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GRUNDFOS INSTRUCTIONS

CRE, CRIE, CRNE,


CRKE, SPKE, MTRE, CHIE
1 & 3 phase
Installation and operating instructions

Please leave these instructions with the pump


for future reference.
CONTENTS Before beginning installation procedures, these in-
stallation and operating instructions should be stud-
Page
ied carefully. Furthermore, the enclosed installa-
1. General 2 tion and operating instructions for the standard
2. Installation 2 pump should be studied carefully. The installation
2.1 Electrical connection single-phase pumps 3 and operation should also be in accordance with lo-
2.1.1 Mains switch 3 cal regulations and accepted codes of good practice.
2.1.2 Protection against electric shock indirect contact 3
2.1.3 Additional protection 3 1. General
2.1.4 Motor protection 3
GRUNDFOS E-pumps are pumps fitted with frequency-controlled
2.1.5 Overvoltage protection 3
standard motors for single-phase or three-phase mains connec-
2.1.6 Supply voltage 3
tion.
2.1.7 Start/stop of pump 3
The pumps have a built-in PI controller and can be connected to
2.2 Electrical connection three-phase pumps 4
an external sensor enabling control of for instance pressure, dif-
2.2.1 Mains switch 4 ferential pressure, temperature, differential temperature or flow in
2.2.2 Protection against electric shock indirect contact 4 the system in which the pumps are installed. The pumps can be
2.2.3 Additional protection 4
set to uncontrolled operation, i.e. the pump performance can be
2.2.4 Motor protection 4 set according to the demand.
2.2.5 Overvoltage protection 4
The pumps are typically used as pressure booster pumps in sys-
2.2.6 Supply voltage 4
tems with variable demands.
2.2.7 Start/stop of pump 4
The desired setpoint can be set directly on the pump control
2.3 Other connections 5
panel, via an input for external setpoint signal or by means of the
2.4 Signal cables 6
GRUNDFOS wireless remote control R100.
3. Setting the pump 6
All other settings are made by means of the R100.
3.1 Factory setting 6 Important parameters such as actual value of control parameter,
4. Setting by means of control panel 6 power consumption, etc. can be read via the R100.
4.1 Setpoint setting 6 The pump incorporates inputs for external potential-free contacts
4.2 Setting to max. curve duty 7 for start/stop and digital function. The digital function enables ex-
4.3 Setting to min. curve duty 7 ternal setting of max. curve, min. curve, external fault function or
4.4 Start/stop of pump 7 flow switch.
5. Setting by means of R100 7 The pump incorporates an output for a potential-free fault, operat-
ing or ready signal.
5.1 Menu OPERATION 9
5.1.1 Setpoint setting 9 Furthermore, the pump has an input for bus communication. Via
5.1.2 Setting of operating mode 9 the bus communication input, the pump can be controlled and
5.1.3 Fault indications 9 monitored by a building management system or another external
5.1.4 Alarm log 9 control system.
5.2 Menu STATUS 9
5.2.1 Display of actual setpoint 9 2. Installation
5.2.2 Display of operating mode 9 To ensure cooling of motor and electronics, the following must be
5.2.3 Display of actual value 9 observed:
5.2.4 Display of actual speed 10
Place the pump in such a way that sufficient cooling is en-
5.2.5 Display of input power and power consumption 10
sured.
5.2.6 Display of operating hours 10
5.3 Menu INSTALLATION 10 The temperature of the cooling air must not exceed 40C.
5.3.1 Selection of control mode 10 Motor cooling fins and fan blades must be kept clean.
5.3.2 Setting of controller 10 When installed outdoors, the motor must be provided with a suit-
5.3.3 Selection of external setpoint signal 11 able cover to avoid condensation on the electronic components,
5.3.4 Selection of fault, operating or ready signal relay 11 fig. 1.
5.3.5 Blocking of the buttons on the pump 11
5.3.6 Allocation of pump number 11 Fig. 1
5.3.7 Selection of function for digital input 11
5.3.8 Setting of stop function 11
5.3.9 Setting of sensor 12
5.3.10 Setting of min. and max. curves 12
6. External forced-control signals 12
6.1 Start/stop input 12
TM02 0789 0101

6.2 Digital input 12


7. External setpoint signal 13
8. Bus signal 13
9. Priority of settings 13
For further installation, see installation and operating instructions
10. Indicator lights and signal relay 14
for the standard pump.
11. Megging 14
12. Technical data single-phase pumps 15
12.1 Supply voltage 15
12.2 Leakage current 15
12.3 Inputs/output 15
13. Technical data three-phase pumps 15
13.1 Supply voltage 15
13.2 Leakage current 15
13.3 Inputs/output 15
13.4 Other technical data 16
14. Disposal 16

2
2.1 Electrical connection single-phase pumps Actual mains connection is shown in fig. 3.
Note: The user or the installer is responsible for the installation of Fig. 3
the correct earthing and protection according to valid national and MGE 71 and MGE 80
local standards. All operations must be carried out by a qualified
electrician.
Never make any connections in the pump terminal
box unless the electricity supply has been switched I
off for at least 5 minutes.

2.1.1 Mains switch


The pump must be connected to an external all-pole mains switch
with a contact separation of at least 3 mm in each pole according
to IEC 364. L
PE
2.1.2 Protection against electric shock indirect contact
N
The pump must be earthed and protected against

TM02 0827 4702


indirect contact in accordance with national regula-
tions.

