Grundfos DME 150 User manual

DME, Variant B (60-940 l/h)
Installation and operating instructions
GRUNDFOS INSTRUCTIONS
Further languages
http://net.grundfos.com/qr/i/99301275

English (GB)
2
English (GB) Installation and operating instructions
Original installation and operating instructions
CONTENTS
Page
1. Safety instructions
These installation and operating instructions contain
general instructions that must be observed during
installation, operation and maintenance of the pump.
It must therefore be read by the installation engineer
and the relevant qualified operator prior to
installation and start-up, and must be available at the
installation location at all times.
1.1 Symbols used in this document
1. Safety instructions 2
1.1 Symbols used in this document 2
1.2 Qualification and training of personnel 3
1.3 Safety instructions for the operator/user 3
1.4 Safety of the system in the event of a
failure in the dosing pump 3
1.5 Dosing chemicals 3
1.6 Diaphragm breakage 4
1.7 Operation with loose dosing head screws 4
2. General description 5
2.1 Applications 5
2.2 Improper operating methods 5
2.3 Type key 6
3. Technical data 7
3.1 Mechanical data 7
3.2 Electrical data 7
3.3 Dimensions 7
4. Installation 8
4.1 Safety instructions 8
4.2 Installation environment 8
4.3 Installation of pump 8
4.4 Installation example 9
4.5 Electrical connection 9
5. Functions 10
5.1 Control panel 10
5.2 Start/stop of pump 11
5.3 Priming/venting of pump 11
5.4 Indicator lights 11
5.5 Menu 12
5.6 Manual 13
5.7 Anti-cavitation 13
5.8 Capacity limitation 14
5.9 Counters 14
5.10 Resetting 15
5.11 Return 15
5.12 Language 16
5.13 Alarm 16
5.14 Measuring units 17
5.15 Control panel lock 18
6. Start-up 19
7. Calibration 20
7.1 Direct calibration 21
7.2 Check calibration 22
8. Service 22
8.1 Regular maintenance 22
8.2 Cleaning 22
8.3 Perform service 22
8.4 Diaphragm breakage 24
8.5 Operation with loose dosing head screws 24
8.6 Repairs 25
9. Fault finding chart 25
10. Disposal 25
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
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
Notes or instructions that make the job
easier and ensure safe operation.

English (GB)
3
1.2 Qualification and training of personnel
The personnel responsible for the installation,
operation and service must be appropriately
qualified for these tasks. Areas of responsibility,
levels of authority and the supervision of the
personnel must be precisely defined by the operator.
If necessary, the personnel must be trained
appropriately.
Risks of not observing the safety instructions
Non-observance of the safety instructions may have
dangerous consequences for the personnel, the
environment and the pump and may result in the loss
of any claims for damages.
It may lead to the following hazards:
• Personal injury from exposure to electrical,
mechanical and chemical influences.
• Damage to the environment and personal injury
from leakage of harmful substances.
1.3 Safety instructions for the operator/
user
The safety instructions described in these
instructions, existing national regulations on health
protection, environmental protection and for accident
prevention and any internal working, operating and
safety regulations of the operator must be observed.
Information attached to the pump must be observed.
Leakages of dangerous substances must be
disposed of in a way that is not harmful to the
personnel or the environment.
Damage caused by electrical energy must be
prevented, see the regulations of the local electricity
supply company.
Only original accessories and original spare parts
should be used. Using other parts can result in
exemption from liability for any resulting
consequences.
1.4 Safety of the system in the event of a
failure in the dosing pump
The dosing pump was designed according to the
latest technologies and is carefully manufactured
and tested.
If it fails regardless of this, the safety of the overall
system must be ensured. Use the relevant
monitoring and control functions for this.
1.5 Dosing chemicals
Caution
Before starting work on the pump, the
pump must be disconnected from the
power supply. The system must be
pressureless!
Note
The mains plug is the separator separating
the pump from the mains.
Caution
Make sure that any chemicals that are
released from the pump or any damaged
lines do not cause damage to system parts
and buildings.
The installation of leak monitoring
solutions and drip trays is recommended.
Warning
Before switching the supply voltage back
on, the dosing lines must be connected in
such a way that any chemicals in the
dosing head cannot spray out and put
people at risk.
The dosing medium is pressurised and can
be harmful to health and the environment.
Warning
When working with chemicals, the
accident prevention regulations applicable
at the installation site should be applied
(e.g. wearing protective clothing).
Observe the chemical manufacturer's
safety data sheets and safety instructions
when handling chemicals!
Warning
The pump must not be used with
crystallising media.
Caution
A deaeration hose, which is routed into a
container, e.g. a drip tray, must be
connected to the deaeration valve.
Caution
The dosing medium must be in liquid
aggregate state!
Observe the freezing and boiling points of
the dosing medium!
Caution
The resistance of the parts that come into
contact with the dosing medium, such as
the dosing head, valve ball, gaskets and
lines, depends on the medium, media
temperature and operating pressure.
Ensure that parts in contact with the
dosing medium are resistant to the dosing
medium under operating conditions, see
data booklet!
Should you have any questions regarding
the material resistance and suitability of
the pump for specific dosing media, please
contact Grundfos.

