Grundfos UPE Series 2000 Installation And Operating Instructions Manual

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Installation And Operating Instructions Manual
GRUNDFOS MAGNA
UPE Series 2000
Installation and operating instructions
Montage- und Betriebsanleitung
,QVWUXNFMDPRQWDXLHNVSORDWDFML
Notice d’installation et d’entretien
Istruzioni di installazione e funzionamento
Instrucciones de instalación y funcionamiento
£ÄÈǽÅ×ÅÇËÁÔÓÔÁÓÈ×ËÁÉÌÅÉÔÏÙÒǽÁ×
Installatie- en bedieningsinstructies
Monterings- och driftsinstruktion
Asennus- ja käyttöohjeet
Monterings- og driftsinstruktion
GRUNDFOS
INSTRUCTIONS
Declaration of Conformity
We
GRUNDFOS
declare under our sole responsibility that the prod-
ucts
MAGNA UPE Series 2000
, to which this declaration relates, are
in conformity with the Council Directives on the approximation of the
laws of the EC Member States relating to
Machinery (98/37/EC).
Standard used: EN 292.
Electromagnetic compatibility (89/336/EEC).
Standard used: EN 61 800-3.
Electrical equipment designed for use within certain voltage lim-
its (73/23/EEC) [95].
Standards used: EN 60 335-1 and EN 60 335-2-51.
Konformitätserklärung
Wir
GRUNDFOS
erklären in alleiniger Verantwortung, daß die Pro-
dukte
MAGNA UPE Serie 2000
, auf die sich diese Erklärung
bezieht, mit den folgenden Richtlinien des Rates zur Angleichung
der Rechtsvorschriften der EG-Mitgliedstaaten übereinstimmen:
Maschinen (98/37/EG).
Norm, die verwendet wurde: EN 292.
Elektromagnetische Verträglichkeit (89/336/EWG).
Norm, die verwendet wurde: EN 61 800-3.
Elektrische Betriebsmittel zur Verwendung innerhalb bestimmter
Spannungsgrenzen (73/23/EWG) [95].
Normen, die verwendet wurden: EN 60 335-1 und
EN 60 335-2-51.
'HNODUDFMD]JRGQR
FL
Déclaration de Conformité
Nous
GRUNDFOS
déclarons sous notre seule responsabilité que
les produits
MAGNA Série UPE 2000
auxquels se réfère cette
déclaration sont conformes aux Directives du Conseil concernant le
rapprochement des législations des Etats membres CE relatives à
Machines (98/37/CE).
Standard utilisé: EN 292.
Compatibilité électromagnétique (89/336/CEE).
Standard utilisé: EN 61 800-3.
Matériel électrique destiné à employer dans certaines limites de
tension (73/23/CEE) [95].
Standards utilisés: EN 60 335-1 et EN 60 335-2-51.
Dichiarazione di Conformità
Noi
GRUNDFOS
dichiariamo sotto la nostra esclusiva responsabilità
che i prodotti
MAGNA UPE Serie 2000
ai quali questa dichiarazione
se riferisce sono conformi alle Direttive del Consiglio concernente il
ravvicinamento delle legislazioni degli Stati membri CE relative a
Macchine (98/37/CE).
Standard usato: EN 292.
Compatibilità elettromagnetica (89/336/CEE).
Standard usato: EN 61 800-3.
Materiale elettrico destinato ad essere utilizzato entro certi limiti
di tensione (73/23/CEE) [95].
Standard usati: EN 60 335-1 e EN 60 335-2-51.
Declaración de Conformidad
Nosotros
GRUNDFOS
declaramos bajo nuestra única responsabili-
dad que los productos
MAGNA Serie UPE 2000
a los cuales se
refiere esta declaración son conformes con las Directivas del Con-
sejo relativas a la aproximación de las legislaciones de los Estados
Miembros de la CE sobre
Máquinas (98/37/CE).
Norma aplicada: EN 292.
Compatibilidad electromagnética (89/336/CEE).
Norma aplicada: EN 61 800-3.
Material eléctrico destinado a utilizarse con determinadas lími-
tes de tensión (73/23/CEE) [95].
Normas aplicadas: EN 60 335-1 y EN 60 335-2-51.
¼ÌÖÓÈÙÍ;ÒÆÖÓÈ×
Overeenkomstigheidsverklaring
Wij
GRUNDFOS
verklaren geheel onder eigen verantwoordelijkheid
dat de produkten
MAGNA UPE Serie 2000
waarop deze verklaring
betrekking heeft in overeenstemming zijn met de Richtlijnen van de
Raad inzake de onderlinge aanpassing van de wetgevingen van de
Lid-Staten betreffende
Machines (98/37/EG).
Norm: EN 292.
Elektromagnetische compatibiliteit (89/336/EEG).
Norm: EN 61 800-3.
Elektrisch materiaal bestemd voor gebruik binnen bepaalde
spanningsgrenzen (73/23/EEG) [95].
Normen: EN 60 335-1 en EN 60 335-2-51.
Försäkran om överensstämmelse
Vi
GRUNDFOS
försäkrar under ansvar, att produkterna
MAGNA
UPE Serie 2000
, som omfattas av denna försäkran, är i
överensstämmelse med Rådets Direktiv om inbördes närmande till
EU-medlemsstaternas lagstiftning, avseende
Maskinell utrustning (98/37/EC).