Protective earth conductors must always have a yellow/green


(PE) or yellow/green/blue (PEN) colour marking.
2.1.3 Additional protection 2.1.7 Start/stop of pump
If the pump is connected to an electric installation where an earth The number of starts and stops via the mains voltage must not
leakage circuit breaker is used as additional protection, this cir- exceed 4 times per hour.
cuit breaker must be marked with the following symbol: When the pump is switched on via the mains, it will start after ap-
prox. 5 seconds.
ELCB
If a higher number of starts and stops is desired, the input for ex-
ternal start/stop must be used when starting/stopping the pump.
Note: When an earth leakage circuit breaker is selected, the total
When the pump is started/stopped via an external on/off switch, it
leakage current of all the electrical equipment in the installation
will start immediately.
must be taken into account.
The leakage current of the pump can be found in section
12.2 Leakage current.
2.1.4 Motor protection
The pump requires no external motor protection. The motor incor-
porates thermal protection against slow overloading and blocking
(IEC 34-11: TP 211).
2.1.5 Overvoltage protection
The pump is overvoltage-protected through built-in varistors be-
tween phase-neutral and phase-earth.
2.1.6 Supply voltage
1 x 200-240 V 10%, 50/60 Hz, PE.
The supply 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.
The wires in the pump terminal box must be as short as possible.
Excepted from this is the protective earth conductor which must
be so long that it is the last one to be disconnected in case the
cable is inadvertently pulled out of the cable entry.
Figure 2 shows an example of a mains-connected pump with
mains switch, back-up fuses and additional protection.
Fig. 2
MGE 71 and MGE 80
TM02 0792 0101

N N
ELCB Max. 10 A PE
L L
PE

3
2.2 Electrical connection three-phase pumps 2.2.6 Supply voltage
Note: The user or the installer is responsible for the installation of 3 x 460-480 V 10%, 60 Hz, PE.
the correct earthing and protection according to valid national and The supply voltage and frequency are marked on the pump
local standards. All operations must be carried out by a qualified nameplate. Please make sure that the motor is suitable for the
electrician. electricity supply on which it will be used.
Never make any connections in the pump terminal The wires in the pump terminal box must be as short as possible.
box unless the electricity supply has been switched Excepted from this is the protective earth conductor which must
off for at least 5 minutes. be so long that it is the last one to be disconnected in case the
cable is inadvertently pulled out of the cable entry.
2.2.1 Mains switch
Figure 4 shows an example of a mains-connected pump with
The pump must be connected to an external all-pole mains switch mains switch, back-up fuses and additional protection.
with a contact separation of at least 3 mm in each pole according Fig. 4
to IEC 364.
MGE 90 to MGE 132
2.2.2 Protection against electric shock indirect contact
Max. 16/32 A
The pump must be earthed and protected against L1 L1
indirect contact in accordance with national regula-

TM00 9270 4696


L2 ELCB L2
tions.
L3 L3
Protective earth conductors must always have a yellow/green PE
(PE) or yellow/green/blue (PEN) colour marking.
Note: As the leakage current of 5 hp to 10 hp motors is
> 3.5 mA, these motors must be connected to especially Actual mains connection is shown in figs. 5 and 6.
reliable/sturdy earth connections. Fig. 5
MGE 90 and MGE 100
The leakage current of the individual motor size can be found in
section 13.2 Leakage current.
L1
EN 50 178 and BS 7671 specify the following: L2 L1
Leakage current > 3.5 mA: L3
L2
The pump must be stationary and installed permanently. Further- L3
more, the pump must be connected permanently to the electricity

TM00 7631 1596


supply or may be connected via an industrial type of plug (CEE).
The plug must comply with EN 60 309 or IEC 309.
The earth connection must be carried out as duplicate conduc-
tors.
2.2.3 Additional protection Fig. 6
If the pump is connected to an electric installation where an earth MGE 112 and MGE 132
leakage circuit breaker is used as additional protection, this cir-
cuit breaker must be of the type:
Which is suitable for handling leakage currents and cutting-in L1 L1
with short pulse-shaped leakage. L2 L2
Which trips out when alternating fault currents and fault cur- L3 L3
rents with DC content, i.e. pulsating DC and smooth DC fault
currents, occur.

TM00 7665 1696


For these pumps an earth leakage circuit breaker type B must be
used.
This circuit breaker must be marked with the following symbols:

ELCB

Note: When an earth leakage circuit breaker is selected, the total 2.2.7 Start/stop of pump
leakage current of all the electrical equipment in the installation The number of starts and stops via the mains voltage must not
must be taken into account. exceed 4 times per hour.
The leakage current of the pump can be found in section When the pump is switched on via the mains, it will start after ap-
13.2 Leakage current. prox. 5 seconds.
2.2.4 Motor protection If a higher number of starts and stops is desired, the input for ex-
ternal start/stop must be used when starting/stopping the pump.
The pump requires no external motor protection. The motor incor-
When the pump is started/stopped via an external on/off switch, it
porates thermal protection against slow overloading and blocking
will start immediately.
(IEC 34-11: TP 211).
2.2.5 Overvoltage protection
The pump is overvoltage-protected through built-in varistors be-
tween the phases and between phases and earth.

