Grundfos SMART Digital XL DDA 60-10 User manual

SMART Digital XL - DDA
From 60 to 200 l/h
Installation and operating instructions
GRUNDFOS INSTRUCTIONS
Further languages
http://net.grundfos.com/qr/i/98767821

English (GB)
2
English (GB) Installation and operating instructions
Original installation and operating instructions
CONTENTS
Page
1. General information 3
1.1 Symbols used in this document 3
1.2 Qualification and training 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 4
1.5 Dosing chemicals 4
1.6 Diaphragm leakage 4
1.6.1 Diaphragm leakage detection (optional) 5
2. Storage and handling 5
2.1 Storage 5
2.2 Unpacking 5
2.3 Transport 5
3. Product introduction 6
3.1 Applications 6
3.2 Improper operating methods 6
3.3 Symbols on the pump 7
3.4 Nameplate 7
3.5 Type key 8
3.6 Product overview 9
4. Technical data / Dimensions 10
4.1 Technical data 10
4.2 Technical data for CIP (Clean-In-Place)
applications 12
4.2.1 Dimensions 12
5. Assembly and installation 13
5.1 Pump assembly 13
5.1.1 Requirements 13
5.1.2 Aligning and installing the mounting plate 13
5.1.3 Installing the pump on the mounting plate 13
5.1.4 Adjusting the control cube position 14
5.2 Hydraulic connection 14
5.3 Electrical connection 16
6. Startup 18
6.1 Preparing the pump for startup 18
6.2 Starting up the pump 18
6.3 Setting the menu language 19
6.4 Deaerating the pump 20
6.5 Calibrating the pump 20
6.5.1 Calibration process - example for DDA
60-10 21
7. Operation 22
7.1 Control elements 22
7.2 Display and symbols 22
7.2.1 Navigation 22
7.2.2 Operating states 22
7.2.3 Sleep mode (energy-saving mode) 22
7.2.4 Overview of display symbols 23
7.3 Main menus 24
7.3.1 Operation 24
7.3.2 Info 24
7.3.3 Alarm 24
7.3.4 Setup 25
7.4 Operation modes 25
7.4.1 Manual 25
7.4.2 Pulse 26
7.4.3 Analog 0/4-20 mA 26
7.4.4 Batch (pulse-based) 27
7.4.5 Dosing timer cycle 28
7.4.6 Dosing timer week 29
7.5 Analog output 30
7.6 SlowMode 30
7.7 Stop after power failure 31
7.8 FlowControl 32
7.9 Pressure monitoring 33
7.9.1 Pressure setting ranges 33
7.9.2 Calibration of pressure sensor 33
7.10 Flow measurement 34
7.11 AutoFlowAdapt 34
7.12 Auto deaeration 34
7.13 Diaphragm leak. detect. 34
7.14 Key lock 35
7.14.1 Temporary deactivation 35
7.14.2 Deactivation 35
7.15 Display setup 35
7.15.1 Units 35
7.15.2 Additional display 35
7.16 Time+date 36
7.17 Bus communication 36
7.17.1 GENIbus communication 36
7.17.2 Possible industrial bus types 36
7.17.3 Activate communication 36
7.17.4 Setting the bus address 37
7.17.5 Characteristics of bus communication 37
7.17.6 Deactivate communication 37
7.17.7 Communication faults 37
7.18 Inputs/Outputs 38
7.18.1 Relay outputs 38
7.18.2 External stop 39
7.18.3 Empty and Low level signals 39
7.19 Basic settings 39
8. Service 40
8.1 Regular maintenance 40
8.2 Cleaning 40
8.3 Service system 40
8.4 Perform service 41
8.4.1 Service overview 42
8.4.2 Dismantling the dosing head, diaphragm
and valves 43
8.4.3 Reassembling the dosing head,
diaphragm and valves 43
8.4.4 Replacing the deaeration valve 44
8.4.5 Replacing the DLD sensor 44
8.4.6 Replacing the mains cable 44

