Grundfos SMART Digital XL DDE Operating instructions

SMART Digital XL
DDA and DDE
From 60 to 200 l/h
Service instructions
GRUNDFOS INSTRUCTIONS
Installation and operating instructions
DDE
http://net.grundfos.com/qr/i/98767824
Installation and operating instructions
DDA
http://net.grundfos.com/qr/i/98767821

English (GB)
2
English (GB) Service instructions
Original service instructions
CONTENTS
Page
1. Purpose and target group of this document
This document is intended for trained and certified service
persons, and describes advanced repair and testing procedures
for the SMART Digital XL dosing pump types DDA and DDE from
60 to 200 l/h.
To identify your product see the type key and nameplate
description in the installation and operating instructions:
Installation and operating instructions DDA
• http://net.grundfos.com/qr/i/98767821
Installation and operating instructions DDE
• http://net.grundfos.com/qr/i/98767824
2. Symbols used in this document
2.1 Hazard statements
The text accompanying the hazard symbol WARNING is
structured in the following way:
2.2 Notes
2.2.1 Safety instructions
Important safety information as well as instructions on standard
service procedures for users can be found in the installation and
operating instructions of the product.
Installation and operating instructions DDA
• http://net.grundfos.com/qr/i/98767821
Installation and operating instructions DDE
• http://net.grundfos.com/qr/i/98767824
2.3 Diaphragm leakage
If the diaphragm leaks or is broken, dosing liquid escapes from
the drain opening in the dosing head.
In case of diaphragm leakage, the safety diaphragm protects the
pump housing against the ingress of dosing liquid.
When dosing crystallising liquids, the drain opening can be
blocked by crystallisation. If the pump is not taken out of
operation immediately, pressure can build up between the
diaphragm and the safety diaphragm. In consequence, dosing
liquid can penetrate the safety diaphragm and enter the pump
housing.
Most dosing liquids don't cause any danger when entering the
pump housing. A few liquids can cause a chemical reaction with
inner parts of the pump. In the worst case, this chemical reaction
can produce explosive gases in the pump housing.
1. Purpose and target group of this document 2
2. Symbols used in this document 2
2.1 Hazard statements 2
2.2 Notes 2
2.3 Diaphragm leakage 2
3. Special tools 3
3.1 PC Tool for E-Products 3
3.2 Profi tester 3
3.3 Hydraulic test unit 3
4. Replacing the I/O board 3
5. Replacing the control cube 4
5.1 Dielectric voltage withstand test 5
6. Firmware update, analog I/O calibration,
store/restore settings 5
6.1 Required equipment 5
6.2 Updating the firmware 7
6.3 Updating the GUI data 7
6.4 Updating the motor controller 8
6.5 Calibrating the analog input 8
6.6 Calibrating the analog output 9
6.7 Storing and restoring the pump settings 9
7. Service kits and spare parts 10
The procedures described in this document require
expert knowledge and must only be carried out by
certified service persons authorised and qualified by
Grundfos.
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious personal injury.
SIGNAL WORD
Description of hazard
Consequence of ignoring the warning.
- Action to avoid the hazard.
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
- Before starting any work on the product, pull out
the mains plug, or switch off the power supply and
make sure it cannot be accidentally switched on.
- Keep liquids away from the power supply and
electrical components.
WARNING
Chemical hazard
Death or serious personal injury
- Before starting work on the pump, the system
must be pressureless.
- 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.
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. If the
safety diaphragm is damaged, the pump cannot be
repaired and must be replaced.