4
2.3 Other connections Fig. 8
The connection terminals of external potential-free contacts for MGE 90 and MGE 100
start/stop and digital function, external setpoint signal, sensor sig-
nal, GENIbus and relay signal are shown in figs. 7, 8 and 9.
Note: If no external on/off switch is connected, short-circuit termi- 8: +24 V
0/4-20 mA
nals 2 and 3 using a short wire. 0-5/10 V 4-20 mA 7: Sensor input
Note: As a precaution, the wires to be connected to the following 6: GND (frame)
connection groups must be separated from each other by rein- 10 k 5: +5 V

Group 1
0/4-20 mA 0-5/10 V
forced insulation in their entire lengths: 4: Setpoint input
3: GND (frame)
1. Inputs (external start/stop, digital function, setpoint and sen- 2: Start/stop
sor signals, terminals 1-9, and bus connection, A, Y, B). 1: Digital input
All inputs (group 1) are internally separated from the mains- A: RS-485A
conducting parts by reinforced insulation and galvanically Y: Screen
B: RS-485B
separated from other circuits.
All control terminals are supplied by protective extra-low volt-
age (PELV), thus ensuring protection against electric shock.
2. Output (relay signal, terminals NC, NO, C). C NO NC

Group 2 Group 3
The output (group 2) is galvanically separated from other cir- Signal relay
cuits. Therefore, the supply voltage or protective extra-low
voltage can be connected to the output as desired. L1
3. Supply voltage (terminals L and N or L1, L2, L3). L2 Mains
connection

TM00 6788 0101


A galvanically safe separation must fulfil the requirements for re- L3
inforced insulation including creepage distances and clearances
specified in EN 50 178.
Fig. 7
MGE 71 and MGE 80
Fig. 9
MGE 112 and MGE 132
Group 2

Group 3

NC C NO N PE L

0/4-20 mA 8: +24 V
0-5/10 V 4-20 mA 7: Sensor input
6: GND (frame)
10 k 5: +5 V

Group 1
0/4-20 mA 0-5/10 V 4: Setpoint input
3: GND (frame)
2: Start/stop
1: Digital input
A: RS-485A
Y: Screen
0-10 V 1: Digital input
0/4-20 mA 4-20 mA 9: GND (frame) B: RS-485B
8: +24 V
Group 1

0/1
7: Sensor input
B: RS-485B
1 9 8 7 B Y A Y: Screen
Group 2

A: RS-485A NC
NO Signal relay
STOP C
RUN
6: GND (frame)
0/4-20 mA 0-10 V 5: +10 V L1
TM02 0795 4702

10K 4: Setpoint input


Group 3

3: GND (frame) L2
Mains
2: Start/stop connection
6 5 4 3 2
L3
TM00 7666 1002

5
2.4 Signal cables Fig. 13
Use screened cables having a cross-sectional area of min. H
0.5 mm and max. 1.5 mm for external on/off switch, digital in-
put, setpoint and sensor signals.
Max.
The screens of the cables must be connected to frame at both
ends with good frame connection. They must be as close as

TM00 5547 0995


possible to the terminals, fig. 10.
Min.
Fig. 10

The max. curve can for instance be used in connection with the
venting procedure during installation.
The min. curve can be used in periods in which a minimum flow is
required.

TM00 7667 1696


The operating modes (Stop, Normal, Min., Max.) can all be set on
the pump control panel.
If the electricity supply to the pump is disconnected, the pump
setting will be stored.
Screws for frame connections must always be tightened The remote control R100 offers additional possibilities of setting
whether a cable is fitted or not. and status displays, see section 5. Setting by means of R100.
The wires in the pump terminal box must be as short as possi-
ble.
3.1 Factory setting
For the bus connection a screened 2-core cable must be used. The pumps have been factory-set to uncontrolled operation. The
Connect the screen to terminal Y at both ends, fig. 11. setpoint value corresponds to 100% of the maximum pump per-
formance (see data sheet for the pump).
Fig. 11
Other pump settings are marked with bold-faced type under each
individual display in sections 5.1 Menu OPERATION and
5.3 Menu INSTALLATION.

4. Setting by means of control panel


TM00 7601 0101

Y At high system temperatures, the pump may be so


hot that only the buttons should be touched to avoid
burns.

The pump control panel, fig. 14, incorporates the following:


3. Setting the pump
Buttons, + and , for setpoint setting.
E-pumps can be set to two control modes, i.e. controlled and un-
Light fields, yellow, for indication of setpoint.
controlled operation, fig. 12.
Indicator lights, green (operation) and red (fault).
In controlled-operation mode, the pump will adjust its perform-
ance to the desired setpoint for the control parameter (pressure, Fig. 14
differential pressure, temperature, differential temperature or Light fields Buttons
flow). Figure 12 shows a pressure-controlled pump as an exam-
ple of controlled operation.
In uncontrolled-operation mode, the pump will operate accord-
ing to the constant curve set.

TM00 7600 1196


Fig. 12
Controlled operation Uncontrolled operation
H H Indicator lights

4.1 Setpoint setting


H set
The desired setpoint is set by pressing the button + or .
TM00 7668 1696

The light fields on the control panel will indicate the setpoint set.
See the following examples, figs. 15 and 16.
Example: Pump in controlled-operation mode (pressure control):
Q Q
Figure 15 shows that the light fields 5 and 6 are activated, indicat-
ing a desired setpoint of 3 bar with a sensor measuring range
The pumps have been factory-set to uncontrolled operation, see from 0 to 6 bar. The setting range is equal to the sensor measur-
section 3.1 Factory setting. ing range (see sensor nameplate).
In addition to normal operation (controlled or uncontrolled opera- Fig. 15
tion), the following operating modes can be selected, Stop, Min.
[bar]
or Max., fig. 13. 6
TM00 7743 1896

6
Example: Pump in uncontrolled-operation mode: 5. Setting by means of R100
In uncontrolled-operation mode, the pump performance is set The pump is designed for wireless communication with the
within the range from min. to max. curve, fig. 16. GRUNDFOS remote control R100.
Fig. 16 The R100 communicates with the pump via infra-red light. The
transmitter and the receiver are incorporated in the pump control
H
panel, fig. 19.
Fig. 19