Använd standard: EN 292.
Elektromagnetisk kompatibilitet (89/336/EC).
Använd standard: EN 61 800-3.
Elektrisk material avsedd för användning inom vissa spännings-
gränser (73/23/EC) [95].
Använda standarder: EN 60 335-1 och EN 60 335-2-51.
Vastaavuusvakuutus
Me
GRUNDFOS
vakuutamme yksin vastuullisesti, että tuotteet
MAGNA UPE Sarja 2000
, jota tämä vakuutus koskee, noudattavat
direktiivejä jotka käsittelevät EY:n jäsenvaltioiden koneellisia laitteita
koskevien lakien yhdenmukaisuutta seur.:
Koneet (98/37/EY).
Käytetty standardi: EN 292.
Elektromagneettinen vastaavuus (89/336/EY).
Käytetty standardi: EN 61 800-3.
Määrättyjen jänniterajoitusten puitteissa käytettävät sähköiset
laitteet (73/23/EY) [95].
Käytetyt standardit: EN 60 335-1 ja EN 60 335-2-51.
Overensstemmelseserklæring
Vi
GRUNDFOS
erklærer under ansvar, at produkterne
MAGNA UPE
Serie 2000
, som denne erklæring omhandler, er i overensstem-
melse med Rådets direktiver om indbyrdes tilnærmelse til EF
medlemsstaternes lovgivning om
Maskiner (98/37/EF).
Anvendt standard: EN 292.
Elektromagnetisk kompatibilitet (89/336/EØF).
Anvendt standard: EN 61 800-3.
Elektrisk materiel bestemt til anvendelse inden for visse
spændingsgrænser (73/23/EØF) [95].
Anvendte standarder: EN 60 335-1 og EN 60 335-2-51.
Bjerringbro, 15th August 2003
Svend Aage Kaae
Technical Manager
3
GRUNDFOS MAGNA
UPE Series 2000
Installation and
operating instructions
Page 4
Montage- und
Betriebsanleitung
Seite 25
,QVWUXNFMDPRQWDX
LHNVSORDWDFML
6WURQD 
Notice d’installation
et d’entretien
Page 73
Istruzioni di installazione
e funzionamento
Pag. 97
Instrucciones de instalación
y funcionamiento
Pág. 120
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Å̽ÄÁ 
Installatie- en
bedieningsinstructies
Pag. 168
Monterings- och
driftsinstruktion
Sida 191
Asennus- ja
käyttöohjeet
Sivu 212
Monterings- og
driftsinstruktion
Side 233
4
CONTENTS
Page
1. General description 4
1.1 Twin-head pumps 5
2. Applications 5
2.1 Pumped liquids 5
3. Installation 5
3.1 Changing the terminal box position 5
3.2 Twin-head pumps 5
3.3 Non-return valve 6
3.4 Frost protection 6
4. Electrical connection 6
4.1 Supply voltage 6
4.2 Wiring diagram 7
5. Start-up 8
5.1 Condensed water in terminal box 8
6. Functions 8
6.1 Control modes 8
6.2 Selection of control mode 9
6.3 Automatic night-time duty 9
6.4 Constant-curve duty 10
6.5 Max. or min. curve duty 10
6.6 Temperature influence 10
6.7 External start/stop 11
6.8 External fault signal 11
6.9 Indicator lights 11
6.10 Expansion modules 11
6.11 GENI module 14
6.12 LON module 15
7. Setting the pump 15
7.1 Factory setting 15
7.2 Control panel 16
7.3 Remote control R100 17
7.4 R100 display overview 18
7.5 Menu OPERATION 19
7.6 Menu STATUS 19
7.7 Menu INSTALLATION 20
7.8 Priority of settings 21
8. Fault finding chart 22
9. Megging 23
10. Technical data 24
11. Disposal 24
Before beginning installation procedures,
these installation and operating instruc-
tions should be studied carefully. The in-
stallation and operation should also be in
accordance with local regulations and ac-
cepted codes of good practice.
1. General description
The GRUNDFOS MAGNA UPE Series 2000 is a
complete range of circulator pumps with integrated
differential pressure control enabling adjustment of
pump performance to the actual system require-
ments. In many systems, this will mean a considera-
ble reduction in power consumption, prevent noise
from thermostatic valves and similar fittings, and im-
prove the control of the system.
The desired head can be set on the pump control
panel.
The following functions can be set by means of the
pump control panel, see fig. 20, page 16:
AUTO (factory setting).
During operation, the pump can automatically re-
duce the factory-set setpoint and adjust it to the
actual system characteristic. This setting ensures
minimum energy consumption and will be the opti-
mum setting in most installations.
Proportional-pressure control.
The head is changed continuously in accordance
with the flow demand in the system. The desired
setpoint can be set on the pump control panel.
Constant-pressure control.
A constant head is maintained, irrespective of flow
demand. The desired setpoint can be set on the
pump control panel.
Automatic night-time duty.
The pump changes automatically between normal
duty and night-time duty on the basis of the flow-
pipe temperature. The control modes mentioned
above and constant-curve duty can be combined
with automatic night-time duty.