English (GB)
3
1. General information
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 startup, and must be available at the
installation location at all times.
1.1 Symbols used in this document
The text accompanying the hazard symbols is
structured in the following way:
1.2 Qualification and training
The persons 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 persons
must be precisely defined by the operator. If
necessary, the persons must be trained
appropriately.
Risks of not observing the safety instructions
Non-observance of the safety instructions may have
dangerous consequences for persons, 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 humans, animals and the
environment 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 humans,
animals and 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.
8.5 Resetting the service system 44
8.6 Diaphragm leakage 45
8.6.1 Dismantling the dosing head, diaphragm
and valves in case of diaphragm leakage 45
8.6.2 Dosing liquid in the pump housing 45
8.7 Repairs 46
9. Faults 46
9.1 List of faults 47
9.1.1 Faults with error message 47
9.1.2 General faults 50
10. Disposal 50
Read this document before installing the
product. Installation and operation must
comply with local regulations and accepted
codes of good practice.
WARNING
Indicates a hazardous situation which, if
not avoided, could result in death or
serious personal injury.
CAUTION
Indicates a hazardous situation which, if
not avoided, could result in minor or
moderate personal injury.
SIGNAL WORD
Description of hazard
Consequence of ignoring the warning.
- Action to avoid the hazard.
A blue or grey circle with a white graphical
symbol indicates that an action must be
taken.
If these instructions are not observed, it
may result in malfunction or damage to the
equipment.
Tips and advice that make the work easier.
WARNING
Electric shock
Death or serious personal injury
- Keep liquids away from the power
supply and electrical components.
Before starting work on the pump, the
pump must be in the "Stop" operating state
or be disconnected from the power supply.
The system must be pressureless.
The mains plug is the separator separating
the pump from the mains.

English (GB)
4
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
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.
When working with chemicals, the accident
prevention regulations applicable at the installation
site should be applied (e.g. wearing protective
clothing and safety goggles).
Observe the chemical manufacturer's safety data
sheets and safety instructions when handling
chemicals!
A deaeration hose, which is routed into a container,
e.g. a drip tray, must be connected to the deaeration
valve.
1.6 Diaphragm leakage
If the diaphragm leaks or is broken, dosing liquid
escapes from the drain opening on the dosing head.
See fig. 4, pos. 16. Observe section 8.6 Diaphragm
leakage.
To avoid any danger resulting from diaphragm
leakage, 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
8.6.1 Dismantling the dosing head, diaphragm
and valves in case of diaphragm leakage.
• 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.
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
Danger of explosion, if dosing liquid
has entered the pump housing!
Death or serious personal injury
Operation with damaged diaphragms can
lead to dosing liquid entering the pump
housing.
- In case of diaphragm leakage,
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
8.6.1 Dismantling the dosing head,
diaphragm and valves in case of
diaphragm leakage.

English (GB)
5
1.6.1 Diaphragm leakage detection (optional)
Applies to DDA-AR control variant.
Pumps with diaphragm leakage detection (DLD)
have a special dosing head with a special diaphragm
and a pressure switch. The pressure switch is fitted
and connected to the pump on delivery.
For pumps with diaphragm leakage detection the
pressure differential between inlet and outlet side
must be at least 2 bar / 29 psi.
Fig. 1 Diaphragm leakage detection
In case of a leak in the working diaphragm:
• Dosing medium (4) penetrates between working
diaphragm (D1) and protective diaphragm (D3)
and is transferred to the pressure switch (1)
through the signal diaphragm (D2).
• On the next discharge stroke the increasing
pressure activates the pressure switch (1).
• The pump indicates an alarm and stops.
The pump provides two relay outputs, which can be
used to trigger an external alarm, for example.
Replace the diaphragm as soon as possible after a
diaphragm leakage was detected.
If both the working diaphragm (D1) and the
protective diaphragm (D3) are damaged, dosing
liquid escapes from the drain opening (3) on the
dosing head.
2. Storage and handling
2.1 Storage
• Observe the permissible ambient conditions. See
section 4. Technical data / Dimensions.
• The storage location must be protected from rain,
humidity, condensation, direct sunlight and dust.
• The product must be drained completely.
• The product must be cleaned.
2.2 Unpacking
• Mount as soon as possible after unpacking.
• Observe the permissible ambient conditions. See
section 4. Technical data / Dimensions.
2.3 Transport
• The product must only be transported by trained
persons.
• Wear personal protective equipment.
• Observe the permissible ambient conditions. See
section 4. Technical data / Dimensions.
• The product must be drained completely.
• The product must be cleaned.
• Use the original packaging or equivalent to
protect the product during transport.
• Use appropriate lifting and transporting devices.
• Secure the product during transport to prevent it
from tilting and moving.
• Avoid strong impact loads.
• If the pump is installed in a system during
transport, make sure it is secured on the
mounting plate with the 6 vertical safety screws.
See section 5.1.3 Installing the pump on the
mounting plate.
TM06 7258 3716
Pos. Components
1 Pressure switch
2 Dosing head
3 Drain opening
4 Dosing medium
D1 Working diaphragm
D2 Signal diaphragm (intermediate layer)
D3 Protective diaphragm
Replace the pressure switch, if the
diaphragm of the pressure switch is
damaged.
Immediately separate the pump from the
power supply. Observe section
1.6 Diaphragm leakage.
D1 D2 D3
1
3
4
2