English (GB)
3
3. Special tools
3.1 PC Tool for E-Products
The PC Tool for E-Products consists of hardware for pump
connection and software for your computer. It is required for
special service tasks, like firmware update and I/O board
calibration after replacement.
For analog output calibration, an additional multimeter is
required.
See section 6. Firmware update, analog I/O calibration,
store/restore settings
3.2 Profi tester
The Profi tester is a special tool to check the inputs and outputs
of Grundfos dosing pumps.
Product number: 99600937
3.3 Hydraulic test unit
The hydraulic test unit is used to check the hydraulic performance
of Grundfos dosing pumps.
Product number: 99600938
4. Replacing the I/O board
Before replacing the I/O board you can use the Profi tester to
check if it is damaged. See section 3.2 Profi tester.
1. Read section 2.2.1 Safety instructions.
2. Make the system pressureless.
3. Before starting any work on the product, pull out the mains
plug, or switch off the power supply and make sure it cannot
be accidentally switched on.
Fig. 1 Replacing the I/O board - overview
4. Remove the signal connections from I/O board (1).
5. Remove seal sticker (3).
The grey area (2) indicates the position of the plug connector at
the backside of the I/O board. The grey area (4) indicates where
the cable is fixed at the main circuit board (5).
6. Remove the screws at the corners of I/O board (1).
– Wrench size: TORX PLUS 15 IP
7. Carefully pull off the right side of the I/O board until you can
reach the plug connector (2) on the backside.
Fig. 2 I/O board plug connector
8. To disconnect plug connector (2) proceed as follows:
– Press both latches (A) to unlock the plug.
– Carefully pull off the plug in the direction of the arrow (B).
9. Remove the I/O board.
10. Connect the new I/O board and install it in reverse order.
11. Tighten the screws using a torque wrench.
– Torque [Nm]: 1.7 (± 0.2)
12. Apply new seal sticker (3). Make sure the seal sticker covers
the side cover and the top left screw of the I/O board.
Perform I/O board calibration
If an I/O board with analog connections was replaced, these
connections must be calibrated.
The number of analog connections depends on the pump type
and control variant.
Perform calibration according to section 6. Firmware update,
analog I/O calibration, store/restore settings.
TM07 3368 4918
Pos. Description
1 I/O board
2 Plug connector position at backside of I/O board
3 Seal sticker
4Position of I/O board cable connection at main circuit
board
5 Main circuit board
The cable from the I/O board to the main circuit
board is short. The cable is fixed permanently at the
main circuit board.
Do not pull off the I/O board with force, otherwise the
main circuit board or the cable can be damaged. The
main circuit board and the cable cannot be repaired.
1
2
4
5
3
TM07 3751 0219
Type Control variant Analog input Analog output
DDA AR YES YES
FCM YES YES
DDE AR YES -
B- -
A
B
A
2

English (GB)
4
5. Replacing the control cube
1. Read section 2.2.1 Safety instructions.
2. Make the system pressureless.
3. Before starting any work on the product, pull out the mains
plug, or switch off the power supply and make sure it cannot
be accidentally switched on.
Fig. 3 Replacing the control cube - overview
4. Remove the I/O board (1) according to section 4. Replacing
the I/O board.
5. Unplug FlowControl or DLD signal connection (10).
6. Carefully remove both protective caps on control cube (9)
using a thin flathead screwdriver.
7. Remove the screws from control cube (9).
– Wrench size: TORX PLUS 15 IP
8. For best access to main circuit board (6) turn control cube (9)
to the right.
The main circuit board (6) and the mains connection are fixed at
the side cover (7). There are several cables connecting the main
circuit board with other product components.
9. Remove the screws from side cover (7).
– Wrench size: TORX PLUS 15 IP
– Leave the mains cable fixed at the side cover.
10. Carefully open the side cover (7) at the front side of the pump,
until you can reach the hall sensor plug connector (5) on the
main circuit board.
Fig. 4 Hall sensor plug connector
11. Carefully pull off the plug in the direction of the arrow. You can
use a pair of needle-nosed pliers (A), if necessary. The plug is
not locked.
12. Carefully pull off side cover (7) until you can reach the control
cube plug connector (8) on the main circuit board.
Fig. 5 Control cube plug connector
13. To disconnect plug connector (8) proceed as follows:
– Press both latches (B) to unlock the plug.
– Carefully pull off the plug in the direction of the arrow (C).
14. Remove the control cube and gasket.
15. Carefully pre-bend the cable of the new control cube as
shown in detail (D).
Fig. 6 Control cube cable placement
16. Put the new control cube gasket in place.
17. Pass the cable through the control cube installation hole as
shown in detail (E).
18. Plug in the control cube cable at the main circuit board.
19. Plug in the hall sensor cable at the main circuit board.
TM07 3369 4918
Pos. Description
1 I/O board
2 Plug connector position at backside of I/O board
3 Seal sticker
4Position of I/O board cable connection at main circuit
board
5 Hall sensor plug connector position at main circuit board
6 Main circuit board
7Side cover (mains cable and main circuit board are fixed
at this cover)
8Control cube plug connector position at main circuit
board
9 Control cube
10 FlowControl or DLD signal connection (DDA only)
The cables from the main circuit board to other
product components are short.
Do not pull off the side cover with force, otherwise
the main circuit board or cables can be damaged.
The main circuit board and cables (except control
cube cable) cannot be repaired.
1
2
3
9
4
5
10
6
7
8
TM07 3752 0219TM07 3757 0219TM07 3758 0219
B
7
A
5
9
7
B
8
B
C
D
E