The R100 remote control, the connection to an exter-
nal fault signal transmitter or the application of the
digital input offer further functions:
Constant-curve duty.
The pump runs at a constant speed on or between
the max. and min. curves (to be selected with the
R100).
Temperature influence.
The head varies depending on the liquid tempera-
ture (to be selected with the R100).
External start/stop.
The pump can be started or stopped via the digital
input.
External fault signal.
The pump controls an external fault signal trans-
mitter via a potential-free output.
Additional functions can be obtained by fitting an
expansion module to the pump:
GENI module:
External analog control of head or speed from
an external 0-10 V signal transmitter.
External forced control via inputs for:
- Max. curve,
- Min. curve.
Bus communication via GENIbus.
The pump can be controlled and monitored by a
GRUNDFOS Pump Management System 2000, a
building management system or another type of
external control system.
Control of twin-head pumps.
The control of twin-head pumps is described in
sections 1.1 and 6.11.4.
LON module:
Bus communication via LON.
This module enables connection to a network
based on LonWorks
technology and to other
units which are based on this communication
standard.
5
1.1 Twin-head pumps
Twin-head pumps have a GENI module incorporated
in each terminal box. The modules are internally con-
nected with a wire. The modules determine the pump
operating mode, see section 6.11.4 Control of twin-
head pumps.
2. Applications
The GRUNDFOS MAGNA is designed for circulating
liquids in heating systems. The pump can also be
used in domestic hot-water systems.
The pump range is primarily used in
systems with a variable flow.
The pump range can also be used in
•systems with a constant flow where it is desirable
to optimize the setting of the pump duty point,
systems with variable flow-pipe temperatures.
2.1 Pumped liquids
Thin, clean, non-aggressive and non-explosive liq-
uids, not containing solid particles, fibres or mineral
oil.
In heating systems, the water should meet the re-
quirements of accepted standards on water quality in
heating systems, e.g. the German standard VDI
2035.
In domestic hot-water systems, it is advisable to
use GRUNDFOS MAGNA pumps only for water with
a degree of hardness lower than approx. 14°dH.
For water with a higher degree of hardness a direct-
coupled TPE pump is recommended.
3. Installation
Arrows on the pump housing indicate the liquid flow
direction through the pump.
3.1 Changing the terminal box position
Change the terminal box position as follows:
1. Remove the inspection screw (1) and the four
screws (2) in the stator housing, see fig. 1.
2. Lift off the stator housing (3). Keep the rotor (4)
in place using a suitable tool, e.g. a tee key (M8)
(5), see fig. 2.
3. Check that the O-ring (6) is intact. A defective
O-ring must be replaced.
4. Hold the stator housing/terminal box (3) in the
desired position.
5. Lower the stator housing over the rotor. Keep
the rotor in place as described in point 2.
6. Fit and tighten the four screws and the inspec-
tion screw.
Fig. 1
Fig. 2
3.2 Twin-head pumps
Note: Twin-head pumps mounted in horizontal pipes
must be fitted with an automatic air vent (Rp ¼) in
the upper part of the pump housing, see fig. 3.
The automatic air vent is not supplied with the pump.
Fig. 3
The pump must not be used for the trans-
fer of inflammable liquids such as diesel
oil, petrol or similar liquids.
Before any dismantling of the pump, the
system must be drained or the isolating
valves on either side of the pump must be
closed as the pumped liquid may be scald-
ing hot and under high pressure.
TM02 5506 3402 TM02 5507 3402
Pos. Description
1 Inspection screw
2Screw
3 Stator housing/terminal box
4 Rotor
5Tee key
6O-ring
TM02 6445 0603
2
3
1
5
4
6
6
3.3 Non-return valve
If a non-return valve is fitted in the pipe system, see
fig. 4, it must be ensured that the set minimum dis-
charge pressure of the pump is always higher than
the closing pressure of the valve. This is especially
important in proportional-pressure control mode
(reduced head at low flows).
Fig. 4
3.4 Frost protection
If the pump is not being used during periods of frost,
the necessary steps must be taken to prevent frost
bursts.
4. Electrical connection
The electrical connection and protection should be
carried out in accordance with local regulations.
The pump requires no external motor protection.
The operating voltage and frequency are marked
on the pump nameplate. Please make sure that
the motor is suitable for the electricity supply on
which it will be used.
Open the terminal box cover as shown in fig. 5.
Fig. 5
If the terminal box cover cannot be lifted sufficiently,
it can be removed as shown in fig. 6.
Fig. 6
4.1 Supply voltage
1 x 230-240 V –10%/+6%, 50/60 Hz.
TM02 0640 0301
Never make any connections in the pump
terminal box unless the electricity supply
has been switched off for at least 5 min-
utes.
The earth terminal of the pump must be
earthed.
The pump must be connected to an ex-
ternal mains switch with a contact sepa-
ration of at least 3 mm in each pole.
Earthing or neutralization can be used for
protection against indirect contact.
Megging must be carried out as de-
scribed in section 9. Megging.
If the pump is connected to an electric in-
stallation where an earth leakage circuit
breaker (ELCB) is used as additional pro-
tection, this circuit breaker must trip out
when earth fault currents with DC content
(pulsating DC) occur.
