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Service instructions

DMX and DMH

1 / 1396611949 0306 GB 13

Table of contents1. Type identification ........................................................................................................................... 21.1 Nameplate ........................................................................................................................................................... 22. Type key ........................................................................................................................................... 32.1 Torques and lubricants ........................................................................................................................................ 42.2 Lubricants ............................................................................................................................................................ 43. Service tools .................................................................................................................................... 54. Spare parts ....................................................................................................................................... 65. Dismantling and assembly ............................................................................................................. 85.1 General information ............................................................................................................................................. 85.2 Interval between cleaning and maintenance ....................................................................................................... 85.3 Dismantling and assembly of dosing head .......................................................................................................... 95.4 Oil change (DMH) .............................................................................................................................................. 116. Fault finding charts ....................................................................................................................... 126.1 DMX................................................................................................................................................................... 126.2 DMH................................................................................................................................................................... 137. Drawings......................................................................................................................................... 147.1 DMX................................................................................................................................................................... 147.2 DMH................................................................................................................................................................... 14

GPipes

Stamp

1. Type identification

1.1 Nameplate

Fig. 1 DMX, DMH nameplate

TM03

2544

450

5

Pos. Description Pos. Description

1 Type designation 7 Country of origin

2 Model 8 Year-week code

3 Max. capacity [l/h] 9 Marks of approval, CE-mark, etc.

4 Voltage 10 Max. pressure [bar]

5 Frequency 11 Serial number

6 Product number

DMX4-10 B-PP / E / T-X-4144X

4.00 L / hr , 10.00 bar , 50 Hz

S / N : 512345221 - 4 - 10108

230 / 400V50 / 60HZ 440 / 480V 60HZ96293585P1053705 12345

Made in Germany

1

3

45

6

7 8 9

10

112

2 / 13

m

2

2. Type keyExample: DMX 160 - 5 B PP /E /T -X -E 1 QQ X E0

Type range Motor variant

DMX E0 PTC motor for frequency controlDMH

E1 Motor type EEx de C T3, 3 x 400 V,50 Hz (only DMX-B or DMX-AT)

Maximum flow [l/h]E2 Motor type EEx de C T4, 3 x 400 V,

50 Hz (only DMX-B or DMX-AT)

Maximum pressure [bar]E3 API approval

Mains plugControl variant

X No plugB Standard F EU (Schuko)AR* Etron E26 (analog/pulse control) B USA, Canada

AT3 Servomotor, 1 x 230 V, 50/60 Hz supply, 4-20 mA control

I Australia, New Zealand, TaiwanE Switzerland

AT4 Servomotor, 24 V, 50/60 Hz supply,4-20 mA control Connection, suction/discharge

AT5 Servomotor, 1 x 115 V, 50/60 Hz supply,4-20 mA control

B6 Pipe 4/6 mm4 Tube 6/9 mm

AT6 Servomotor, 1 x 230 V, 50/60 Hz supply,4-20 mA control, EEx d II BT 4

6 Tube 9/12 mmB9 Tube 19/27 mm, PVC

AT7 Servomotor, 1 x 115 V, 50/60 Hz supply,4-20 mA control, EEx d II BT 4

Q Tube 19/27 mm and 25/34 mmS Tube 0.375"/0.5”

Dosing head variantA Threaded Rp ¼"A1 Threaded Rp ¾"

PP Polypropylene A2 Threaded Rp 1 ¼"PV PVDF (polyvinylidene fluoride) V Threaded NPT ¼"PVC Polyvinyl chloride A9 Threaded NPT ½", maleSS Stainless steel, DIN 1.4401 A3 Threaded NPT ¾"Y Hastelloy C A7 Threaded NPT ¾", malePV-R PVDF + integrated relief valve A4 Threaded NPT 1 ¼" PVC-R PVC + integrated relief valve A8 Threaded NPT 1 ¼", malePP-L PP + integrated diaphragm leakage detection K Cementing d. 40 mmPV-L PVDF + integrated diaphragm leakage detection