English (GB)
4
1.6 Diaphragm breakage
If the diaphragm leaks or is broken, dosing liquid
escapes from the drain opening (fig. 1) on the dosing
head. Observe section 8.4 Diaphragm breakage.
To avoid any danger resulting from diaphragm
breakage, observe the following:
• Perform regular maintenance. See section
8.1 Regular maintenance.
• Never operate the pump with blocked or soiled
drain opening.
– If the drain opening is blocked or soiled,
proceed as described in section
8.3.2 Dismantling the diaphragm and valves.
• Never attach a hose to the drain opening. If a
hose is attached to the drain opening, it is
impossible to recognise escaping dosing liquid.
• Take suitable precautions to prevent harm to
health and damage to property from escaping
dosing liquid.
• Never operate the pump with damaged or loose
dosing head screws.
1.7 Operation with loose dosing head
screws
Warning
Danger of explosion, if dosing liquid has
entered the pump housing!
Operation with damaged diaphragm can
lead to dosing liquid entering the pump
housing.
In case of diaphragm breakage,
immediately separate the pump from the
power supply!
Make sure the pump cannot be put back
into operation by accident!
Dismantle the dosing head without
connecting the pump to the power supply
and make sure no dosing liquid has
entered the pump housing. Proceed as
described in section 8.3.2 Dismantling the
diaphragm and valves.
Warning
Danger of explosion, if dosing liquid has
entered the pump housing!
Operation with damaged or loose dosing
head screws can lead to dosing liquid
entering the pump housing.
If the pump was operated with damaged or
loose dosing head screws, immediately
separate the pump from the power supply!
Make sure the pump cannot be put back
into operation by accident!
Dismantle the dosing head without
connecting the pump to the power supply
and make sure no dosing liquid has
entered the pump housing. Proceed as
described in section 8.3.2 Dismantling the
diaphragm and valves.

English (GB)
5
2. General description
The Grundfos DME dosing pump is a self-priming
diaphragm pump.
The pump consists of:
•acabinet incorporating the drive unit and
electronics,
•adosing head with back plate, diaphragm,
valves, connections and vent valve,
•acontrol panel incorporating display and
buttons. The control panel is fitted either to the
end or to the side of the cabinet.
The motor is controlled in such a way that the dosing
gets as even and constant as possible, irrespective
of the capacity range in which the pump is operating.
This is carried out as follows:
The speed of the suction stroke is kept constant and
the stroke relatively short, irrespective of the
capacity. Contrary to conventional pumps, which
generate the dosing stroke as a short pulse, the
duration of the dosing stroke will be as long as
possible. Thus, an even dosing without peak values
is ensured. As the pump is always dosing at full
stroke length, it ensures the same high accuracy and
suction capability, irrespective of the capacity, which
is infinitely variable in the ratio of 1:800.
The pump features an LCD display and a user-
friendly control panel which gives access to the
pump functions.
2.1 Applications
The pump is suitable for liquid, non-abrasive, non-
flammable, non-crystallising and non-combustible
media strictly in accordance with the instructions in
these installation and operating instructions.
Areas of application (among others)
• Drinking water treatment
• Wastewater treatment
• Cooling water treatment
• Washing systems
• Process water treatment
• Chemical industry.
2.2 Improper operating methods
The operational safety of the pump is only
guaranteed if it is used in accordance with section
2.1 Applications.
Warning
Other applications or the operation of
pumps in ambient and operating
conditions, which are not approved, are
considered improper and are not
permitted. Grundfos cannot be held liable
for any damage resulting from incorrect
use.
Warning
The pump must not be used with
crystallising media.
Warning
The pump is NOT approved for operation
in potentially explosive areas!
Warning
A sunscreen is required for outdoor
installation!