The earth leakage circuit breaker must
be marked with the symbol shown:
!
TM02 0456 3503
"
TM02 0457 3503
!
TM02 7441 3503
"
TM02 7442 3503
7
4.2 Wiring diagram
Fig. 7
Concerning demands on signal wires and signal
transmitters, see section 10. Technical data.
A connection example can be found on page 255.
Note:
If no external on/off switch is connected, the con-
nection across terminals STOP and should be
maintained.
All cables used must be heat-resistant up to
+85°C.
All cables used must be installed in accordance
with EN 60 204-1.
TM02 0235 4302
S
T
O
P
78
NC NOC
213
N
L
Mains connection
Signal output
Start/stop
NC NO C
Wires connected to
- outputs NC, NO, C,
- input Start/stop and
- supply terminals
must be separated from each other and
from the supply by reinforced insulation.
All wires connected to a terminal block
must be tied up at the terminals.
8
5. Start-up
Do not start the pump until the system has been
filled with liquid and vented. Furthermore, the re-
quired minimum inlet pressure must be available at
the pump inlet, see section 10. Technical data. The
system cannot be vented through the pump.
As the pump is self-venting, it need not be vented
before start-up.
Fig. 8
5.1 Condensed water in terminal box
To prevent problems with condensed water in the
terminal box, the pump temperature should be ap-
proximately the same as the ambient temperature
before start-up.
6. Functions
Most functions can be selected by means of the
pump control panel. However, some functions can
only be selected via the R100 or via bus.
6.1 Control modes
GRUNDFOS MAGNA pumps can be set to the con-
trol mode which is most suitable for the individual
system.
Three control modes are available:
AUTO (factory setting),
Proportional pressure,
Constant pressure.
Each of the above-mentioned control modes can be
combined with automatic night-time duty, see section
6.3 Automatic night-time duty.
AUTO:
Can be set by means of the control panel or via the
R100, see section 7. Setting the pump.
The control mode AUTO can reduce the pump per-
formance continuously.
The setpoint of the pump has been factory-set as fol-
lows and cannot be changed manually:
MAGNA UPE/UPED 32-120, 40-120 to 6 metres.
MAGNA UPE/UPED 50-60, 65-60 to 3 metres.
When the pump registers a lower pressure on the
max. curve, A
2
, the AUTO function automatically se-
lects a correspondingly lower control curve, H
set2
,
thus reducing the energy consumption.
Fig. 9
A
1
: Original duty point.
A
2
: Lower registered pressure on the max.
curve.
A
3
: New duty point after AUTO control.
H
set1
: Original setpoint setting.
H
set2
: New setpoint after AUTO control.
: Factory setting.
The AUTO function can be reset by pressing the but-
ton for approx. 10 seconds until the control mode
is back to the starting point (AUTO or AUTO with
automatic night-time duty).
Proportional-pressure control:
Can be set by means of the control panel or via the
R100, see section 7. Setting the pump.
The pump head is reduced at falling water demand
and increased at rising water demand, see fig. 10.
Constant-pressure control:
Can be set by means of the control panel or via the
R100, see section 7. Setting the pump.
The pump maintains a constant pressure, irrespec-
tive of water demand, see fig. 10.
Fig. 10
If the inspection screw is to be slackened,
see fig. 8, care should be taken to ensure
that the escaping, scalding hot liquid does
not cause personal injury or damage to
components.
TM02 5508 3402
Inspection screw
TM02 0251 4800
Q
H
set1
H
set2
H
max
2
A
1
A
2
A
3
H
max
Control
curves
H
max
2
2
H
Q
H
Q
Proportional
pressure
H
set
Hset
Hset
Constant
pressure
TM00 5546 4596
9
6.2 Selection of control mode
GRUNDFOS recommends to let the pump remain in
control mode AUTO as, in most cases, this will be
the best setting of the pump.
If another setting is required and the control mode
and head have not been specified for the system (for
instance, an uncontrolled standard pump is replaced
by a GRUNDFOS MAGNA pump), it is advisable to
use the settings in section 6.2.1.
6.2.1 Guide to the selection of control mode based on system type
6.2.2 Setpoint setting
The setpoint can be set by pressing or when
the pump is in control mode:
proportional pressure,
constant pressure or
constant-curve duty.
Set the setpoint so that it matches the system.
A too high setting may result in noise in the system
whereas a too low setting may result in insufficient
heat in some places of the heating system.
6.3 Automatic night-time duty
Can be set by means of the control panel or via the
R100, see section 7. Setting the pump.
Once automatic night-time duty has been activated,
the pump will change automatically between normal
duty and night-time duty (min. curve duty). Change-
over between normal duty and night-time duty takes
place as a result of the flow-pipe temperature meas-
ured by an integrated temperature sensor.
The pump automatically changes over to night-time
duty when the temperature sensor registers a flow-
pipe temperature drop of more than 10-15°C within
approx. 2 hours. The temperature drop must be at
least 0.1°C/min.
Changeover to normal duty takes place without a
time lag when the temperature has increased by ap-
prox. 10°C.
System type for instance ...
select this con-
trol mode ...