TM00 7746 1896


Q

TM02 0791 0101


4.2 Setting to max. curve duty
During communication, the R100 must be pointed at the control
Press + continuously to change over to the max. curve of the panel.
pump (top light field flashes). When the top light field is on, + When the R100 communicates with the pump, the red indicator
must be pressed for 3 seconds before the light field starts flash- light will flash rapidly.
ing.
The R100 offers additional possibilities of setting and status dis-
To change back, press continuously until the desired setpoint plays for the pump.
is indicated.
Fig. 17

H
TM00 7345 1196

Q
Max. curve

4.3 Setting to min. curve duty


Press continuously to change over to the min. curve of the
pump (bottom light field flashes). When the bottom light field is
on, must be pressed for 3 seconds before the light field starts
flashing.
To change back, press + continuously until the desired setpoint
is indicated.
Fig. 18

H
TM00 7346 1196

Q
Min. curve

4.4 Start/stop of pump


Stop the pump by continuously pressing until none of the light
fields are activated and the green indicator light flashes.
Start the pump by continuously pressing + until the desired set-
point is indicated.

7
The displays are divided into four parallel menus, fig. 20:
0. GENERAL (see operating instructions for the R100)
1. OPERATION
2. STATUS
3. INSTALLATION
The number stated at each individual display in fig. 20 refers to
the section in which the display is described.
Fig. 20

0. GENERAL 1. OPERATION 2. STATUS 3. INSTALLATION

5.1.1 5.2.1 5.3.1

5.1.2 5.2.2 5.3.2

5.1.3 5.2.3 5.3.3

5.2.4 5.3.4

5.1.4

5.2.5 5.3.5

5.2.6 5.3.6

5.3.7

5.3.8

5.3.9

5.3.10

8
5.1 Menu OPERATION Setpoint signal outside signal range (only 4-20 mA)
When communication between the R100 and the pump has been External fault
established, the first display in this menu will appear. Dry running
5.1.1 Setpoint setting Other fault
A fault indication can be reset in this display if the cause of the
fault has disappeared.
5.1.4 Alarm log

Setpoint set
Actual setpoint
Actual value
In this display, the setpoint is set. If faults have been indicated, the last five fault indications will ap-
pear in the alarm log. Alarm log 1 shows the newest/latest fault.
In controlled-operation mode, the setting range is equal to the
sensor measuring range. The example shows the fault indication Undervoltage, the fault
code and the number of minutes the pump has been connected to
In uncontrolled-operation mode, the setpoint is set in % of the
the electricity supply after the fault occurred.
maximum performance. The setting range will lie between the
min. and max. curves. The time cannot be displayed for three-phase pumps as the soft-
ware does not support this function.
Select one of the following operating modes:
Stop, 5.2 Menu STATUS
Min. (min. curve), The displays appearing in this menu are status displays only. It is
Max. (max. curve). not possible to change or set values.
If the pump is connected to an external setpoint signal, the set- The displayed values are the values that applied when the last
point in this display will be the maximum value of the external set- communication between the pump and the R100 took place. If a
point signal, see section 7. External setpoint signal. status value is to be updated, point the R100 at the control panel
If the pump is controlled via external signals (Stop, Min. curve or and press OK.
Max. curve) or a bus, this will be indicated in the display if set- If a parameter, e.g. speed, should be called up continuously,
point setting is attempted. press OK constantly during the period in which the parameter in
question should be monitored.
In this case, the number of possible settings will be reduced, see
section 9. Priority of settings. The tolerance of the displayed value is stated under each display.
The tolerances are stated as a guide in % of the maximum values
5.1.2 Setting of operating mode of the parameters.
5.2.1 Display of actual setpoint

Select one of the following operating modes:


Stop,
Tolerance: 2%
Min.,
This display shows the actual setpoint and the external setpoint in
Normal (duty), % of the range from minimum value to the setpoint set, see sec-
Max. tion 7. External setpoint signal.
The operating modes can be selected without changing the set- 5.2.2 Display of operating mode
point setting.
5.1.3 Fault indications

This display shows the actual operating mode (Stop, Min., Normal
(duty) or Max.). Furthermore, it shows where this operating mode
If the pump is faulty, the cause will appear in this display. was selected (R100, Pump, BUS, External or Stop func.). For fur-
ther details about the stop function (Stop func.), see section
Possible causes:
5.3.8 Setting of stop function.
Too high motor temperature
5.2.3 Display of actual value
Undervoltage
Overvoltage
Phase failure (three-phase pumps only)
Mains supply failure (three-phase pumps only)
Too many restarts (after faults)
Overload
Sensor signal outside signal range (only 4-20 mA)

9
The actually measured value of a connected sensor will appear in In this display, the gain (Kp) and the integral-action time (Ti) of the
this display. built-in PI controller can be set if the factory setting is not the op-
If no sensor is connected to the pump, will appear in the dis- timum setting:
play. The gain (Kp) is set within the range from 0.1 to 20.
5.2.4 Display of actual speed The integral-action time (T i) is set within the range from 0.1 to
3600 s. If 3600 s is selected, the controller will function as a
P controller.
Furthermore, it is possible to set the controller to inverse control
(if the setpoint is increased, the speed will be reduced). In the
case of inverse control, the gain (Kp) must be set within the range
from 0.1 to 20.
Setting the PI controller:
For most applications, the factory setting of the controller con-
Tolerance: 5%
stants Kp and Ti will ensure optimum pump operation. In the fol-
The actual pump speed will appear in this display. lowing cases, a change of the setting can be useful or necessary.
5.2.5 Display of input power and power consumption A change of the Ti setting can be useful:
In a differential-pressure control system if the sensor is placed
far away from the pump.
A change of the Ti setting, and in some cases the Kp setting, may
be necessary:
If the pump is controlled on the basis of temperature or differ-
ential temperature.
The table below shows the recommended controller settings:
Tolerance: 10%
This display shows the actual pump input power from the mains Kp
supply. The power is displayed in W or kW. System/
Heating Cooling Ti
application
The pump power consumption can also be read from this display. 1) 2)
The value of power consumption is an accumulated value calcu- system system
lated from the pumps birth and it cannot be reset.
5.2.6 Display of operating hours
0.5 0.5