B8 Cementing d. 40 mm and flange DN 32PVC-L PVC + integrated diaphragm leakage detection

SS-L SS + integrated diaphragm leakage detection B1 Tube 6/12 mm/cementing d. 12 mmY-L Y + integrated diaphragm leakage detection

B2 Tube 13/20 mm/cementing d. 25 mPV-RL PVDF + integrated relief valve and

diaphragm leakage detection B3 Welding d. 16 mm

PVC-RL PVC + integrated relief valve anddiaphragm leakage detection

B4 Welding d. 25 mmB5 Welding d. 40 mm

SS-H SS + heating flange in dosing head (electric) B7 Welding d. 40 mm and flange DN 3

Gasket materialC1 Welding flange DN 32, SSP Flange 1 ¼"

E EPDM (ethylene propylene diene monomer)Valve type

V FKM (fluorocarbon)T PTFE (polytetrafluoroethylene, also called Teflon®) 1 Standard

Valve ball material2 Spring-loaded

3 Spring-loaded, 0.05 bar suction, 0.8 bar dischargeC Ceramic

G Glass 4 Spring-loaded, discharge side onlyT PTFE (polytetrafluoroethylene (Teflon®))

Supply voltageSS Stainless steel, DIN 1.4401Y Hastelloy 0 Without motor, IEC flange

Control panel positionG 1 x 230 V, 50/60 HzH 1 x 120 V, 50/60 Hz

X No control panelE 230/400 V, 50/60 Hz

or 440/480 V, 60 HzF Front-mountedW Wall-mounted F Without motor, NEMA flange (US)

3 / 13

2.1 Torques and lubricantsThis section shows the screws and nuts to be tightened to a certain torque as well as the lubricants to be used.After approx. 6 to 10 working hours or two days, tighten the dosing head screws crosswise using a torque wrench.

Thread Eze, part no. 96611372 (0.5 l).

2.2 Lubricants

2.2.1 DMH

2.2.2 DMXChange of gear grease should be performed by authorized, qualified personnel only.For change of grease, contact Grundfos.To ensure trouble-free operation, we recommend that you change the gear grease after 5 years or 20,000 operating hours.

Pump Torque [Nm] Lubricant

DMH 251, 10 barDMH 252 8 - 10 Thread Eze

DMH 251, 16 barDMH 253 10 - 12 Thread Eze

DMH 251, 25 bar 13 - 15 Thread EzeDMH 254DMH 255DMH 257

50 - 54 Thread Eze

DMX 6 - 7 Thread Eze

Pump type Model

One dosing head Two dosing heads

Oil typeQuantity[l]

Product number

Quantity[l]

Product number

DMH 251 1.3 96607801 1.3 96607801 white oilDMH 252, 10 bar 1.3 96607801 1.3 96607801 white oilDMH 252, 16 bar 1.3 96607806 1.3 96607806 DHG 68DMH 253 1.3 96607806 1.3 96607806 DHG 68DMH 254 3.5 96607807 4.5 96607808 DHG 68DMH 255 3.5 96607807 4.5 96607808 DHG 68DMH 257 5.5 96607809 7.5 96607810 DHG 68DMH 280 1.3 96607806 1.3 96607806 DHG 68DMH 281 1.3 96607806 1.3 96607806 DHG 68DMH 283 3.5 96607807 4.5 96607808 DHG 68DMH 285 5.5 96607809 7.5 96607810 DHG 68DMH 286 5.5 96607809 7.5 96607810 DHG 68DMH 287 5.5 96607809 7.5 96607810 DHG 68DMH 288 3.5 96607807 4.5 96607808 DHG 68

Alternatives to white oil (Paraffin 55 DAB7) Alternatives to DHG 68

Manufacturer Designation Manufacturer Designation

ARAL Autin PL (DAB7) ARAL Degol BMB 68BP BP-Energol WM2 BP BP-Energol GR-XP 68ESSO Esso Marcol 82 (M82) Chevron Chevron NL gear compound 68Fina Fina Vestan A 70 B ESSO Spartan BP 68Texaco Texaco white oil pharmaceutical 70 Fina Fina Giran 68Shell Odina 15 Mobil Oil Mobilgear 626

Texaco Texaco Meropa 68Shell Tellus 68elf Reductelf SP 68

4 / 13

3. Service toolsThe following drawings and tables show standard and torque tools for pump service..

A B C

Pos. Description Suppl. information Part no.