All types of system AUTO
Relatively great
head losses in
the boiler circuit
and the distribu-
tion pipes
1. Two-pipe
heating sys-
tems with
thermostatic
valves and:
with a dimensioned pump head higher than 4 me-
tres,
Proportional
pressure
very long distribution pipes,
strongly throttled pipe balancing valves,
differential pressure regulators,
great head losses in those parts of the system
through which the total quantity of water flows (e.g.
boiler, heat exchanger and distribution pipe up to
the first branching).
2. Primary circuit pumps in systems with great head losses in the primary
circuit.
Relatively small
head losses in
the boiler circuit
and the distribu-
tion pipe
1. Two-pipe
heating sys-
tems with
thermostatic
valves and:
with a dimensioned pump head lower than 2 me-
tres,
Constant
pressure
dimensioned for natural circulation,
with small head losses in those parts of the system
through which the total quantity of water flows (e.g.
boiler, heat exchanger and distribution pipe up to
the first branching) or
modified to a high differential temperature between
flow pipe and return pipe (e.g. district heating).
2. Underfloor heating systems with thermostatic valves.
3. One-pipe heating systems with thermostatic valves or pipe balancing
valves.
4. Primary circuit pumps in systems with small head losses in the pri-
mary circuit.
10
6.4 Constant-curve duty
Can be set via the R100, see section 7. Setting the
pump.
The pump can be set to operate according to a con-
stant curve, like an uncontrolled pump, see fig. 11.
MAGNA UPE/UPED 32-120 and 40-120:
Select one of 10 curves between the max. and min.
curves.
MAGNA UPE/UPED 50-60 and 65-60:
Select one of 5 curves between the max. and min.
curves.
Fig. 11
6.5 Max. or min. curve duty
Can be set by means of the control panel, via the
GENI module or via the R100, see section 7. Setting
the pump.
The pump can be set to operate according to the
max. or min. curve, like an uncontrolled pump, see
fig. 12.
This operating mode is available, irrespective of the
control mode.
Fig. 12
The max. curve mode can be selected if an uncon-
trolled pump is required.
The min. curve mode can be used in periods in
which a minimum flow is required. This operating
mode is for instance suitable for manual night-time
duty if automatic night-time duty is not desired.
6.6 Temperature influence
Can be set via the R100, see section 7. Setting the
pump.
When this function is activated in proportional or
constant control mode, the setpoint for head will be
reduced according to the liquid temperature. It is
possible to set temperature influence to function at
liquid temperatures below 80°C or below 50°C.
These temperature limits are called T
max.
. The set-
point is reduced in relation to the head set (= 100%)
according to the characteristics below.
Fig. 13
In the above example, T
max.
= 80°C has been se-
lected. The actual liquid temperature T
actual
causes
the setpoint for head to be reduced from 100% to
H
actual
.
The temperature influence function requires:
Proportional or constant-pressure control mode.
The pump must be installed in the flow pipe.
System with flow-pipe temperature control
(e.g. according to outdoor temperature).
Temperature influence is suitable in:
systems with variable flows (e.g. two-pipe heating
systems), in which the activation of the tempera-
ture influence function will ensure a further reduc-
tion of the pump performance in periods with small
heating demands and consequently a reduced
flow-pipe temperature, and
systems with almost constant flows (e.g. one-pipe
heating systems and underfloor heating systems),
in which variable heating demands cannot be reg-
istered as changes in the head (as is the case
with two-pipe heating systems). In such systems,
the pump performance can only be adjusted by
activating the temperature influence function.
Selection of T
max.
In systems with a dimensioned flow-pipe tempera-
ture of:
up to and including 55°C, select T
max.
= 50°C,
above 55°C, select T
max.
= 80°C.
TM02 0245 4300TM00 5547 4596
Q
H
Max.
Min.
Q
H
Q
H
Max.
Min.
TM01 0626 1797
30%
100%
°CT
805020
H
H
Q
T
actual
H
actual
11
6.7 External start/stop
The pump can be started or stopped via a digital in-
put.
Functional diagram: Start/stop input:
6.8 External fault signal
The pump incorporates a signal output for a poten-
tial-free fault signal.
The fault signal output is activated when the pump
registers a fault. The fault signal relay is activated to-
gether with the red indicator light, pos. 2, fig. 20, on
the pump.
Function of signal output:
Resetting of fault indications:
A fault indication can be reset in one of the following
ways:
Briefly press , or on the pump. This will
not influence the pump performance set.
Briefly switch off the electricity supply to the
pump.
By means of the R100, see section 7.4 R100 dis-
play overview.
Before the pump can revert to normal duty, the fault
cause must be eliminated.
If the fault disappears by itself, the fault indication
will automatically be reset.
The fault cause will be stored in the pump alarm log.
The latest five faults can be called up by means of
the R100.
6.9 Indicator lights
For position on pump, see fig. 20, section 7.2 Control
panel.
The indicator lights, pos. 2, are used for operating
and fault indication. Furthermore, they indicate
whether the pump is externally controlled.
Note: When the R100 remote control communicates
with the pump, the red indicator light will flash
rapidly.
The function of the operating and fault indicator
lights can be found in section 8. Fault finding chart.
The indicator light for external control is on
if
the pump control panel is inactive,
the pump is in constant-curve operating mode,
the temperature influence is active or
the pump is controlled by an external unit.