Dp

L [m]
L < 5 m: 0.5
0.5 L > 5 m: 3
Dp L > 10 m: 5
Tolerance: 2%
The value of operating hours is an accumulated value and cannot
be reset.
0.5 0.5
5.3 Menu INSTALLATION
5.3.1 Selection of control mode p

Q 0.5 0.5

0.5 0.5 10 + 5L
t
Select one of the following control modes (see fig. 12): L [m]
Controlled,
Uncontrolled.
The desired performance is set in section 5.1.1 Setpoint setting.
Dt 0.5 10 + 5L
Note: If the pump is connected to a bus (see section 8. Bus sig-
nal), it is not possible to select the control mode via the R100.
L [m]
5.3.2 Setting of controller
L [m]

t 0.5 0.5 30 + 5L

1. Heating systems are systems in which an increase in pump


performance will result in a rise in temperature at the sensor.
2. Cooling systems are systems in which an increase in pump
performance will result in a drop in temperature at the sensor.

10
5.3.3 Selection of external setpoint signal The digital input of the pump (terminal 1, fig. 7, 8 or 9) can be set
to different functions.
Select one of the following functions:
Min. (min. curve),
Max. (max. curve),
Ext. fault (external fault),
Flow switch.
The selected function is activated by closing the contact between
The input for external setpoint signal can be set to different signal
the following terminals:
types.
1 and 9 of single-phase pumps (fig. 7) and
Select one of the following types:
1 and 3 of three-phase pumps (fig. 8 or 9).
0-5 V (potentiometer) (three-phase pumps only),
See also section 6.2 Digital input.
0-10 V,
Min.:
0-20 mA,
When the input is activated, the pump is operating according to
4-20 mA, the min. curve.
Not active. Max.:
If Not active is selected, the setpoint set by means of the R100 or When the input is activated, the pump is operating according to
on the control panel will apply. the max. curve.
The setpoint set is the maximum value of the external setpoint Ext. fault:
signal, section 7. External setpoint signal. The actual value of the When the input is activated, a timer is started. If the input is acti-
external setpoint can be read from section 5.2.1 Display of actual vated for more than 5 seconds, the pump is stopped and a fault is
setpoint. indicated. If the connection is disconnected for more than 5 sec-
onds, the fault condition will cease and the pump can be restarted
5.3.4 Selection of fault, operating or ready signal relay
manually by resetting the fault indication.
The typical application will be detection of missing inlet pressure
or water shortage by means of a pressure switch installed on the
suction side of a pump.
Flow switch:
When this function is active, the pump will be stopped when a
connected flow switch detects a low flow.
It is only possible to use this function if the pump is connected to
It can be selected in which situation the relay should be activated: a pressure sensor.
Fault (fault indication), When the input is activated for more than 5 seconds, the stop
function incorporated in the pump will take over, see section
Operation (operating indication),
5.3.8 Setting of stop function.
Ready (ready indication).
5.3.8 Setting of stop function
See section 10. Indicator lights and signal relay.
5.3.5 Blocking of the buttons on the pump

When the stop function is active, the pump will be stopped at very
low flows to avoid unnecessary power consumption.
The buttons + and on the pump can be set to: It is only possible to use this function if the pump is connected to
Active, a pressure sensor.
Not active. The stop function can be set to:
Active,
5.3.6 Allocation of pump number
Not active.
There are two possibilities of low-flow detection:
1. By means of the built-in low-flow detector which automati-
cally starts functioning if no flow switch is chosen/connected to
the digital input. The pump will check the flow regularly by re-
ducing the speed for a short time, thus checking the change in
pressure. If there is no or a small change in pressure, the
pump will detect a low flow.
A number between 1 and 64 can be allocated to the pump. In the
case of bus communication, a number must be allocated to each 2. By means of a flow switch connected to the digital input. When
pump. the input is activated for more than 5 seconds, the stop func-
tion of the pump takes over. Unlike the built-in low-flow detec-
5.3.7 Selection of function for digital input
tor, the flow switch measures the minimum flow at which the
pump must stop. The pump will not check the flow regularly by
reducing the speed.
When the pump detects a low flow, the speed will be increased
until the stop pressure (actual setpoint + 0.5 x H) is reached and
the pump stops. When the pressure has fallen to the start pres-
sure (actual setpoint 0.5 x H), the pump will restart.

11
H indicates the difference between start and stop pressures, fig. 5.3.10 Setting of min. and max. curves
21.
Fig. 21
H

Set the min. and max. curves in % of maximum performance if


Stop pressure the operating range must be reduced, fig. 23.
H Fig. 23
Start pressure
H

TM00 7744 1896


100%
Max. curve
Q
H is factory-set to 10% of actual setpoint.
H can be set within the range from 5% to 30% of actual setpoint.