A Torque wrench4 - 20 [Nm] SV0292

20 - 100 [Nm] SV0269

B Ratched insert tool Part for torque wrench SV0295

C Hexagon head driverM6 - 5 mm SV0296M8 - 6 mm SV0297

M10 - 8 mm SV0298

5 / 13

4. Spare partsKit type Contents Valve kit:

TM03

2610

460

5 - T

M03

2644

470

5

Valve Two complete valve kits(suction and discharge)

Diaphragm/valve parts Diaphragm andinternal valve components

Diaphragm Diaphragm

Valve parts kit

TM03

2668

460

5 - T

M03

2669

470

5

Diaphragm

TM03

2643

460

5

Material Product numbers

Type Model Flow [l/h] Dosing head/gasket/valve ballsDiaphragm/valve parts

Diaphragm Valve

DMX 221

4, 8, 16PP/EPDM/PTFE 96375311

9637533996375368

Stainless steel/FKM/stainless steel 96375312 96375369

7, 14, 27PP/EPDM/PTFE 96375309

9637533896375368


12, 26, 50PP/EPDM/PTFE 96375313

9637534096375368


17, 39, 75PP/EPDM/PTFE 96375315

9637534196375366


25, 60, 115PP/EPDM/PTFE 96375307

9637533796375366


DMX 226

24, 52, 67,100, 132, 142,

190

PP/EPDM/PTFE 9637532396375345

96375366


37, 82, 95,160, 199, 224,

280

PP/EPDM/PTFE 9637531796375342

96375366


60, 130, 152,255, 321, 380,

460

PP/EPDM/PTFE 96375319

96375343

96375366


249, 315, 525,765


PP/EPDM/PTFE 96375322 96375370

DMH 251 AllPP/EPDM/PTFE 96375325

96375346

96375368


DMH 252 AllPP/EPDM/PTFE 96375325 96375368



9637534796375366



9537534896375366


DMH 255

194, 270, 332,403

PP/EPDM/PTFE 96375331

95375349

96375366


550PP/EPDM/PTFE 96375333 96375372


DMH 257 AllPP/EPDM/GLAS 96375335

9637535196375374


DMH 280 AllPP/EPDM/PTFE

Stainless steel/FKM/stainless steel

6 / 13











Material Product numbers

Type Model Flow [l/h] Dosing head/gasket/valve ballsDiaphragm/valve parts

Diaphragm Valve

7 / 13

5. Dismantling and assembly

5.1 General informationIf it is necessary to dismantle the pump, either because it is choked or damaged, please follow the instructions in the following sections.

Position numbers of parts (digits) refer to drawings and parts lists; position numbers of tools (letters) refer to section 3. Service tools.

5.1.1 Before dismantling the pump• When dosing dangerous liquids, always refer to the corresponding safety data sheets.• Wear protective clothing (goggles and gloves) when working on the connections and cables.• Maintenance should only be carried out by authorized specialists.• Flush and clear all parts before dismantling.• Disconnect the electricity supply to the motor.• Remove the electric cable in accordance with local regulations.• Close the isolating valves, if fitted, to avoid draining the system.• Note the centre of gravity of the pump to prevent it from overturning.

5.1.2 Before assembly• Clean and check all parts.• Order the necessary service kits.• Replace defective parts by new parts.• Always replace gaskets and O-rings when the pump is overhauled.

5.1.3 During assembly• Lubricate and tighten screws and nuts to correct torque as stated in section ..

5.2 Interval between cleaning and maintenance

5.2.1 DMXClean the overflow valve and replace the diaphragm, if necessary,• every 12 months, or• if faults occur.• Gear grease see page LubricantsClean the valves:• At least every 12 months or after 4000 operating hours, or• if the pump is not performing, or• in the event of a fault.