English (GB)
6
3. Product introduction
The DDA dosing pump is a self-priming diaphragm
pump. It consists of a housing with PMS (Permanent
Magnet Synchronous) motor and electronics, a
dosing head with double PTFE diaphragm and
valves, and the control cube.
Excellent dosing features of the pump:
• Optimal intake even with degassing media, as
the pump always works at full suction stroke
volume.
• Continuous dosing, as the medium is sucked up
with a short suction stroke, regardless of the
current dosing flow, and dosed with the longest
possible dosing stroke.
3.1 Applications
The pump is suitable for liquid, non-abrasive,
non-flammable and non-combustible media.
Observe the technical data of the product. See
section 4.1 Technical data.
Observe the freezing and boiling points of the dosing
medium.
Make sure that parts in contact with the dosing
medium are resistant to the dosing medium under
operating conditions. See data booklet:
• http://net.grundfos.com/qr/i/99021865.
Should you have any questions regarding the
material resistance and suitability of the pump for
specific dosing media, please contact Grundfos.
A sunscreen is required for outdoor installation.
Areas of application
• Drinking water treatment
• Wastewater treatment
• Boiler water treatment
• Cooling water treatment
• Process water treatment
• CIP (Clean-In-Place). Observe section
4.2 Technical data for CIP (Clean-In-Place)
applications.
• Swimming pool water treatment
• Chemical industry
• Ultrafiltration process and reverse osmosis
• Food and beverage industry
• Paper and pulp industry
• Irrigation
3.2 Improper operating methods
The operational safety of the pump is only
guaranteed if it is used in accordance with section
3.1 Applications.
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.
The pump is NOT approved for operation
in potentially explosive areas, automotive
applications or marine applications.
Frequent disengagement from the mains
voltage, e.g. via a relay, can result in
damage to the pump electronics and in the
breakdown of the pump. The dosing
accuracy is also reduced as a result of
internal start procedures.
Do not control the pump via the mains
voltage for dosing purposes!
Only use the "External stop" function to
start and stop the pump!
Only use the deaeration valve for
deaerating the pump. Make sure the
deaeration valve is closed during normal
operation.

English (GB)
7
3.3 Symbols on the pump
3.4 Nameplate
Fig. 2 Nameplate
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 power supply!
The device complies with electrical safety class I.
TM06 7046 3418
Pos. Description Pos. Description
1 Type designation 6 Enclosure class
2 Voltage 7 Marks of approval
3 Frequency 8 Country of origin
4 Power consumption 9 Max. operating pressure
5 Max. dosing flow 10 Model
P
QU
Type
Model
f
Pmax
Imax
99140620
Made in France
psi
gphA l/h
Bar
W IP 65
'tdϳϲϯϮϳWĮŶnjƚĂů'ĞƌŵĂŶLJ
NEMA 4X
psi
gphA l/h
Bar
W IP 65
12 3 45 6 7
8910
10