6.10 Expansion modules
The pump can be fitted with an expansion module
enabling communication with external signals (signal
transmitters).
Two types of expansion module are available:
GENI module.
LON module.
The fitting of a module is illustrated in fig. 14.
Open the terminal box cover and fit the module, see
!, " and #.
Start/stop input
Normal duty
Stop
Signal
output
Description
Not activated:
The electricity supply has been
switched off,
the pump is running or
the pump has been set to stop.
Activated:
The pump has registered a fault.
Q
H
Q
H
132
NC NO C
12 3
NC NO C
Before removing the terminal box cover,
make sure that the electricity supply has
been switched off for at least 5 minutes.
12
Fig. 14
!
TM02 0241 2101
"
TM02 0242 2101
#
TM02 0805 2101
13
Note:
If the 0-10 V input is used, there must be a con-
nection across terminals MIN and (input for
min. curve must be closed).
All cables used must be heat-resistant up to
+85°C.
All cables used must be installed in accordance
with EN 60 204-1.
Concerning demands on signal wires and signal
transmitters, see section 10. Technical data.
Connection examples (GENI module) can be found
on pages 256 to 259.
Fig. 15 Fig. 16
Wiring diagram for GENI module: Wiring diagram for LON module:
TM02 0236 2101
TM02 0237 2101
Wires connected to
- outputs NC, NO, C,
- inputs Start/stop, A, Y, B, MIN,
MAX, 10 V and
- supply terminals
must be separated from each other and
from the supply by reinforced insula-
tion.
All wires connected to a terminal block
must be tied up at the terminals.
Wires connected to
- outputs NC, NO, C,
- inputs Start/stop, A, B and
- supply terminals
must be separated from each other and
from the supply by reinforced insula-
tion.
All wires connected to a terminal block
must be tied up at the terminals.
4
XQZBYA
MIN
MAX
10 V
5 6 7 9 10 1112 2122 23
Max. curve
Analog 0-10 V
input
Screen
DC 0-10 V
Min. Max.
Bus signal
Twin-head
pump
Min. curve
BA
Bus signal
14
6.11 GENI module
The GENI module offers the following functions:
External analog 0-10 V control,
see section 6.11.1.
External forced control,
see section 6.11.2.
Bus communication via GENIbus,
see section 6.11.3.
Control of twin-head pumps,
see section 6.11.4.
6.11.1 External analog 0-10 V control
The GENI module has an input for an external
0-10 VDC analog signal transmitter. Via this input,
the pump can be controlled by an external controller
if the pump has been set to one of the following con-
trol modes:
Constant curve.
The external analog signal will control the pump
curve within the range from the min. curve to the
constant curve selected according to the charac-
teristic in fig. 17.
Pressure control.
The external analog signal will control the setpoint
for the pump head between the setpoint corre-
sponding to the min. curve and the setpoint se-
lected according to the characteristic in fig. 17.
At an input voltage lower than 0.5 V, the pump will
operate according to the min. curve. The setpoint
cannot be changed.
The setpoint can only be changed when the input
voltage is higher than 0.5 V.
Fig. 17
Note:
The max. curve input must be open.
The min. curve input must be closed.
6.11.2 External forced control
The GENI module incorporates inputs for external
signals for the forced-control functions:
Max. curve duty.
Min. curve duty.
Functional diagram: Max. curve input:
The max. curve input is only active if the terminals of
the start/stop input are connected.
Functional diagram: Min. curve input:
The min. curve input is only active if the terminals of
the start/stop input are connected and the input for
max. curve is open.
6.11.3 Bus communication via GENIbus
The GENI module enables serial communication via
an RS-485 input. The communication is carried out
according to the GRUNDFOS bus protocol, GENI-
bus, and enables connection to the GRUNDFOS
Pump Management System 2000, a building man-
agement system or another type of external control
system.
Via the bus signal, it is possible to set pump operat-
ing parameters, such as desired setpoint, tempera-
ture influence, operating mode, etc. At the same
time, the pump can provide status information about
important parameters, such as actual head, actual
flow, power input, fault indications, etc.
For further details, consult the operating instructions
for the GRUNDFOS Pump Management System
2000 or contact GRUNDFOS.
Note: When the pump is controlled via a bus signal,
the number of settings available on the pump control
panel or via the R100 will be reduced.
The setpoint and the control mode can only be set
via the bus signal. The pump control panel and the
R100 can only set the pump to max. curve and to
stop. However, an R100 is required if a number is to
be allocated to the pump. See also section 7.8 Prior-
ity of settings.
890107654321
m
V
H
U
Max. setpoint/constant curve
Setpoint set/constant curve
Min. curve
TM00 5550 4596
Max. curve
Normal duty
Max. curve
Min. curve
Normal duty
Min. curve
Q
H
Q
H
Q
H
Q
H
15
6.11.4 Control of twin-head pumps
Twin-head pumps have a GENI module incorporated
in each terminal box. The modules are internally con-
nected via a wire.
The twin-head pumps are factory-set to the control
mode AUTO and the operating mode “alternating op-
eration”, which is described below.
The pump has the following operating modes:
Alternating operation. Pump operation alter-
nates every 24 hours. If the duty pump stops due
to a fault, the other pump will start.