O
pe
Note: The non-return valve must be fitted immediately before the

ra
pump, fig. 22. If the non-return valve is fitted between pump and

TM00 7747 1896


ti n
Min. curve

g
diaphragm tank, the pressure sensor must be fitted after the non-

ra
12%

ng
return valve.

e
Fig. 22
Q
Diaphragm tank
The max. curve can be adjusted within the range from maxi-
mum performance (100%) to min. curve.
Correctly installed The min. curve can be adjusted within the range from max.
TM00 7745 1896

non-return valve curve to 12% of maximum performance. The pump has been
factory-set to 24% of maximum performance.
The operating range lies between the min. and max. curves.
Pump
The stop function requires a diaphragm tank of a certain minimum 6. External forced-control signals
size. The tank must be installed immediately after the pump and The pump has inputs for external signals for the forced-control
the precharge pressure must be 0.7 x actual setpoint. functions:
Recommended diaphragm tank size when no flow switch is con- Start/stop of pump.
nected. Digital function.
Nominal flow of pump Diaphragm tank size 6.1 Start/stop input
[gpm] [gallons]
Functional diagram: Start/stop input:
0-30 4.4
31-95 8.0 Start/stop (terminals 2 and 3)
96-140 34.0 H
141-340 86.0 Normal duty
If a diaphragm tank of the above size is installed in the system, Q
the factory setting of H is the correct setting.
If the tank installed is too small, the pump will start and stop too H
often. This can be remedied by increasing H. Stop
5.3.9 Setting of sensor Q

6.2 Digital input


psi By means of the R100, one of the following functions can be se-
200 lected for the digital input:
Min. curve.
Max. curve.
The setting of the sensor is only carried out in the case of control- External fault.
led operation. Flow switch.
Select the following:
Sensor output signal (0-5 V (three-phase pumps only), 0-10 V,
0-20 mA or 4-20 mA),
Sensor measuring unit (bar, mbar, m, kPa, psi, ft, m/h, m/s,
l/s, gpm, C, F or %) and
Sensor measuring range.

12
Functional diagram: Input for digital function: In uncontrolled-operation mode, the setpoint can be set exter-
nally within the range from the min. curve to the setpoint set on
Digital function the pump or by means of the R100, fig. 25.
(terminals 1 and 9 single-phase pumps) Fig. 25
(terminals 1 and 3 three-phase pumps)
%
H
Normal duty
Max. curve
Q
Setpoint set on pump or with the R100
H
Min. curve
Q

H Min. curve

TM00 7669 1696


Max. curve
0 5 V (three-phase pumps only)
Q 0 10 V
H 0 20 mA
4 20 mA
5s External fault
Q 8. Bus signal
H The pump enables serial communication via an RS-485 input.
The communication is carried out according to the GRUNDFOS
5s Flow switch
bus protocol, GENIbus protocol, and enables connection to a
Q building management system or another external control system.
Via the bus signal, it is possible to remote-set pump operating pa-
7. External setpoint signal rameters, like setpoint, operating mode, etc. At the same time,
the pump can provide status information about important parame-
By connecting an analog signal transmitter to the input for the
ters, like actual value of control parameter, input power, fault indi-
setpoint signal (terminal 4), it is possible to remote-set the set-
cations, etc.
point.
Contact GRUNDFOS for further details.
The actual external signal (0-5 V (three-phase pumps only),
0-10 V, 0-20 mA, 4-20 mA) must be selected via the R100, see Note: If a bus signal is used, the number of settings available via
section 5.3.3 Selection of external setpoint signal. the R100 will be reduced.
If uncontrolled operation is selected by means of the R100, the
pump can be controlled by any controller. 9. Priority of settings
In controlled-operation mode, the setpoint can be set externally The start/stop and digital inputs will influence the number of pos-
within the range from the lower value of the sensor measuring sible settings.
range to the setpoint set on the pump or by means of the R100, By means of the R100, the pump can always be set to max. curve
fig. 24. duty or to stop.
Fig. 24 If two or more functions are activated at the same time, the pump
Control will operate according to the function with the highest priority.
parameter The priority of the settings is as shown in the following tables:

Without bus signal


Upper value of sensor measuring range
Possible settings
Setpoint set on pump or with the R100
Priority Control panel on External
pump or R100 signals

1 Stop

Lower value of sensor measuring range 2 Max. curve


TM00 7669 1696

3 Stop
0 5 V (three-phase pumps only)
0 10 V 4 Max. curve
0 20 mA
4 20 mA 5 Min. curve Min. curve

Example: At a lower pressure-sensor value of 0 bar, a setpoint 6 Setpoint setting Setpoint setting
set of 5 bar and an external setpoint of 80%, the actual setpoint
will be as follows: Example: If, via the digital input, the pump has been forced to op-
Hactual = (Hset - Hlower) x %external setpoint + Hlower erate according to the max. curve, the pump control panel and
the R100 can only set the pump to stop.
= (5 - 0) x 80% + 0
= 4 bar

13
With bus signal
10. Indicator lights and signal relay
The operating condition of the pump is indicated by the green and
Possible settings red indicator lights on the pump control panel, fig. 26.
Control Fig. 26
Priority panel on External
Bus signal
pump or signals
R100

TM00 7600 1196


1 Stop

2 Max. curve

3 Stop Stop
Green Red
4 Max. curve The pump incorporates an output for a potential-free signal via an
internal relay.
5 Min. curve
The signal output can be set to fault, operating or ready indication
Setpoint by means of the R100, see section 5.3.4 Selection of fault, oper-
6
setting ating or ready signal relay.
Example: If, via the digital input, the pump has been forced to op- The functions of the two indicator lights and the signal relay are
erate according to the max. curve, the pump control panel, the as shown in the following table:
R100 and the bus signal can only set the pump to stop.

Indicator lights Signal relay activated during:

Fault Opera- Description


tion Fault Operation Ready
(red) (green)
The electricity supply has been switched off.
Off Off
C NO NC C NO NC C NO NC

The pump is operating.