English (GB)
8
3.5 Type key
The type key is used to identify the precise pump
and is not used for configuration purposes.
Example: DDA 60-10 FCM-PVC/V/C-F-31U3U3FG
Type
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG
Max. flow [l/h]
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG
Max. pressure [bar]
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG
Control variant
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG
AR Alarm relay
FCM AR + FlowControl function
Dosing head variant
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG
PVC Polyvinyl chloride
PV PVDF
SS Stainless steel 1.4401
PVC-L PVC + integrated diaphragm leakage
detection
PV-L PV + integrated diaphragm leakage
detection
SS-L SS + integrated diaphragm leakage
detection
Gasket material
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG
E EPDM
VFKM
TPTFE
Valve ball material
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG
C Ceramics
SS Stainless steel 1.4401
Control cube
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG
FFront mounted (change to left or right is
possible)
Supply voltage
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG
3 100-240 V 50/60 Hz single phase
Valve type
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG
1 Standard
2 Spring-loaded
Connection, inlet / outlet
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG
U3U3 2x Union nut G5/4
2x Hose connector 19/20 mm
2x Hose clamp
2x Pipe connector 25 mm
A7A7 2x Union nut G5/4
2x Inlay external thread 3/4 NPT
A1A1 2x Union nut G5/4 (SS)
2x Inlay internal thread Rp3/4 (SS)
A3A3 2x Union nut G5/4 (SS)
2x Inlay internal thread 3/4 NPT (SS)
Mains plug
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG
F EU (Schuko)
B USA, Canada
GUK
I Australia, New Zealand, Taiwan
E Switzerland
J Japan
L Argentina
Design
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG
G Grundfos red
A Grundfos green
B Grundfos black
X Neutral / black
Special variant
DDA 60-10 FCM-PVC/V/C-F-31U3U3FGC3
Standard
C3 Inspection certificate 3.1 (EN 10204)

English (GB)
9
3.6 Product overview
Fig. 3 Front view of the pump
Fig. 4 Dosing head
TM06 7047 2916TM06 7048 2916
1
8
7
2
3
4
5
6
10
11
9
12
13
14
151617
Pos. Description See
section
1 Control cube
2 Graphic LC display 7.2.2
3 Click wheel 7.1
4 [100%] key 7.1
5 Signal inputs/outputs 5.3
6 Mounting plate
7 Mains connection
8 [Start/stop] key 7.1
9 Dosing head
10 Valve, outlet side
11 Deaeration valve
12 Connection, deaeration hose
13
Pressure switch of diaphragm
leakage detection (optional for
DDA-AR)
14 FlowControl sensor plug (only
DDA-FCM)
15 Valve, inlet side
16 Drain opening in case of
diaphragm leakage
17 Signal connection (FlowControl
or diaphragm leakage detection)

English (GB)
10
4. Technical data / Dimensions
4.1 Technical data
Data 60-10 120-7 200-4
Mechanical
data
Turn-down ratio (setting range) [1:X] 800 800 800
Max. dosing capacity [l/h] 60 120 200
[gph] 15.8 32 52.8
Max. dosing capacity with SlowMode 50 % [l/h] 30 60 100
[gph] 7.9 16 26.4
Max. dosing capacity with SlowMode 25 % [l/h] 15 30 50
[gph] 3.95 8 13.2
Min. dosing capacity [l/h] 0.075 0.15 0.25
[gph] 0.0197 0.04 0.066
Max. operating pressure (backpressure) [bar] 10 7 4
[psi] 145 101 58
Max. stroke frequency1) [strokes/
min] 196 188 188
Stroke volume [ml] 5.56 11.58 19.3
Accuracy of repeatability5) [%] 1.5 SP + 0.1 FS5)
Max. suction lift during operation2) [m] 3
Max. suction lift when priming with wet valves2) [m] 1.5
Min. pressure difference between inlet and
outlet side
[bar] 16)
[psi] 14.56)
Max. inlet pressure, inlet side [bar] 2
[psi] 29
Max. viscosity in SlowMode 25 % with
spring-loaded valves3) [mPas]
(= cP) 3000 3000 2000
Max. viscosity in SlowMode 50 % with
spring-loaded valves3) [mPas]
(= cP) 2000 1500 1000
Max. viscosity without SlowMode with
spring-loaded valves3) [mPas]
(= cP) 1000 1000 500
Max. viscosity without spring-loaded valves3) [mPas]
(= cP) 100
Min. internal hose/pipe diameter inlet/outlet
side2), 4) [mm] 19
Min. internal hose/pipe diameter inlet/outlet
side (high viscosity)4) [mm] 19
Min. / Max. liquid temperature (PVDF, SS) [°C] 0 / 50
Min. / Max. liquid temperature (PVC) [°C] 0 / 40
Min. / Max. ambient temperature [°C] 0 / 45
Min. / Max. storage temperature (PVDF, SS) [°C] -20 / 70
Min. / Max. storage temperature (PVC) [°C] -20 / 45
Max. relative humidity (non-condensing) [%] 90
Max. altitude above sea level [m] 2000