Standby operation. One pump is operating con-
tinuously. In order to prevent seizing-up, the other
pump will start at a fixed frequency. If the duty
pump stops due to a fault, the other pump will
start.
The operating mode is selected by means of a me-
chanical contact in each module. The contacts in the
two modules must be set to the same position. If the
contacts are positioned differently, “standby opera-
tion” is selected.
Fig. 18
Operating the pump:
Twin-head pumps can be set and operated in the
same way as single-head pumps. The duty pump
uses its setpoint setting, whether it is made by
means of the control panel, via the R100 or via bus.
Note: Both pumps should be set to the same set-
point and control mode. Different settings will result
in different operation when changing between the
two pumps.
6.12 LON module
The LON module offers the possibility of connecting
the pump to a LonWorks network. The module is
used for data transmission between a network and
pumps of the type MAGNA UPE 32-120, 40-120,
50-60 and 65-60.
For further information, see the documentation files
on the floppy disk supplied with the LON module.
6.12.1 Connection to network
Pumps fitted with a LON module are registered by
the LonWorks network in one of the following ways:
Activate the “Service PIN” button on the module.
Then the module transmits a unique 48 bit
ID-code (Neuron ID), which is registered by the
network.
The bar code on the module or the additional label
supplied is scanned and registered by the net-
work. The bar code is in Code 128 format. The ad-
ditional label can be attached to the building in-
stallation plan.
Fig. 19
7. Setting the pump
For the setting of the pump, use:
control panel.
R100 remote control.
bus communication (not described in detail in
these instructions. Contact GRUNDFOS).
The following table shows the application of the indi-
vidual operating units and in which section the func-
tion has been described.
“–” = not available with this operating unit.
7.1 Factory setting
The pump is factory-set to AUTO without automatic
night-time duty.
TM02 0243 2101
Standby operation
Alternating
operation
TM02 0244 2101
Possible settings
Control
panel
R100
AUTO 7.2.1 7.7.1
Automatic night-time duty 7.2.1 7.7.2
Proportional-pressure
control
7.2.1 7.7.1
Constant-pressure control 7.2.1 7.7.1
Setpoint setting 7.2.2 7.5.1
Max. curve duty 7.2.3 7.5.2
Min. curve duty 7.2.4 7.5.2
Constant-curve duty 7.5.2
Temperature influence 7.7.3
Activation/deactivation of
pump buttons
7.7.4
Allocation of pump number 7.7.5
Start/stop 7.2.5 7.5.2
Resetting of fault indica-
tions
7.2.6 7.5.3
Reading of various data
7.6.1 -
7.6.7
Service PIN
16
7.2 Control panel
The control panel, fig. 20, incorporates the following:
For further information, see section 8. Fault finding
chart.
Fig. 20
7.2.1 Control mode setting
Description of function, see section 6.1 Control
modes.
Change the control mode by pressing , pos. 3,
according to the following cycle:
•AUTO,
constant pressure, , and
proportional pressure, .
Automatic night-time duty can be activated together
with each of the control modes.
The light symbols in pos. 4, see fig. 20, indicate the
pump settings:
“–” = no light.
7.2.2 Setpoint setting
The setpoint of the pump is set by pressing or
when the pump has been set to proportional-pres-
sure control, constant-pressure control or constant-
curve duty.
The light fields, pos. 5, on the control panel will indi-
cate the setpoint set.
MAGNA UPE/UPED 32-120 and 40-120:
The light fields can indicate a maximum setpoint of
10 metres.
Fig. 21
MAGNA UPE/UPED 50-60 and 65-60:
The light fields can indicate a maximum setpoint of
5 metres.
Fig. 22
At high liquid temperatures, the pump may
be so hot that only the buttons should be
touched to avoid burns.
Buttons, pos. 1 and 3, for setting.
Light fields for indication of
control mode and night-time duty, pos. 4,
head, performance and operating mode, pos. 5.
Indicator lights, pos. 2,
for operating and fault indication and
symbol for indication of external control.
TM02 0250 4300
Light in Control mode
Automatic
night-time
duty
AUTO AUTO NO
Proportional
pressure
NO
Constant
pressure
NO
Constant curve NO
AUTO AUTO YES
Proportional
pressure
YES
Constant
pressure
YES
Constant curve YES
TM02 0482 4800TM02 0483 4800
17
7.2.3 Setting to max. curve duty
Description of function, see section 6.5 Max. or min.
curve duty.
To change over to the max. curve of the pump, press
continuously until MAX illuminates, see fig. 23. To
change back, press continuously until the desired
setpoint is indicated.
Fig. 23
7.2.4 Setting to min. curve duty
Description of function, see section 6.5 Max. or min.
curve duty.
To change over to the min. curve of the pump, press
continuously until MIN illuminates, see fig. 24. To
change back, press continuously until the desired
setpoint is indicated.
Fig. 24
7.2.5 Start/stop of pump
Stop the pump by continuously pressing until
STOP illuminates. When the pump is stopped, the
green indicator light will be flashing.
Start the pump by continuously pressing .
Note: If the pump is to be inoperative for a period, it
is recommended to use the start/stop input, the R100
or to switch off the electricity supply. In this way, the
setpoint setting will remain unchanged when the
pump is to be started again.