English (GB)
6
2.3 Type key
(Cannot be used for pump configuration.)
Code Example DME 60 - 10 B - PP/ E/ C - F - 3 1 1 F
Pump range
Maximum capacity [l/h]:
60
150
375
940
Maximum pressure [bar]:
4
10
B
Control variant:
Basic
PP
PV
SS
Dosing head material:
Polypropylene
PVDF
Stainless steel 1.4401
E
T
V
Gasket material:
EPDM
PTFE
FKM
C
G
SS
T
Valve ball material:
Ceramics
Glass
Stainless steel 1.4401
PTFE
F
S
Control panel:
Front-fitted
Side-fitted
3
Voltage:
1 x 100-240 V, 50/60 Hz
1
2
Valves:
Standard valve
Spring-loaded valve
A1
A2
Q
Connection, suction/discharge:
Threaded Rp 3/4
Threaded Rp 1 1/4
Tubing 19/27 mm + 25/34 mm
F
G
I
B
J
E
L
Mains plug:
EU (Schuko)
UK
AU
USA
JP
CH
Argentina

English (GB)
7
3. Technical data
3.1 Mechanical data
*1Irrespective of counter pressure
*2Maximum suction lift 1 metre
3.2 Electrical data
3.3 Dimensions
See dimensions at the end of these instructions.
All dimensions are in mm.
DME 60 DME 150 DME 375 DME 940
Maximum capacity*1 [l/h] 60 150 376 940
Maximum capacity with anti-cavitation 75 %*1 [l/h] 45 112 282 705
Maximum capacity with anti-cavitation 50 %*1 [l/h] 33.4 83.5 210 525
Maximum capacity with anti-cavitation 25 %*1 [l/h] 16.1 40.4 101 252
Maximum pressure [bar] 10 4 10 4
Maximum stroke rate per minute [strokes/min.] 160
Maximum suction lift during operation [m] 6
Maximum suction lift when priming with wet valves [m] 1.5
Maximum viscosity with spring-loaded valves*2 [mPas] 3000 mPas at 50 % capacity
Maximum viscosity without spring-loaded valves*2 [mPas] 200
Diaphragm diameter [mm] 79 106 124 173
Liquid temperature [°C] 0 to 50
Ambient temperature [°C] 0 to 45
Accuracy of repeatability ± 1 %
Sound pressure level [dB(A)] < 70
DME 60 DME 150 DME 375 DME 940
Supply voltage [VAC] 1 x 100-240
Maximum current consumption [A] at 100 V 1.20 2.4
at 230 V 0.60 1.0
Maximum power consumption P1[W] 61.33 240
Frequency [Hz] 50/60
Enclosure class IP65
Installation category II
Pollution degree 2
Insulation class B
Supply cable 1.5 m H05RN-F with plug

