06 6500 0416
Spare
Pump fault
SCADA
Pump run
SCADA
External stop
Pump power
Not to scale
Dimensions in inches unless otherwise noted.
Spare
x3
Pump
power
External
stop
Power
Pump run
SCADA
Pump fault
SCADA
Pump
power
External
stop
Pump run
SCADA
Pump fault
SCADA
x2
Spare
x1 Brown
Blue
GND
BUS
BUS
White
Blue
Black
Brown
Cable 1:
Analog external stop pulse
Cable 2:
Level input
Cable 3:
GENIbus,
analog
output
Cable 4:
Relay output
GND
Notes
Remove the jumper for external remote Start-Stop signal.
Pump-1 jumper is between terminals 3 and 4.
Pump-2 jumper is between terminals 20 and 21.
Pump-3 jumper is between terminals 37 and 38.
GND

English (US)
12
8. Startup
1. Retighten all threaded joints.
2. Check the tightness of the entire DSS system and all pipes.
3. Check the electrical wiring and the power supply.
4. For dosing pumps with three-phase motors, additionally check
the direction of rotation and the setting of the motor
protection.
5. Install the inlet line with foot valve in the dosing tank.
– Install the inlet line with a continuous upward slope towards
the dosing pump.
6. Open the isolating valves for the dosing pump.
7. Vent the pump.
For details on venting the dosing pump, see installation and
operating instructions for the dosing pump.
Optional procedure for venting a dosing pump via the sample
or bleed valve:
– Add a hose to the sample or bleed valve that directs the
medium to a drain or back to the dosing tank.
– Open the sample or bleed valve (13). See fig 2.
– Start the pump and continue pumping until medium flows out
of the sample or bleed valve.
– Stop the pump and close the sample or bleed valve. The
hose can either be removed or stay.
8. Check the proper interaction of all electronic signal
accessories such as leakage detection, level switch, alarm
relay, with the controller of the installation.
8.1 Calibration
Calibration must be done with the dosing medium. For details on
calibration, see installation and operating instructions of the
dosing pump.
9. Operation
In normal operation, the DSS system operates independently.
• Do not close the isolating valves on the outlet side of the pump
during normal operation.
– Otherwise the pressure relief valve (7 or 11) will open. See
fig. 2
• Keep all isolating valves closed that are not in the line
between the dosing medium inlet and the injection point, e.g.
valve (3) of the calibration column; the inlet isolating valve (5
or 9) and outlet isolating valve (8 or 12) of the dosing pumps;
and sample or bleed valve (13). The operator decides which
pump is the duty pump and which is the standby pump. See
fig. 2.
• Do not close or block the vent hole of the dosing tank.
• Do not contaminate the dosing tank.
10. Maintenance
10.1 Safety instructions
Warning
Some chemicals react with water, which can lead to
explosions. If the dosing medium can react with
water, the DSS system must be flushed with a
medium compatible with both water and the dosing
medium first, to remove remaining water in the DSS
system.
Caution
Prior to startup, flush all tanks and pipes.
An initial test can be made with water if the dosing
medium is compatible with water.
Note
Note
The DSS system is tested for tightness in the factory.
Some residual water may still be present in the
fittings and pipes.
Warning
Cleaning and maintenance must only be carried out
by authorized and qualified staff.
Wear the stipulated personal protective equipment
(protective clothing, goggles, respirator etc.) when
handling chemicals.
Observe the chemicals manufacturer's safety data
sheets and safety instructions of the chemicals used.
Warning
Shut down the entire installation before starting any
work on the system components and lines.
Before starting maintenance work, disconnect the
DSS system from the power supply.
Before starting maintenance work, depressurize the
outlet line.
Drain and flush dosing head, valves and pipes.
Warning
Safety devices, which have been deactivated during
maintenance, must be activated again immediately
after maintenance.
Note
Note
Store important spare parts close to the DSS system.

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English (US)
10.2 Maintenance intervals
10.2.1 Daily checks
• Inspect the tightness visually.
10.2.2 Regular checks
Carry out regular checks weekly or monthly, depending on the
type of dosing pump and dosing medium. See the installation and
operating instructions of the dosing pump and characteristic of
the dosing medium.
• Check the dosing performance.
• Check the strainer
– clean the strainer, if necessary.
• Maintain the dosing pump
– see installation and operating instructions of the dosing
pump.
• Maintain the pressure loading valve
– see installation and operating instructions of the pressure
loading valve.
• Check all accessories such as pulsation dampers and level
switches to ensure they are functioning properly.
10.2.3 Annual checks
• Check the entire installation
– replace gaskets, O-rings, diaphragms and other wear parts,
if necessary.
11. Long-term shutdown
1. Flush the dosing tank, lines, pipes, connections and pumps.
– The flushing can be done with water if the dosing medium is
compatible with water.
– In case of danger of frost, remove remaining medium from
tanks, lines and connections with compressed air.
2. Disconnect the DSS system from the power supply.
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.
Note
Note
After maintenance, check the proper functioning and
tightness of the entire installation.
Warning
Some chemicals react with water, which can lead to
explosions. If the dosing medium can react with
water, the DSS system must be flushed with a
medium compatible with the dosing medium.

14

Grundfos companies
GRUNDFOS Kansas City
17100 West 118th Terrace
Olathe, Kansas 66061
Phone: [phone]
Fax: [phone]
www.grundfos.us
GRUNDFOS Canada
2941 Brighton Road
Oakville, Ontario L6H 6C9 Canada
Phone: [phone]
Telefax: [phone]
www.grundfos.ca
GRUNDFOS México
Boulevard TLC No. 15
Parque Industrial Stiva Aeropuerto
C.P. 66600 Apodaca, N.L. México
Phone: [phone]
Fax: [phone]
www.grundfos.mx

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