Perman-
Off
ently on
C NO NC C NO NC C NO NC

The pump has been set to stop.


Off Flashing
C NO NC C NO NC C NO NC

The pump has stopped because of a fault. Restarting will


be attempted (it may be necessary to restart the pump by
Perman-
Off resetting the fault indication). In case of the fault causes
ently on
C NO NC C NO NC C NO NC dry running and external fault, the pump must be re-
started manually by resetting the fault indication.
The pump is operating, but it has been stopped because
of a fault.
If the cause is sensor signal outside signal range, the
pump will continue operating according to the max. curve
Perman- Perman- and the fault indication cannot be reset until the signal is
ently on ently on inside the signal range.
C NO NC C NO NC C NO NC If the cause is setpoint signal outside signal range, the
pump will continue operating according to the min. curve
and the fault indication cannot be reset until the signal is
inside the signal range.
The pump has been set to stop, but it has been stopped
Perman- because of a fault.
Flashing
ently on
C NO NC C NO NC C NO NC

A fault indication can be reset in one of the following ways: 11. Megging
By briefly pressing the button + or on the pump. This will Note: Megging of an installation incorporating E-pumps is not al-
not change the setting of the pump. lowed, as the built-in electronics may be damaged.
A fault indication cannot be reset by means of + or if the
buttons have been locked.
By switching off the electricity supply until the indicator lights
are off.
By means of the R100, see section 5.1.3 Fault indications.
When the R100 communicates with the pump, the red indicator
light will flash rapidly.

14
12. Technical data single-phase pumps 13. Technical data three-phase pumps
12.1 Supply voltage 13.1 Supply voltage
1 x 200-240 V 10%, 50/60 Hz, PE. 3 x 460 - 480V 10%, 60 Hz, PE.
See nameplate. See nameplate.
Back-up fuse Back-up fuse
Motor sizes from 0.5 hp to 1.5 hp: Max. 10 A. Motor sizes from 1.0 to 7.5 hp: Max. 16 A.
Standard as well as quick-blow or slow-blow fuses may be used. Motor size 10 hp : Max. 32 A.
Standard as well as quick-blow or slow-blow fuses may be used.
12.2 Leakage current
Earth leakage current < 3.5 mA. 13.2 Leakage current
The leakage currents are measured in accordance with Motor size Leakage current
EN 60 355-1. [hp] [mA]
1.0 to 4.0 < 3.5
12.3 Inputs/output
5.0 to 7.5 hp <5
Start/stop
7.5 hp, 1400-1800 min-1 < 10
External potential-free switch.
Voltage: 5 VDC. 10 < 10
Current: < 5 mA.
Screened cable.* The leakage currents are measured in accordance with
EN 60 355-1.
Digital
External potential-free switch. 13.3 Inputs/output
Voltage: 5 VDC.
Start/stop
Current: < 5 mA.
External potential-free switch.
Screened cable.*
Voltage: 5 VDC.
Setpoint signals Current: < 5 mA.
Potentiometer Screened cable.*
0-10 VDC, 50 k (via internal voltage supply). Digital
Screened cable. * External potential-free switch.
Maximum cable length: 100 m. Voltage: 5 VDC.
Voltage signal Current: < 5 mA.
0-10 VDC, R i >50 k Screened cable.*
Tolerance: +0%/3% at maximum voltage signal. Setpoint signals
Screened cable. *
Potentiometer
Maximum cable length: 500 m.
0-5 VDC, 10 k (via internal voltage supply).
Current signal Screened cable.*
DC 0-20 mA/4-20 mA, Ri = 175 Maximum cable length: 100 m.
Tolerance: +0%/3% at maximum current signal.
Voltage signal
Screened cable. *
0-5 VDC/0-10 VDC, R i >50 k
Maximum cable length: 500 m.
Tolerance: +0%/3% at maximum voltage signal.
Sensor signals Screened cable.*
Voltage signal Maximum cable length: 500 m.
0-10 VDC, R i >50 k (via internal voltage supply). Current signal
Tolerance: +0%/3% at maximum voltage signal. DC 0-20 mA/4-20 mA, Ri = 250
Screened cable. * Tolerance: +0%/3% at maximum current signal.
Maximum cable length: 500 m. Screened cable.*
Current signal Maximum cable length: 500 m.
DC 0-20 mA/4-20 mA, Ri = 175 . Sensor signals
Tolerance: +0%/3% at maximum current signal.
Voltage signal
Screened cable. *
Maximum cable length: 500 m. 0-5 VDC/0-10 VDC, R i >50 k (via internal voltage supply).
Tolerance: +0%/3% at maximum voltage signal.
Electricity supply to sensor: Screened cable.*
+24 VDC, max. 40 mA. Maximum cable length: 500 m.
Signal output Current signal
Potential-free changeover contact. DC 0-20 mA/4-20 mA, Ri = 250.
Maximum contact load: 250 VAC, 2 A. Tolerance: +0%/3% at maximum current signal.
Minimum contact load: 5 VDC, 1 mA. Screened cable.*
Screened cable: 0.5 - 2.5 mm. Maximum cable length: 500 m.
Maximum cable length: 500 m.
Electricity supply to sensor:
Bus input +24 VDC, max. 40 mA.
GRUNDFOS bus protocol, GENIbus protocol, RS-485.
Signal output
0.5 - 1.5 mm screened 2-core cable.
Potential-free changeover contact.
Maximum cable length: 500 m.
Maximum contact load: 250 VAC, 2 A.
* Cross section min. 0.5 mm and max. 1.5 mm. Minimum contact load: 5 VDC, 1 mA.
Screened cable: 0.5 - 2.5 mm.
Maximum cable length: 500 m.
Bus input
GRUNDFOS bus protocol, GENIbus protocol, RS-485.
0.5 - 1.5 mm screened 2-core cable.
Maximum cable length: 500 m.
* Cross section min. 0.5 mm and max. 1.5 mm.