English (GB)
8
4. Installation
4.1 Safety instructions
• Liquid is under pressure and may be hazardous.
• When working with chemicals, local safety rules
and regulations must be observed (e.g. wear
protective clothes).
• Before starting work on the dosing pump and
system, disconnect the electricity supply to the
pump, ensuring that it cannot be accidentally
switched on. Before reconnecting the electricity
supply, make sure that the dosing hose is
positioned in such a way that any chemical left in
the dosing head is not ejected, thereby exposing
persons to danger.
• If the vent valve in the dosing head is used, it
must be connected to a hose which is led back to
the tank.
• When changing a chemical, make sure that the
materials of the dosing pump and system are
resistant to the new chemical. If there is any risk
of chemical reaction between the two types of
chemicals, clean the pump and system
thoroughly before adding the new chemical.
Proceed as follows:
Place the suction tube in water and press the
button until residual chemical has been removed.
Note: When the buttons and are pressed
simultaneously, the pump can be set to run for a
specific number of seconds at maximum
capacity. The remaining number of seconds will
appear in the display. The maximum value is
300 seconds.
4.2 Installation environment
• Exposure to direct sunlight should be avoided.
This applies especially to pumps with plastic
dosing heads, as this material can be damaged
by sunlight.
• If the pump is installed outside, an enclosure or
similar protection is required to protect the pump
against rain and similar weathers.
4.3 Installation of pump
• See also the installation example in section
4.4 Installation example.
• Always install the pump on the supporting foot
with vertical suction and discharge ports.
• Always use suitable tools for the mounting of
plastic parts. Never apply unnecessary force.
• Make sure that the dosing pump and system are
designed in such a way that neither system
equipment nor buildings are damaged in case of
leakage from the pump or rupture of hoses/pipes.
The installation of leakage hoses and collecting
tanks is recommended.
• Make sure that the drain hole in the dosing head
points downwards, see fig. 1.
Fig. 1
100%
100%
Caution
The dosing head may contain water from
the factory test. If a liquid which must not
come into contact with water is to be
dosed, it is recommended to let the pump
run with another liquid to remove the water
from the dosing head before installation.
Caution
Cross-tighten the dosing head screws with
a torque wrench once before
commissioning and again after 2-5
operating hours at 5.5 Nm (+ 0.5/- 0 Nm).
Caution
Never attach a hose to the drain opening.
TM02 8949 0315
Drain hole

English (GB)
9
4.4 Installation example
The drawing in fig. 2 shows an installation example.
Fig. 2
4.5 Electrical connection
• The electrical connection of the pump should be
carried out by qualified persons in accordance
with local regulations.
• For electrical data of the pump, see section
3.2 Electrical data.
The DME pump can be installed in many different ways. The sketch below shows an example with side-
fitted control panel. The tank is a Grundfos chemical tank.
TM02 8600 0604
Warning
Danger to life due to non-tripping of the
residual current device (RCD)!
If the pump is connected to an electric
installation where a residual current device
(RCD) is used as an additional protection,
this RCD must trip when earth fault
currents with DC content (pulsating DC)
and smooth DC earth fault currents occur.
This means that a RCD type B, sensitive to
universal current, must be used.

English (GB)
10
5. Functions
5.1 Control panel
Fig. 3
TM02 8601 0604
100%
LCD display,
see section 5.5
Navigation/
settings,
see section 5.5
Maximum capacity
(priming),
see section 5.3
Green
indicator light,
see section 5.4
Menu,
see section 5.5
Navigation/
settings,
see section 5.5
On/off button,
see section 5.5
Power supply
Red
indicator light,
see section 5.4

English (GB)
11
5.2 Start/stop of pump
The pump can be started/stopped locally on the
pump control panel.
5.3 Priming/venting of pump
The pump control panel incorporates a button.
Press this button if the maximum pump capacity is
required over a short period, e.g. during start-up.
When the button is released, the pump automatically
returns to the previous operating mode.
During priming/venting, it is recommended to let the
pump run without a counter pressure or to open the
vent valve.
Note: When the buttons and are pressed
simultaneously, the pump can be set to run for a
specific number of seconds at maximum capacity.
The remaining number of seconds will appear in the
display. The maximum value is 300 seconds.
5.4 Indicator lights
The green and red indicator lights on the pump are
used for operating and fault indication.
The functions of the indicator lights appear from the
table below:
1Please contact a Grundfos service centre.
2Alarms can be reset when the faults have
been corrected.
3The pump will make 10 attempts to restart before
going into permanent OFF mode.
100%
100%
Condition Green LED Red LED Display
Pump running On Off Normal indication
Set to stop Flashing Off Normal indication
Pump fault Off On EEPROM
Supply failure Off Off OFF
Overheating Off On MAX. TEMP.
Internal communication fault Off On INT. COM.
Internal Hall fault1Off On HALL
Maximum pressure exceeded2Off3On OVERLOAD
No motor rotation detected1Off On ORIGO

