Grundfos SMART Digital XL Service Guide
Grundfos SMART Digital XL Service Guide
SMART Digital XL
DDA and DDE
From 60 to 200 l/h
Service instructions
WARNING WARNING
Indicates a hazardous situation which, if not avoided, Danger of explosion, if dosing liquid has entered
could result in death or serious personal injury. the pump housing!
Death or serious personal injury
The text accompanying the hazard symbol WARNING is Operation with damaged diaphragms can lead to
structured in the following way: dosing liquid entering the pump housing.
- In case of diaphragm leakage, immediately
SIGNAL WORD
separate the pump from the power supply!
Description of hazard - Make sure the pump cannot be put back into
Consequence of ignoring the warning. operation by accident!
- Action to avoid the hazard. - Dismantle the dosing head without connecting the
pump to the power supply and make sure no
2.2 Notes dosing liquid has entered the pump housing. If the
safety diaphragm is damaged, the pump cannot be
repaired and must be replaced.
If these instructions are not observed, it may result in
malfunction or damage to the equipment.
2
3. Special tools 7. Carefully pull off the right side of the I/O board until you can
reach the plug connector (2) on the backside.
English (GB)
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 A
special service tasks, like firmware update and I/O board
calibration after replacement. B
For analog output calibration, an additional multimeter is 2
required.
See section 6. Firmware update, analog I/O calibration, A
store/restore settings
The hydraulic test unit is used to check the hydraulic performance 8. To disconnect plug connector (2) proceed as follows:
of Grundfos dosing pumps. – Press both latches (A) to unlock the plug.
Product number: 99600938 – Carefully pull off the plug in the direction of the arrow (B).
9. Remove the I/O board.
4. Replacing the I/O board
10. Connect the new I/O board and install it in reverse order.
Before replacing the I/O board you can use the Profi tester to 11. Tighten the screws using a torque wrench.
check if it is damaged. See section 3.2 Profi tester.
– Torque [Nm]: 1.7 (± 0.2)
1. Read section 2.2.1 Safety instructions.
12. Apply new seal sticker (3). Make sure the seal sticker covers
2. Make the system pressureless. the side cover and the top left screw of the I/O board.
3. Before starting any work on the product, pull out the mains
Perform I/O board calibration
plug, or switch off the power supply and make sure it cannot
be accidentally switched on. 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.
5
2
4
3
Fig. 1 Replacing the I/O board - overview
Pos. Description
1 I/O board
2 Plug connector position at backside of I/O board
3 Seal sticker
Position of I/O board cable connection at main circuit
4
board
5 Main circuit board
3
5. Replacing the control cube 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
English (GB)
9 B
7
5
10
4
20. Install the side cover again. 6. Firmware update, analog I/O calibration,
English (GB)
– Make sure that the cables do not have any sharp bends and store/restore settings
are not pinched.
– Make sure the I/O board cable is placed correctly for 6.1 Required equipment
subsequent I/O board installation. The update & calibration process requires hardware to connect
21. Tighten the screws using a torque wrench. the pump to a PC and software to perform the process.
– Torque [Nm]: 1.7 (± 0.2) 6.1.1 Hardware for firmware update and analog I/O calibration
22. Turn the control cube into the original position.
PC Tool Link
23. Mount the screws at the control cube.
The package (part no. 96705378) contains the PC Tool Link,
24. Tighten the screws using a torque wrench. various cables and a driver CD.
– 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.
WARNING
5
6.1.2 Additional hardware for analog output calibration COM port and user configuration
English (GB)
To measure the actual current on the analog output, a multimeter 1. Start PC-Tool E-Products.
and a separate cable are required: 2. A message is displayed, indicating that no COM port is
• The multimeter must have a DC current measuring range of 0- selected.
200 mA or 0-400 mA. – Click "OK" to select the correct COM port.
• The multimeter must have an accuracy of current 3. Click "Communication" in the next window and select the
measurement < 0.5 % Full Scale. suitable port:
• 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:
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
TM07 4037 1020
6
6.2 Updating the firmware 6.3 Updating the GUI data
English (GB)
This kind of update does not affect the pump This kind of update does not affect the pump
settings. settings.
1. Make sure you have installed and configured the hardware 1. Make sure you have installed and configured the hardware
and software according to section 6.1 Required equipment. and software according to section 6.1 Required equipment.
2. Start "PC-Tool E-Products" and click the "Firmware update" 2. Start "PC-Tool E-Products" and click the "Firmware update"
button. button.
3. Click "Select file for PIC32 flash" and select the *.aes file in 3. Click "Select file for SPI flash" and select the *.bin file in the
the text box: text box:
7
6.4 Updating the motor controller 6.5 Calibrating the analog input
English (GB)
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.
TM07 4040 1020
8
6.6 Calibrating the analog output 6.7 Storing and restoring the pump settings
English (GB)
Calibration of the analog output is a two-step process: 1. Make sure you have installed and configured the hardware
• Set the analog output to a reference value of 20 mA and and software according to section 6.1 Required equipment.
measure the actual current, using a multimeter (expected 2. Start "PC-Tool E-Products" and click "Standard configuration
range: 18-22 mA) [F6]".
• Write the measured value back into the pump, so the pump Storing settings
can adjust its output accordingly.
3. Click "Receive" to receive the current settings.
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 "Custom
configuration [F7]" button:
After some seconds, a window with the binary data pops up.
Fig. 17 Opening the "Custom configuration" menu
The displayed binary data looks like glyphs and
3. Connect a multimeter to the analog output. Observe section
symbols, not like readable text.
6.1.4 Establishing the Analog output connection (for I/O
calibration).
4. Click "Set 20 mA". 4. Click "File > Save as…" to store the received settings.
5. Read the measured current from the multimeter and enter the 5. Select a folder and enter a meaningful file name to store the
value into the input field. settings. The file name extension ".bin" is appended
– Example: 19.85 mA. automatically.
Restoring settings
TM07 4045 1020
9
7. Service kits and spare parts
English (GB)
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
10
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