English (GB)
11
1) The maximum stroke frequency varies depending on calibration
2) Data is based on measurements with water
3) Maximum suction lift: 1 m, dosing capacity reduced (approx. 30 %)
4) Length of inlet line: 1.5 m, length of outlet line: 10 m (at max. viscosity)
5) FS = Full-scale (maximum actual dosing flow), SP = Setpoint
6) For FCM control variant and for pumps with diaphragm leakage detection the pressure difference must be
at least 2 bar / 29 psi.
Electrical data
Voltage [V] 100-240 V ± 10 %, 50/60 Hz
Length of mains cable [m] 1.5
Max. inrush current for 2 ms (100 V) [A] 35
Max. inrush current for 2 ms (240 V) [A] 70
Max. power consumption P1[W] 62
Enclosure class IP65, Nema 4X
Electrical safety class I
Pollution degree 2
Signal input
Max. load for level input 12 V, 5 mA
Max. load for pulse input 12 V, 5 mA
Max. load for External stop input 12 V, 5 mA
Min. pulse length [ms] 5
Max. pulse frequency [Hz] 100
Impedance at 0/4-20 mA analog input [Ω]15
Accuracy of analog input (full-scale value) [%] ± 0.5
Min. resolution of analog input [mA] 0.02
Max. loop resistance in external circuit [Ω] 150
Signal output
Max. resistive load on relay output [A] 0.5
Max. voltage on relay/analog output [V] 30 VDC / 30 VAC
Max. loop resistance in external circuit of the
0/4-20 mA analog output [Ω] 500
Accuracy of analog output (full-scale value) [%] ± 0.5
Min. resolution of analog output [mA] 0.02
Weight/size
Weight (PVC, PVDF) [kg] 6.7 7.9 8.9
Weight (stainless steel) [kg] 7.2 8.3 9.1
Diaphragm diameter [mm] 74 97 117
Sound
pressure Max. sound pressure level [dB(A)] 80
Approvals CE, CSA-US, NSF61, EAC, ACS, RCM
Data 60-10 120-7 200-4

English (GB)
12
4.2 Technical data for CIP (Clean-In-Place) applications
Short-term temperature limits for max. 40 minutes at max. 2 bar operating pressure:
4.2.1 Dimensions
Fig. 5 Dimensional sketch
Max. liquid temperature for dosing head material PVDF [°C] 85
Max. liquid temperature for dosing head material stainless steel [°C] 120
The dosing head material Polyvinyl chloride (PVC) must not be used in CIP applications.
TM06 7049 3818
C
B
283.5
G 5/4
A1A2
D
A
140.5
25
194
183.5
4 x Ø 7
4 x Ø 9
187
159
140
29
36
172.513
105 136 180
7
10 Ø 7
Pump type Dosing head
material
A
[mm]
A1
[mm]
A2
[mm]
B
[mm]
C
[mm]
D
[mm]
DDA 60-10 PVC/PV 410 374 26 263 112 45
DDA 60-10 SS 405 364 - 263 112 45
DDA 120-7 PVC/PV 410 374 26 276.5 97 45
DDA 120-7 SS 405 364 - 276.5 97 45
DDA 200-4 PVC/PV 410 374 26 287.5 88 45
DDA 200-4 SS 405 364 - 287.5 88 45