5.2.2 DMHCheck the oil level and add oil if necessary:• Check the oil level every two weeks and add oil, if necessary.Clean the valves:• At least every 12 months or after 4000 operating hours, or• if the pump is not performing, or• in the event of a fault.Clean the valves and replace, if necessary (for stainless steel valves: inner parts of valve).Change diaphragms and gear oil• every 12 months, change the dosing liquid and gear oil• in dusty installation sites, change gear oil every 3000 operating hours.Clean ball check of the double diaphragm• after a diaphragm breakage, remove the ball check immediately and clean it.

8 / 13

5.3 Dismantling and assembly of dosing headThe drawings in this section are schematic drawings. Consequently, the number of screws and appearance of parts may differ according to pump type.

Step Action1

TM03

2608

460

5

Remove the valves• Stop the pump.• Remove the connections.• Unscrew valves counter-clockwise.

See Clean the valves, page Clean the valves.

2

TM03

2604

460

5

Remove the dosing head• Loosen the locking screw.• While the pump is running, set the stroke-length

adjusting knob to 100%.• Tighten the locking screw.• Stop the pump.• Remove the connections.• Loosen the socket head screws.• Remove the dosing head. Note the position of the

dosing head in order to refit it correctly.

3

TM

03

2605

46

05

Remove the diaphragm• Insert a screwdriver through the centre of the label

showing the motor direction of rotation. • Turn the fan blades until the diaphragm reaches the

front dead centre (the diaphragm detaches itself from the diaphragm flange).

• Screw the diaphragm counter-clockwise.

Check the support plate, If any• Check the support plate for damage/wear.

Check the adaptor ring (only DMX)• Check the adaptor ring for damage/wear.

4

TM

032

606

46

05

Fitting the diaphragm

Fit the adaptor ring (only DMX)• Position the adaptor ring in the gearbox with the cur-

vature against the dosing head.Fit the support plate and ring, If any• Ensure that the support plate behind the diaphragm

rests in the groove of the new diaphragm.Fit the diaphragm• Screw the new diaphragm completely into position,

then rotate back until the holes in the diaphragm and flange coincide.

• Turn the fan blades until the diaphragm reaches the bottom dead centre. (The diaphragm is pulled onto the diaphragm flange.).

5

TM

03

2607

46

05

Fit the dosing head• Fit the dosing head in the correct position on the

gear housing by means of the screws and tighten ac-cording to the table in section 2.1 Torques and lubri-cants.

9 / 13

6

TM

032

644

470

5 -T

M03

261

0 4

605

Clean the valves• Dismantle/assemble the valves as shown in the

drawing to the left. • Clean all parts and replace faulty parts by new ones.

7

TM

02

020

2 4

100

Fit the valves• Fit the valves so that the arrows point in the flow di-

rection. Screw the valves clockwise. • Fit the connections.

8

TM

0326

76

470

5 -

TM

032

025

47

05

Commissioning

Fill the dosing head(only for systems without flooded suction)• Unscrew the discharge valve (pos. 5).• Add the dosing liquid to the dosing head.• Screw the discharge valve (pos. 5) back in.

Deaerate the dosing pump• Open the deaeration valve (pos.11) of the dosing

line (if installed), or remove pressure on the dis-charge side so that the liquid is able to issue without counter pressure.

• Run the pump for approx. one minute or until the air has escaped from the dosing head.

• Close the deaeration valve (pos.11) of the dosing line.

Step Action

10 / 13

5.4 Oil change (DMH)

Step Action1

TM

032

633

470

5

Drain the gear oil• Stop the pump.• Unscrew the oil plug (pos. 1) inclusiv the gasket

(pos. 1b) and collect the gear oil in a container.• Screw the oil plug and the new gasket back in and

tighten well.Note: Risk of leaks and damage caused by oil loss. For each oil change, use a new flat gasket (pos. 1b).

