Grundfos UPE Series 2000 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

£ÄÈÇ½Å×ÅÇËÁÔÓÔÁÓÈ×ËÁÉÌÅÉÔÏÙÒÇ½Á×

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ÙÍÍ¾ÒÆÖÓÈ×

–

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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ËÁÉÌÅÉÔÏÙÒÇ½Á×

ÅÌ½ÄÁ 

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

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

H

Q

H

Q

Proportional

pressure

H

set

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

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

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