English (GB)
13
5. Assembly and installation
5.1 Pump assembly
5.1.1 Requirements
• The installation location must be protected from
rain, humidity, condensation, direct sunlight and
dust.
• The installation location must have sufficient
lighting to ensure safe operation.
• Observe the permissible ambient conditions. See
section 4.1 Technical data.
• The mounting surface must be stable.
• The mounting plate must be mounted horizontally
e.g. on a tank.
• Dosing must flow upwards vertically.
5.1.2 Aligning and installing the mounting plate
The mounting plate can be used as a drill template,
please see fig. 5for drill hole distances.
1. Indicate drill holes.
2. Drill holes.
3. Secure mounting plate using four screws on a
bracket or a tank.
5.1.3 Installing the pump on the mounting plate
1. Remove the locking screws from their transport
position on the mounting plate.
2. Place the pump on the mounting plate support
clamps and slide it in as far as possible.
– The mounting plate moves into the final
position when you tighten the locking screws.
3. Carefully screw in and tighten the 2 horizontal
locking screws using a torque wrench.
– Wrench size: TORX PLUS 15 IP
– Torque [Nm]: 1.7 (+/- 0.2)
Fig. 6 Installing the pump on the mounting
plate
4. For applications where the mounting surface
vibrates, or if the pump is installed in a system
during transport, secure the pump on the
mounting plate with the 6 vertical safety screws
using a torque wrench.
– Wrench size: TORX PLUS 15 IP
– Torque [Nm]: 1.7 (+/- 0.2)
Install the pump in such a way that the
plug can easily be reached by the operator
during operation. This will enable the
operator to separate the pump from the
power supply quickly in case of
emergency.
TM06 7050 3418

English (GB)
14
5.1.4 Adjusting the control cube position
The control cube is fitted to the front of the pump on
delivery. It can be turned by 90 ° so that the user can
select to operate the pump from the right or left side.
1. Switch off the power supply.
2. Carefully remove both protective caps on the
control cube using a thin screwdriver.
3. Remove the screws.
– Wrench size: TORX PLUS 15 IP
4. Carefully lift off the control cube only so far from
the pump housing that no tensile stress is
produced on the flat band cable.
– Make sure no liquid enters the housing.
5. Turn the control cube by 90 ° and re-attach.
– Make sure the O-ring is placed correctly.
6. Push down the cube and tighten the screws
using a torque wrench.
– Torque [Nm]: 1.7 (± 0.2)
7. Attach the protective caps observing the correct
orientation.
Fig. 7 Adjusting control cube
5.2 Hydraulic connection
The dosing head may contain water from the factory
check. When dosing media which should not come
into contact with water, another medium must be
dosed beforehand.
Faultless function can only be guaranteed in
conjunction with lines supplied by Grundfos.
The lines used must comply with the pressure limits
as per section 4.1 Technical data.
Important information on installation
• Observe suction lift and line diameter, see
section 4.1 Technical data.
• Shorten hoses and pipes at right angles.
• Ensure that there are no loops or kinks in the
hoses.
• Keep inlet line as short as possible.
• Route inlet line up towards the inlet valve.
• Installing a strainer in the inlet line protects the
entire installation against dirt and reduces the
risk of leakage.
• Install a pressure-relief valve in the outlet line to
provide protection against impermissibly high
pressure.
• We recommend the installation of a pulsation
damper downstream the pump:
– for pipe installations.
– for hose installations where the pump is
operated with ≥75 % of its dosing capacity.
• Only control variant DDA-FCM and DDA with
DLD:
For discharge quantities < 1 l/h we recommend
the use of an additional spring-loaded valve
(approx. 2 bar) on the outlet side for the safe
generation of the necessary differential pressure.
Install the control cube correctly to ensure
the enclosure class (IP65 / Nema 4X) and
shock protection.
TM06 7051 2916
WARNING
Chemical hazard
Death or serious personal injury
- Observe the material safety data sheet
of the dosing medium.
- Wear protective clothing (gloves and
goggles) when working on the dosing
head, connections or lines.
Pressure differential between inlet and
outlet side must be at least 1 bar / 14.5 psi.
For control variant FCM and for pumps
with diaphragm leakage detection the
pressure differential between inlet and
outlet side must be at least 2 bar / 29 psi.