Fill the gear oil• Check that the oil plug(pos. 1) is tightened.• Unscrew and remove the aeration screw and oil-

level gauge (pos. 2).• Set the stroke-length adjusting knob (pos. 3) to “0”.• Slowly add the hydraulic oil through the aeration

screw opening (pos. 2), until the oil reaches the mark on the oil-level gauge. For amount of oil, see section 2.1 Torques and lubricants.

• Wait 30 minutes.• Run the pump for approx. 5 minutes with a stroke ad-

justment of 0%.• Run the pump for approx. 10 minutes with a stroke

adjustment of 40%.

Check the oil level• Switch off pump.• Unscrew and remove the aeration screw and oil-

level gauge (pos. 2), check the oil level and add oil if necessary.

• Fit the aeration screw and oil-level gauge (pos. 2).

Vent the dosing pump(for pumps with air vent screw (pos. 4))• Remove cover (pos. 7) from the stroke-length

adjusting knob (pos. 3).• Loosen the locking screw (pos. 6).• Set the stroke-length adjusting knob (pos.3) to 15%.• Loosen the degassing valve (pos. 4) by one rotation

to the left.• Run the pump for approx. 5 minutes.• Tighten the degassing valve (pos. 4).• Set the stroke-length adjusting knob (pos.3) to the

duty point.• Tighten the locking screw (pos. 6).• Refit cover (pos. 7).

245

6 7

1

1b

3

11 / 13

6. Fault finding charts

6.1 DMX

Fault Cause Remedy

Pump does not run.

Pump not connected to mains. Connect the pump to the mains.Wrong mains voltage. Replace the pump.Electrical failure. Return the pump to the service centre for repair.The empty-tank indicator light is flashing in the display. Remove the cause.The integrated diaphragm leakage detection is acti-vated. ERROR and MBS are flashing in the display. Replace the diaphragm.

Pump does not suck.

Suction line leaking. Replace or seal the suction line.Cross-section of suction line too narrow or suction line too long.

Check recommended installation specifications in the installation and operating instructions.

Suction line clogged. Rinse or replace the suction line.Foot valve covered by sediment. Suspend the suction line at a higher position.Suction line buckled. Lay the suction line correctly and check for damage.Crystalline deposits in valves. Clean the valves.Diaphragm broken or diaphragm tappet torn out. Replace the diaphragm.

Pump does not dose.

Air in suction line and dosing head. Vent the pump. Wait until the pump has been vented.

Stroke adjustment set to zero. Turn the stroke-length adjusting knob in the direction of the "+".

Liquid too viscous or density too high. Check the installation.Crystalline deposits in valves. Clean the valves.

Valves not correctly assembled. Assemble the inside parts of the valve in the correct order and check or possibly correct the flow direction.

Injection point blocked. Check and possibly correct the flow direction, or remove the clog.

Inexpert installation of lines and peripheral equipment. Check for leakages and correct installation.

Dosing output of pump is inaccurate.

Dosing head not fully vented. Repeat the venting.Degassing liquid. Check the installation.Valves partially soiled or incrusted. Clean the valves.Zero point misadjusted. Adjust the zero point to the actual counter pressure.Counter pressure fluctuations. Use a counter-pressure valve and a pulsation damper.Suction height fluctuations. Keep the suction level constant.Siphon effect (pre-charge pressure higher than counter pressure). Install a counter-pressure valve.

Leaky or porous suction line or discharage line. Leaky or porous suction line or discharage line.Parts in contact with pumped liquid not resistant. Replace with resistant materials.

Dosing diaphragm worn out (incipient tears). Replace the diaphragm in accordance with the mainte-nance instructions.

Mains voltage fluctuating. Decrease the counter pressure of the pump.Variation of the dosing liquid (density and viscosity). Examine the concentration, possibly use an agitator.

12 / 13

6.2 DMH

Fault Diagnosis Cause Remedy

No dosing flow even at a low counter pressure. Pump makes no noise.

No motor sound or vibrations. Fan is not rotating. Motor is not running. Connect the motor to the power supply.

Replace the motor if blown.When the aeration screw is removed, use the oil-level gauge to observe a calm oil surface. There is no “sloshing”.