7.2.6 Resetting of fault indications
The fault indications are reset by briefly pressing any
button. The settings remain unchanged. If the fault
has not disappeared, the fault indication will reap-
pear. The time until the fault reappears may vary
from 0 to 255 seconds.
7.3 Remote control R100
The pump is designed for wireless communication
with the GRUNDFOS remote control R100. The
R100 communicates with the pump via infra-red
light.
During communication, the R100 must be pointed at
the pump control panel. When the R100 is communi-
cating with the pump, the red indicator light will flash
rapidly.
The R100 offers additional possibilities of setting and
status displays for the pump.
TM02 0246 4300 TM02 0247 4300
Max. curve
MAX
m MIN
Min. curve
18
7.4 R100 display overview
The R100 displays are divided into four parallel
menus, see fig. 25:
0. GENERAL, see operating instructions for R100
1. OPERATION
2. STATUS
3. INSTALLATION
The number stated at each individual display in
fig. 25 refers to the section in which the display is de-
scribed.
Fig. 25
3. INSTALLATION0. GENERAL 2. STATUS
7.5.3
7.6.2
7.6.3
7.6.4
7.6.5
7.7.5
7.7.4
7.7.3
7.6.6
7.6.7
7.5.2
7.7.1
7.6.1
7.5.1
7.5.4
7.7.2
1. OPERATION
19
7.5 Menu OPERATION
When the communication between the R100 and the
pump has been established, menu OPERATION ap-
pears in the display.
7.5.1 Setpoint
This display depends on the control mode selected
in the display “Control mode” in menu INSTALLA-
TION.
If the pump is forced-controlled via external signals,
the number of possible settings will be reduced, see
section 7.8 Priority of settings. Attempts to change
the settings will result in an indication in the display
saying that the pump is forced-controlled and
changes therefore cannot be made.
This display will appear when the pump is in AUTO
mode.
Set the desired setpoint by pressing the buttons “+”
and “–” on the R100 (not possible when the pump
has been set to AUTO).
Furthermore, it is possible to select one of the follow-
ing operating modes:
Stop,
Min. (min. curve),
Max. (max. curve).
The display is different if proportional pressure, con-
stant pressure or constant curve has been selected.
The actual duty point of the pump is indicated by a
square in the Q/H field. No indication at low flow.
7.5.2 Operating mode
Select one of the following operating modes:
Stop,
Min. (min. curve),
Normal (AUTO, proportional pressure, constant
pressure or constant curve),
Max. (max. curve).
7.5.3 Fault Indications
If the pump is faulty, the cause will appear in this dis-
play.
Possible causes:
Pump blocked,
Internal fault,
Undervoltage,
Module fault,
Fault in module communication.
The fault indication can be reset in this display. If the
fault has not disappeared when resetting is at-
tempted, the fault indication will reappear in the dis-
play when communicating with the pump.
7.5.4 Alarm log
The alarm code with text appears in this display. The
display will also show the number of minutes the
pump has been connected to the electricity supply
after the fault occurred.
The last five fault indications will appear in the alarm
log.
7.6 Menu STATUS
The displays appearing in this menu are status dis-
plays only. It is not possible to change or set values.
The actual values in the display are stated as a
guide.
7.6.1 Actual setpoint
Field “Actual setpoint”:
Actual setpoint of pump.
Field “corresponding to”:
Actual setpoint in % of the setpoint set if the pump is
connected to an external analog 0-10 V signal trans-
mitter or if temperature influence or proportional-
pressure control is activated.
20
7.6.2 Operating mode
This display shows the actual operating mode (Stop,
Min., Normal or Max.) and where is was selected
(Pump, R100, BUS or External).
7.6.3 Head and flow
The actual head and flow of the pump.
In the case of small flow values, “<” will be indicated
in front of the lowest possible value for the pump in
question.
Tolerance:
±10% of maximum head/flow.
7.6.4 Speed
The actual pump speed.
Tolerance:
±50 min
-1
.
7.6.5 Liquid temperature
The actual temperature of the pumped liquid.
Tolerance:
±10°C.
7.6.6 Power input and power consumption
Actual power input and power consumption of the
pump.
The value of power consumption is an accumulated
value and cannot be set to zero.
Tolerance:
Power input:
±5% of maximum power input.
Power consumption:
±5%.
7.6.7 Operating hours
Operating hours of the pump.
The value of operating hours is an accumulated
value and cannot be set to zero.
Tolerance:
±0.1%.
7.7 Menu INSTALLATION
In this menu, the settings are chosen that should be
considered when installing the pump.
7.7.1 Control mode
Description of function, see section 6.1 Control
modes or section 6.4 Constant-curve duty.
One of the following control modes can be selected:
AUTO,
Prop. pressure (proportional pressure),
Const. pressure (constant pressure),
Const. curve (constant curve).
Setting of setpoint and curve is carried out in display
7.5.1 Setpoint in menu OPERATION (not possible
when the pump has been set to AUTO).
7.7.2 Automatic night-time duty
In this display, automatic night-time duty can be acti-
vated or deactivated.
Automatic night-time duty can be set to:
Active,
Not active,
irrespective of the control mode selected.
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Grundfos UPE Series 2000 Installation And Operating Instructions Manual

Tyyppi
Installation And Operating Instructions Manual