English (GB)
12
5.5 Menu
The pump features a user-friendly menu which is
activated by pressing the button. During start-up,
all texts will appear in English language. To select
language, see section 5.12 Language.
All menu items are described in the following
sections. When appears at a menu item, it
means that this item is activated. By selecting
"RETURN" anywhere in the menu structure, you will
return to the operating display without changes.
Fig. 4
See section 5.6 See section 5.11
See section 5.7 See section 5.12
See section 7. See section 5.8
See section 5.9 See section 5.13
See section 5.15 See section 5.14
See section 5.10

English (GB)
13
5.6 Manual
The pump is dosing as constantly and evenly as
possible, without any external signals.
Set the quantity to be dosed in l/h or ml/h. The pump
automatically changes between the measuring units.
Setting range:
DME 60: 75 ml/h - 60 l/h
DME 150: 200 ml/h - 150 l/h
DME 375: 500 ml/h - 375 l/h
DME 940: 1200 ml/h - 940 l/h
Fig. 5
5.7 Anti-cavitation
The pump features an anti-cavitation function.
When this function is selected, the pump extends its
suction stroke, resulting in optimized priming.
The anti-cavitation function is used:
• when pumping liquids of high viscosity,
• in the case of a long suction tube and
• in the case of a high suction lift.
Depending on the circumstances, the motor speed
during the suction stroke can be reduced by 75 %,
50 % or 25 % compared to the normal motor speed
during the suction stroke.
The maximum pump capacity is reduced when the
anti-cavitation function is selected. See section
3.1 Mechanical data.
Fig. 6
Set value
Operating display

English (GB)
14
5.8 Capacity limitation
This function offers the possibility of reducing the
maximum pump capacity (MAX. CAP.). It influences
the functions in which the pump is normally operating
at maximum capacity.
Under normal operating conditions, the pump cannot
operate at a capacity which is higher than the one
stated in the display. This does not apply to the
maximum capacity button , see section
5.3 Priming/venting of pump.
Fig. 7
5.9 Counters
The pump can display "non-resettable" counters for:
•"QUANTITY"
Accumulated value of dosed quantity in litres or
US gallons.
•"STROKES"
Accumulated number of dosing strokes.
•"HOURS"
Accumulated number of operating hours.
•"POWER ON"
Accumulated number of times the electricity
supply has been switched on.
Fig. 8
100%
Operating display
Set maximum
capacity
Operating display
Total number
of starts
Total number
of operating
hours
Total number
of strokes
Total dosed
quantity

English (GB)
15
5.10 Resetting
When "DEFAULT" is activated, the pump will return
to the factory settings.
Note: The calibration is also set back to the default
setting. This means that a new calibration is required
when the "DEFAULT" function has been used.
Default settings are the factory settings of standard
pumps. Select "DEFAULT" in the "SETUP" menu.
Default settings:
Fig. 9
5.11 Return
Fig. 10
The "RETURN" function makes it possible to return
from any level in the menu to the operating display
without changes after the menu functions have been
used.
Operating mode: Manual
Capacity: Maximum capacity
Control panel lock: Unlocked
Default lock code: 2583
Anti-cavitation: Not active
Capacity limitation: Maximum capacity
Alarm reset required to restart the pump
Language: English
Units: Metric
Operating display Operating display
without changes

English (GB)
16
5.12 Language
The display text can be displayed in one of the
following languages:
• English
•German
• French
• Italian
• Spanish
• Portuguese
•Dutch
• Swedish
• Finnish
• Danish
• Czech
•Slovak
•Polish
•Russian
Fig. 11
5.13 Alarm
The alarm can be reset automatically (AUT. RES.) or
manually (MAN. RES.).
Operating display Operating display Operating display
without changes

English (GB)
17
5.14 Measuring units
It is possible to select metric units (litre/millilitre) or
US units (gallons/millilitre).
Metric measuring units:
• Set the quantity to be dosed in litres per hour (l/h)
or millilitres per hour (ml/h).
•For calibration, set the quantity to be dosed in
ml per 100 strokes.
• Under the "QUANTITY" menu item in the
"COUNTERS" menu, the dosed quantity is
indicated in litres.
US measuring units:
• Set the quantity to be dosed in gallons per hour
(gph).
•For calibration, set the quantity to be dosed in
ml per 100 strokes.
• Under the "QUANTITY" menu item in the
"COUNTERS" menu, the dosed quantity is
indicated in US gallons (gal).
Fig. 12
Operating display
3 x
Operating display