English (GB)
15
Hose connection, type U3U3
For details on connection types, see section
3.5 Type key.
1. Make sure the system is pressureless.
2. Push union nut (2) and hose clamp (3) across
hose (4).
3. Push hose (4) completely onto hose connector
(1) and tighten hose clamp (3).
4. Install hose connector (1) with union nut (2) at
inlet and outlet valve.
– Make sure the gasket at the valve is placed
correctly.
– Tighten union nuts manually. Do not use tools.
– If using PTFE gaskets, retighten union nuts
after 2-5 operating hours.
5. Attach a deaeration hose to the corresponding
connection (see fig. 4, pos. 12) and run it into a
suitable container or collecting tray.
Fig. 8 Hydraulic connection
Pipe connection, type U3U3
For details on connection types, see section
3.5 Type key.
1. Make sure the system is pressureless.
2. Push union nut (2) across pipe (3).
3. For PVC pipe:
Glue inlay (1) to end of pipe (3) according to pipe
manufacturer's specification.
4. For PVDF pipe:
Weld inlay (1) to end of pipe (3) according to pipe
manufacturer's specification.
5. Install pipe with union nut (2) at inlet and outlet
valve.
– Make sure the gasket at the valve is placed
correctly.
– Tighten union nuts manually. Do not use tools.
– If using PTFE gaskets, retighten union nuts
after 2-5 operating hours.
6. Attach a deaeration hose to the corresponding
connection (see fig. 4, pos. 12) and run it into a
suitable container or collecting tray.
Fig. 9 Hydraulic connection
TM06 7052 2916
1
2
4
3
TM06 7299 3216
1
2
3

English (GB)
16
Pipe connection, types A1A1, A3A3, A7A7
For details on connection types, see section
3.5 Type key.
1. Make sure the system is pressureless.
2. Push union nut (2) across pipe (3).
3. Apply appropriate sealing material to thread of
inlay (1).
4. Screw inlay (1) to end of pipe (3).
5. Install pipe with union nut (2) at inlet and outlet
valve.
– Make sure the gasket at the valve is placed
correctly.
– Tighten union nuts manually. Do not use tools.
– If using PTFE gaskets, retighten union nuts
after 2-5 operating hours.
6. Attach a deaeration hose to the corresponding
connection (see fig. 4, pos. 12) and run it into a
suitable container or collecting tray.
Fig. 10 Hydraulic connection, type A7A7
Fig. 11 Hydraulic connection, type A1A1, A3A3
5.3 Electrical connection
The mains plug is the separator separating the pump
from the mains.
All electrical connections must be carried out by a
qualified electrician in accordance with local
regulations.
The pump can start automatically when the power
supply is switched on.
The enclosure class (IP65 / Nema 4X) is only
guaranteed if plugs or protective caps are correctly
installed.
Do not manipulate mains plug or cable.
The rated voltage of the pump must conform to local
conditions. See section 3.4 Nameplate.
TM06 7300 3216TM06 7376 3216
1
2
3
1
2
3
CAUTION
Automatic startup
Minor or moderate personal injury
- Make sure the pump has been correctly
installed and is ready to be started
before you switch on the power supply.

English (GB)
17
Signal connections
Fig. 12 Wiring diagram of the electrical connections
WARNING
Electric shock
Death or serious personal injury
- Electric circuits of external devices
connected to the pump inputs must be
separated from dangerous voltage by
means of double or reinforced
insulation!
TM06 7054 3818
2
1
34445
3
22
1
23
4
1
2
1
3
Ź
2
1
GND GND
GND
12
34
12
34
12
5
34
34
12
12
5
34
45
3
1
GND
BUS
BUS
Symbol Function Pin assignment
1/brown 2/white 3/blue 4/black
Analog GND/(-) mA (+) mA
External stop GND X
Pulse GND X
1234
Low-level signal XGND
Empty signal XGND
1/brown 2/white 3/blue 4/black 5/yellow/green
Analog output (+) mA GND/(-) mA
1 2/brown 3/blue 4 5/black
GENIbus RS-485 A RS-485 B GND
1/brown 2/white 3/blue 4/black
Relay 1 XX
Relay 2 XX