15
13.4 Other technical data Sound pressure level
EMC (electromagnetic compatibility) Single-phase pumps:
EN 61 800-3. <70 dB(A).
Motors of 0.5 to 7.5 hp, except for 7.5 hp, 1400-1800 min-1: Three-phase pumps:
Residential areas - unlimited distribution,
corresponding to CISPR 11, class B, group 1. Motor Speed stated Sound pressure
Motors of 10 hp and 7.5 hp, 1400-1800 min-1: on nameplate level
Residential areas - limited distribution. [hp] [min-1] [dB(A)]
Industrial areas - unlimited distribution,
2800-3000 63
corresponding to CISPR 11, class A, group 1. 1.0
When pumps fitted with motors of 10 hp and 7.5 hp, 3400-3600 68
1400-1800 min-1, are installed in residential areas, an additional 2800-3000 63
EMC filter is required to obtain class B, group 1 status. 1.5
3400-3600 68
The motor fulfils EN 50 178.
2800-3000 63
Contact GRUNDFOS for further information. 2
3400-3600 68
Enclosure class
2800-3000 64
Standard: IP 55 (IEC 34-5). 3
Insulation class 3400-3600 68
F (IEC 85). 2800-3000 64
4
Ambient temperature 3400-3600 68
During operation: 4F to +104F (20C to +40C) 2800-3000 68
During storage/transport: 40F to +140F (40C to +60C)
5 3400-3600 73
Relative air humidity
Maximum 95%. 4200-4500 75
2800-3000 68
7.5 3400-3600 73
4200-4500 75
2800-3000 74
10 3400-3600 79
4200-4500 80

14. Disposal
Disposal of this product or parts of it must be carried out accord-
ing to the following guidelines:
1. Use the local public or private waste collection service.
2. In case such waste collection service does not exist or cannot
handle the materials used in the product, please deliver the
product or any hazardous materials from it to your nearest
GRUNDFOS company or service workshop.

Subject to alterations.

16
LIMITED WARRANTY
Products manufactured by GRUNDFOS PUMPS CORPORATION (GRUNDFOS) are warranted to
the original user only to be free of defects in material and workmanship for a period of 24
months from date of installation, but not more than 30 months from date of manufacture.
GRUNDFOS' liability under this warranty shall be limited to repairing or replacing at
GRUNDFOS' option, without charge, F.O.B. GRUNDFOS' factory or authorized service station,
any product of GRUNDFOS' manufacture. GRUNDFOS will not be liable for any costs of
removal, installation, transportation, or any other charges which may arise in connection with
a warranty claim. Products which are sold but not manufactured by GRUNDFOS are subject to
the warranty provided by the manufacturer of said products and not by GRUNDFOS' warranty.
GRUNDFOS will not be liable for damage or wear to products caused by abnormal operating
conditions, accident, abuse, misuse, unauthorized alteration or repair, or if the product was not
installed in accordance with GRUNDFOS' printed installation and operating instructions.

To obtain service under this warranty, the defective product must be returned to the
distributor or dealer of GRUNDFOS' products from which it was purchased together with proof
of purchase and installation date, failure date, and supporting installation data. Unless
otherwise provided, the distributor or dealer will contact GRUNDFOS or an authorized service
station for instructions. Any defective product to be returned to GRUNDFOS or a service station
must be sent freight prepaid; documentation supporting the warranty claim and/or a Return
Material Authorization must be included if so instructed.

GRUNDFOS WILL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, LOSSES,
OR EXPENSES ARISING FROM INSTALLATION, USE, OR ANY OTHER CAUSES. THERE ARE NO
EXPRESS OR IMPLIED WARRANTIES, INCLUDING MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE, WHICH EXTEND BEYOND THOSE WARRANTIES DESCRIBED OR REFERRED
TO ABOVE.

Some jurisdictions do not allow the exclusion or limitation of incidental or consequential


damages and some jurisdictions do not allow limitations on how long implied warranties may
last. Therefore, the above limitations or exclusions may not apply to you. This warranty gives
you specific legal rights and you may also have other rights which vary from jurisdiction
to jurisdiction.
Being responsible is our foundation
Thinking ahead makes it possible
Innovation is the essence

L-MLE-TL-02 8/04
PRINTED IN USA

Subject to alterations

North American
GrundfosRegional
Pumps Corporation
Headquarters Grundfos
Grundfos Canada,
Canada,
Inc.
Inc. Bombas Grundfos de Mexico, S.A. de C.V.
Grundfos17100
Pumps
W. 118th
Corporation
Terrace 2941
2941
Brighton
Brighton
Road
Road Boulevard TLC #15
17100 W.Olathe,
118th KS
Terrace
66061 Oakville,
Oakville,
Ontario
Ontario
L6H
L6H
6C9
6C9,Canada
Canada Parque Stiva Aeropuerto
Olathe, Telephone
KS 66061 913 227 3400 Telephone:
Telephone:905
(905)
829829-9533
9533 Apodaca, N.L. 66600
Mexico Mexico
Telephone
Fax:(913)
913 227
227-3400
3500 Fax:
Fax:
905
(905)
829829-9512
9512 C.P. 66600 52 81 8144 4000
Telephone:
Fax: (913) 227-3500 Telephone:
Fax: 52 81 8144
52-81-8144-4000
4010
www.grundfos.com Fax: 52-81-8144-4010
www.grundfos.com