Motor runs, but the eccentric shaft is not rotating, no piston movement; spiral pin or motor shaft broken.

Contact Grundfos service.

Oil level is too low, see oil-level gauge. iI the suction line is closed, the pressure-relief valve is not activated.

Not enough oil in pump, air is penetrating the piston flange through the control holes. Fill in oil and vent the pump.

No dosing flow on the discharge side. Dosing head not filled, suction line and tank empty.

Vent the dosing head, fill/replace (tank) on suction side.

No dosing flow even at a low counter pressure.. Pump pro-duces high noise levels, although the pressure- relief valve is activated..

The pressure-relief valve is activated independently of the dosing flow setting (10%-100%).

Valve on discharge side closed. Open the valve.

Counter pressure is higher than the set pres-sure at the pressure-relief valve.

Set the pressure-relief valve to a higher value, but only if the pump is designed for this. Do not block the pressure-relief valve.

Discharge valve installed in the opposite direction of the flow. Check arrow at valve. Install the discharge valve correctly.

The AMS (diaphragm protection valve) responds and the pressure-relief valve is activated independently of the dosing flow setting (10%-100%).

Valve on suction side closed. Open the valve.

Suction filter obstructed. Clean the suction filter and replace it, if nec-essary.

Suction valve blocked (does not open). Dismantle and check the suction valve.

Suction valve spring too strong. Use the correct spring or double-ball valve for checking.

Suction valve installed in the opposite direc-tion of the flow; check arrow at valve. Install the suction valve correctly.

The AMS responds and the pressure-relief valve is activated at 100% dosing flow; When the flow is reduced by approx. 10%-20%, the pressure-relief valve is no longer activated.

Dosing head not completely vented. Fill the dosing head completely.Pump running in cavitation (dosing liquid with too high viscosity; dosing liquid with too low steam pressure at operating temperature = degassing of the liquid; suction lift too high; wrong design of system on suction side).

Contact Grundfos service.

Diaphragm broken (not enough oil in enclo-sure of pump; piston flange).

Clean and grease well all parts using oil according to regulations, then install a new diaphragm.

Pump does not deliver, or pressure relief valve opens.

Pump discharge valve clogged or ball guide in valve worn due to corrosive or abrasive dosing liquid.

Remove the discharge valve, dismantle and clean it. If the bars of the ball guide are worn, replace the valve.

Pump delivers insufficient flow.

Suction valve: During the pressure stroke, the dosing liquid flows back into the suction line.Discharge valve: During the suction stroke, the dosing liquid flows back into the dosing head. The pump takes in less liquid.

Suction/discharge valves dirty or leaky. Clean or replace the valves.

Dosing flow depends highly on the pres-sure; if the counter pressure is low, the dosing flow increases considerably. If the stroke frequency is increased, the dosing flow increases excessively.

Too much clearance between piston and slide valve, or stroke frequency of pump too low (too much slip).

Replace the piston and piston slide valves, use another hydraulic oil with a higher viscos-ity (mainly for frequency controller operation and higher counter pressure).

Manometer discharge line. Counter pressure has seriously increased; pressure-relief valve set too low.

Readjust the zero point. Correct the setting of the pressure-relief valve.

Especially with stroke frequencies below 15 strokes/min., for example with fre-quency converter operation.

Pressure-relief an degassing valve (pos. 7) not working properly.

Replace the valve or replace with ø8 ball, if necessary.

Pump doses too much.

Manometer dischargeline. Counter pressure has seriously dropped. Readjust the zero point.

Heavy overdose.

Pre-charge pressure of suction line higher than counter pressure of discharge line. A positive pressure difference of min. 2 bar is required between suction valve and dis-charge valve for the pump to operate cor-rectly.

Install a counter-pressure valve.

Overdosing at higher dosing flow adjust-ments and flows. Excessive dynamics in suction line. Mount a suction pulsation damper.

13 / 13

7. Drawings

7.1 DMX

7.2 DMH

TM03

186

9 38

05TM

03 2

164

3805

8

3947

5

6

2

1

7813

12 9 325611 10

1

15

14

14 / 13

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