English (GB)
18
FlowControl signal connection (DDA-FCM)
Fig. 13 FlowControl signal connection
DLD signal connection (optional for DDA-AR)
Fig. 14 DLD signal connection
6. Startup
6.1 Preparing the pump for startup
The pump can start automatically when the power
supply is switched on.
• Make sure the pump has been connected
electrically by a qualified person.
• Make sure the power supply specified on the
nameplate matches the local conditions.
• Check that all pipe or hose connections have
been tightened properly and tighten them, if
necessary. See section 5.2 Hydraulic connection.
6.2 Starting up the pump
1. Read section 6.1 Preparing the pump for startup.
2. Switch on the power supply.
3. Proceed according to sections:
– 6.3 Setting the menu language
– 6.4 Deaerating the pump
– 6.5 Calibrating the pump.
TM06 7060 3716TM06 7256 3716
CAUTION
Chemical hazard
Minor or moderate personal injury
- Observe the material safety data sheet
of the dosing medium.
- Wear protective clothing (gloves and
goggles) when working on the dosing
head, connections or lines.
- Collect and dispose of all chemicals in a
way that is not harmful to humans,
animals and the environment.
CAUTION
Automatic startup
Minor or moderate personal injury
- Make sure the pump has been correctly
installed and is ready to be started
before you switch on the power supply.
Tighten the dosing head screws with a
torque wrench before startup and every
time the dosing head has been opened.
After 48 operating hours, retighten the
dosing head screws using a torque
wrench. Torque [Nm]: 6 (+ 1).

English (GB)
19
6.3 Setting the menu language
For description of control elements, see section 7.
1. Turn click wheel to highlight the cog symbol.
TM06 7061 2916
2. Press the click wheel to open the "Setup" menu.
3. Turn the click wheel to highlight the "Language"
menu.
4. Press the click wheel to open the "Language"
menu.
5. Turn the click wheel to highlight the desired
language.
6. Press the click wheel to select the highlighted
language.
7. Press the click wheel again to confirm the "Confirm
settings?" prompt and apply the setting.
Fig. 15 Set menu language
Operation
English >
Manual >
Actual flow >
Off >
❑
Language
Operation mode
Analog output
SlowMode
FlowControl active
Operation
Setup
Setup
Language
Language
Language
l/h
Manual
60.0 l/h
Manual
English >
Manual >
Actual flow >
Off >
❑
Language
Operation mode
Analog output
SlowMode
FlowControl active
❑
❑
❑
❑
English
Deutsch
Francais
Espanol
Italiano
❑
❑
❑
❑
English
Deutsch
Francais
Espanol
Italiano
Confirm
settings?
60.0

English (GB)
20
6.4 Deaerating the pump
1. Read section 6.1 Preparing the pump for startup.
2. Open the deaeration valve by approximately half
a turn.
3. Press the [100%] key and hold it down until liquid
flows out of the deaeration hose continuously
and without any bubbles.
4. Close the deaeration valve.
6.5 Calibrating the pump
The pump is calibrated in the factory for media with a
viscosity similar to water at maximum pump
backpressure. See section 4.1 Technical data.
If the pump is operated with a backpressure that
deviates or if dosing a medium whose viscosity
deviates, the pump must be calibrated.
For pumps with FCM control variant, it is not
necessary to calibrate the pump if there is deviating
or fluctuating backpressure as long as the
"AutoFlowAdapt" function has been enabled. See
section 7.11
AutoFlowAdapt .
Requirements
• The hydraulics and electrics of the pump are
connected. See section 5. Assembly and
installation.
• The pump is integrated into the dosing process
under operating conditions.
• The dosing head and inlet line are filled with
dosing medium.
• The pump has been deaerated.
WARNING
Pressurised dosing medium
Death or serious personal injury
- Do not open the deaeration valve by
more than one full turn.
Press the [100%] key and simultaneously
turn the click wheel clockwise to increase
the duration of the process to up to 300
seconds. After setting the seconds, do not
press the key any longer.
During calibration the pump performs 100
strokes/minute as a standard. If the
SlowMode function is activated, the
number of strokes/minute is 60 at 50 %
and 30 at 25 %.