English (GB)
5
20. Install the side cover again.
– Make sure that the cables do not have any sharp bends and
are not pinched.
– Make sure the I/O board cable is placed correctly for
subsequent I/O board installation.
21. Tighten the screws using a torque wrench.
– Torque [Nm]: 1.7 (± 0.2)
22. Turn the control cube into the original position.
23. Mount the screws at the control cube.
24. Tighten the screws using a torque wrench.
– Torque [Nm]: 1.7 (± 0.2)
25. Apply the protective caps.
26. Plug in the I/O board cable.
27. Install the I/O board again.
28. Tighten the screws using a torque wrench.
– Torque [Nm]: 1.7 (± 0.2)
29. Plug in the FlowControl or DLD signal connection (10) again.
30. Perform electrical testing as described in 5.1 Dielectric
voltage withstand test.
31. Apply new seal sticker (3). Make sure the seal sticker covers
the side cover and the top left screw of the I/O board.
32. Perform hydraulic calibration. See installation and operating
instructions.
5.1 Dielectric voltage withstand test
Test voltage: 1400 VAC or 2000 VDC
1. The test voltage must be applied between A and B which are
defined as:
– A: the short-circuited supply voltage connections
– B: all accessible conductive parts (potential earth at mains
cable, I/O board pins)
2. Raise the test voltage to the specified value within 5 seconds
and maintain it for minimum 2 seconds.
6. Firmware update, analog I/O calibration,
store/restore settings
6.1 Required equipment
The update & calibration process requires hardware to connect
the pump to a PC and software to perform the process.
6.1.1 Hardware for firmware update and analog I/O calibration
PC Tool Link
The package (part no. 96705378) contains the PC Tool Link,
various cables and a driver CD.
Fig. 7 PC Tool Link
Fig. 8 RS485 cable with screw terminal connector from PC
Tool Link package
Cable with female 5-pin M12 connector
To connect to the pump's GENIbus or analog output, a cable with
a female 5-pin M12 connector is required:
• Part no. 96632921 (2m)
• or part no. 96632922 (5m)
Fig. 9 Cable with female 5-pin M12 connector
WARNING
Electric shock
Death or serious personal injury
- The described procedures must only be performed
by a qualified electrician.
TM07 4025 0719TM07 4026 0719TM07 4027 0719
For analog output calibration, the analog output and
the GENIbus must be connected at the same time,
so two cables are required in this case.

English (GB)
6
6.1.2 Additional hardware for analog output calibration
To measure the actual current on the analog output, a multimeter
and a separate cable are required:
• The multimeter must have a DC current measuring range of 0-
200 mA or 0-400 mA.
• The multimeter must have an accuracy of current
measurement < 0.5 % Full Scale.
• The cable to connect the multimeter to the current output is
the same as the GENIbus cable. See fig. 9.
6.1.3 Establishing the GENIbus connection (for firmware
update, I/O calibration, store/restore settings)
1. Connect the female 5-pin M12 connector cable (see fig. 9.) to
the GENIbus connector of the pump.
Connector symbol on pump:
2. Connect the open ends of the 5-pin M12 connector cable to
the RS485 cable with screw terminal connector according to
this table:
6.1.4 Establishing the Analog output connection (for I/O
calibration)
1. Connect the female 5-pin M12 connector cable (see fig. 9.) to
the analog output connector of the pump.
Connector symbol on pump:
2. Connect the open ends of the 5-pin M12 connector cable to
the multimeter’s measuring leads according to this table:
6.1.5 Software
To perform the update, the installation of “PC Tool E-Products”
(part. no. 96562934) is required.
You can find the "PC Tool E-Products" page in GTI (Grundfos
Technical Information), where you can download the software and
find more information:
• http://insite.grundfos.com/notes/techmar/modifica.nsf/6e56a364
8c96eb09c1256c13003b9509/860a2698d0d005f2c125788b00
479ba7
The "PC Tool E-Products" page can also be found this way:
• Grundfos Insite->Toolbox->GTI->Service Support Tools->
Grundfos PC Tools\PC Tool E-Product
COM port and user configuration
1. Start PC-Tool E-Products.
2. A message is displayed, indicating that no COM port is
selected.
– Click “OK” to select the correct COM port.
3. Click “Communication” in the next window and select the
suitable port:
Fig. 10 COM port configuration
4. Switch user account for elevated permissions:
– Click “File” -> “Preferences…”
– Click “User” in the left window
– Make sure user “GESE” is selected. If not, select user
“GESE” and enter the respective password:
Fig. 11 User configuration
5. Click "OK" and restart "PC-Tool E-Products"
5-pin M12 connector cable RS485 cable with screw
terminal connector
White Black
Blue Blue
Yellow – Green Yellow
5-pin M12 connector cable Measuring lead of
multimeter
Black DC mA input(+)
Yellow - Green GND (-)
TM07 4036 0719TM07 4037 0719