English (GB)
18
5.15 Control panel lock
It is possible to lock the buttons on the control panel
to prevent malfunction of the pump. The locking
function can be set to "ON" or "OFF". The default
setting is "OFF".
A PIN code must be entered to change from "OFF" to
"ON". When "ON" is selected for the first time,
"_ _ _ _" will appear in the display. If a code has
already been entered, it will appear when an attempt
to change to "ON" is made. This code can either be
re-entered or changed.
If a code has already been entered, active digits are
flashing.
If attempts are made to operate the pump in locked
condition, "LOCKED" will appear in the display for
2 seconds, followed by "_ _ _ _". A code must be
entered. If the entering of a code has not been
started within 10 seconds, the operating display
without changes will appear.
If a wrong code is entered, "LOCKED" will appear in
the display for 2 seconds, followed by "_ _ _ _".
A new code must be entered. If the entering of a
code has not been started within 10 seconds, the
operating display without changes will appear.
This display will also appear if the entering of the
correct code exceeds 2 minutes.
If the locking function has been activated but the
control panel is unlocked, the control panel will be
locked automatically if it is not operated for
2 minutes.
The locking function can also be reactivated by
selecting "ON" in the "LOCK" menu. The previously
entered code will then appear and must be re-
entered by pressing the button four times.
The code can also be changed.
The control panel can be unlocked either by means
of the selected code or the factory code 2583.
The following buttons and inputs are still active when
the panel is locked:
• Priming ( -button).
• On/off button.
Fig. 13
Activating the locking function and locking the
control panel:
1. Select "LOCK" in the menu.
2. Select "ON" by means of the buttons and
and confirm with .
3. Enter or re-enter a code by means of the buttons
, and .
The locking function has now been activated and the
control panel is locked.
Unlocking the control panel (without deactivating
the locking function):
1. Press once. "LOCKED" appears in the
display for 2 seconds, followed by "_ _ _ _".
2. Enter the code by means of the buttons ,
and *.
The control panel has now been unlocked and will
automatically be locked again if the control panel is
not operated for 2 minutes.
Deactivating the locking function:
1. Unlock the control panel as described above.
2. Select "LOCK" in the menu.
3. Select "OFF" by means of the buttons and
and confirm with .
The locking function has now been deactivated and
the control panel is unlocked.
*The panel can always be unlocked with code 2583.
100%
Operating display
Operating display

English (GB)
19
6. Start-up
If the pump is not operating satisfactorily, see section 9. Fault finding chart.
Step Action
1
Prior to start-up, retighten the dosing head screws:
• Cross-tighten the dosing head screws with a torque wrench once
before commissioning and again after 2-5 operating hours at 5.5 Nm.
(+ 0.5/- 0 Nm).
2
Connect the hoses/pipes:
• Connect the suction and dosing tubes/pipes to the pump.
• Connect a tube to the vent valve, if required, and lead the hose to the
tank.
• Never attach a hose to the drain opening.
3
Switch on the electricity supply:
• The display is on.
• The green indicator light is flashing (the pump has stopped).
• Select language, if required, see section 5.12 Language.
4
Start the pump:
• Start the pump by pressing the on/off button.
• The green indicator light is permanently on.
5
Priming/venting:
• Press the button on the pump control panel and let the pump run
without a counter pressure. Open the vent valve, if required.
When the buttons and are pressed simultaneously during
priming, the pump can be set to run for a specific number of seconds at
maximum capacity.
6
Calibration:
• When the pump has been primed and is running at the right counter
pressure, calibrate the pump, see section 7. Calibration
100%
100%
100%
100%
100%

English (GB)
20
7. Calibration
It is important that the pump is calibrated after
installation to ensure that the correct value
(ml/h or l/h) appears in the display.
The calibration can be carried out in two different
ways:
•Direct calibration.
The dosed quantity of 100 strokes is measured
directly. See section 7.1 Direct calibration.
•Check calibration. See section 7.2 Check
calibration.
Fig. 14
Operating display
without changes
Operating displayOperating display
The pump
performs
100 dosing
strokes
Set value,
see section 7.2