English (GB)
7
6.2 Updating the firmware
1. Make sure you have installed and configured the hardware
and software according to section 6.1 Required equipment.
2. Start "PC-Tool E-Products" and click the "Firmware update"
button.
3. Click “Select file for PIC32 flash” and select the *.aes file in
the text box:
Fig. 12 Updating the firmware
4. Power-off the pump.
5. Click “Program”.
6. Power-on the pump. The update process starts.
7. After the update the pump restarts automatically.
6.3 Updating the GUI data
1. Make sure you have installed and configured the hardware
and software according to section 6.1 Required equipment.
2. Start "PC-Tool E-Products" and click the "Firmware update"
button.
3. Click “Select file for SPI flash” and select the *.bin file in the
text box:
Fig. 13 Updating the GUI data
4. Power-off the pump.
5. Click “Program”.
6. Power-on the pump. The update process starts.
7. After the update the pump restarts automatically.
This kind of update does not affect the pump
settings.
TM07 4038 0719
This kind of update does not affect the pump
settings.
TM07 4039 0719

English (GB)
8
6.4 Updating the motor controller
The motor controller update is a three-step process:
• Update of motor controller firmware
• Default boot and validation
• Motor calibration
6.4.1 Updating the motor controller firmware
1. Make sure you have installed and configured the hardware
and software according to section 6.1 Required equipment.
2. Power-on the pump.
3. Start "PC-Tool E-Products" and click the "Firmware update"
button.
4. Click “Motor controller” and select the *.xbin file in the text
box:
Fig. 14 Updating the motor controller firmware
5. Click “Program”. The update process starts.
6.4.2 Default boot and validation
After the update of the motor controller firmware, click “Default
boot, Validate” (fig. 14) to load default parameters and to check if
the update process was successful.
In case of any error, repeat the motor controller firmware update.
6.4.3 Motor calibration
Perform a motor calibration, if the motor does not run properly
after the motor controller firmware update:
1. Start "PC-Tool E-Products" and click the "Firmware update"
button.
2. Click “Motor calibration” (fig. 14). The motor runs at full speed
for some seconds.
3. After the motor calibration the motor stops and the pump
returns to normal operation.
6.5 Calibrating the analog input
1. Make sure you have installed and configured the hardware
and software according to section 6.1 Required equipment.
2. Start "PC-Tool E-Products" and click the "Firmware update"
button.
3. Make sure all cables are disconnected from the analog input
of the pump.
4. Click “Calibrate analog input”. The calibration of the analog
input starts.
Fig. 15 Calibrating the analog input
5. After the update the pump restarts automatically.
This kind of update does not affect the pump
settings.
TM07 4040 0719
TM07 4042 0719

English (GB)
9
6.6 Calibrating the analog output
Calibration of the analog output is a two-step process:
• Set the analog output to a reference value of 20 mA and
measure the actual current, using a multimeter (expected
range: 18-22 mA)
• Write the measured value back into the pump, so the pump
can adjust its output accordingly.
6.6.1 Performing the calibration
1. Make sure you have installed and configured the hardware
and software according to section 6.1 Required equipment.
2. Start "PC-Tool E-Products" and click the "Firmware update"
button.
3. Connect a multimeter to the analog output. Observe section
6.1.4 Establishing the Analog output connection (for I/O
calibration).
4. Click “Set 20 mA”.
5. Read the measured current from the multimeter and enter the
value into the input field.
– Example: 19.85 mA.
Fig. 16 Calibrating the analog output
6. Click “Send value” to send the multimeter value to the pump.
– The pump adjusts the current output accordingly and
restarts.
6.7 Storing and restoring the pump settings
1. Make sure you have installed and configured the hardware
and software according to section 6.1 Required equipment.
2. Start "PC-Tool E-Products" and click "Standard configuration
[F6]".
Storing settings
3. Click “Receive” to receive the current settings.
Fig. 17 Storing settings
After some seconds, a window with the binary data pops up.
4. Click “File > Save as…” to store the received settings.
5. Select a folder and enter a meaningful file name to store the
settings. The file name extension “.bin” is appended
automatically.
Restoring settings
Fig. 18 Restoring settings
6. Browse the folder where the settings are stored. Then select
the .bin file.
7. Click “Send…” to transfer the settings to the pump.
– A message pops up asking if you want to send the
configuration data and stop the pump during transfer.
– Tick the check box and confirm the message with “Yes” to
stop the pump during the transfer.
The settings are transferred to the pump.
The settings are effective after the transfer has finished.
TM07 4045 0719
TM07 4046 0719
The displayed binary data looks like glyphs and
symbols, not like readable text.
TM07 4047 0719

English (GB)
10
7. Service kits and spare parts
For the full range of service kits and spare parts, see the service
kit catalogue:
• http://net.grundfos.com/qr/i/96488862_23
or the Grundfos Product Center:
• https://product-selection.grundfos.com