Grundfosliterature 6375

Service instructions
E-pumps
50/60 Hz
1/3~
Contents
1. Fault correction................................................................................................................................ 2
1.1 General description.............................................................................................................................................. 2
1.1.1 Fault finding ......................................................................................................................................................... 2
1.1.2 Fault log ............................................................................................................................................................... 2
1.1.3 Fault reading via R100......................................................................................................................................... 2
1.1.4 Overview of R100 menus .................................................................................................................................... 4
1.1.5 Stop function........................................................................................................................................................ 7
1.2 Fault correction, single-phase E-pumps .............................................................................................................. 9
1.2.1 Fault correction procedure................................................................................................................................... 9
1.2.2 Fault readings via R100 fault log or PC Tool E-products................................................................................... 15
1.3 Fault correction, three-phase E-pumps, 0.75 - 7.5 kW model B and C ............................................................. 17
1.3.1 Fault correction procedure................................................................................................................................. 17
1.4 Fault correction, three-phase E-pumps, 0.55 - 7.5 kW model D........................................................................ 24
1.4.3 How to use PC Tool E-products on two pumps running duty/standby............................................................... 33
1.5 Fault correction, three-phase E-pumps, 11 - 22 kW model MMGE ................................................................... 34
1.5.2 Indicator lights on the terminal box .................................................................................................................... 34
1.5.4 Checking the terminal box main components.................................................................................................... 41
1.5.5 Dismantling and assembly of terminal box components.................................................................................... 58
1.5.6 Diagrams ........................................................................................................................................................... 72
1.6 Fault correction, three phase E-pumps, 11-22 kWmodel F ............................................................................... 76
1.6.1 Fault finding using alarm and warning codes .................................................................................................... 81
1.6.2 Alarm and warning list ....................................................................................................................................... 81
1.7 Fault correction, three-phase E-pumps, 0.55 - 7.5 kW model G ....................................................................... 85
1.7.3 How to use PC Tool E-products on two pumps running duty/standby............................................................... 94
1.8 Fault correction, Hydro Multi-E .......................................................................................................................... 95
1.8.2 Configuration of Hydro Multi-E......................................................................................................................... 102
1.8.3 Multi-E pumps GSC-file numbers .................................................................................................................... 105
1.8.4 Multi-E system GSC-file numbers.................................................................................................................... 105
1.8.5 PC 410 GSC-file numbers ............................................................................................................................... 105
1.8.6 Emergency operation (optional)....................................................................................................................... 106
90 1 / 109
96576487 0311 GB
1. Fault correction
1.1 General description
Note: General description applies to both single- and three-phase E-pumps.
In case the E-pump does not function as expected, the fault may be found in
the pump
the mains connection
external signals to the MGE motor
the settings made by means of R100 or the factory settings which do not correspond to the desired function
the motor windings
the terminal box.
The actual operational state of the motor can often be ascertained by means of two indicator lights (light emitting diodes) fitted
either on the control panel or inside the MGE motor terminal box. However, combinations of faults and passing states may arise
which cause the indicator light indications not to be a true representation of the actual state of the motor.
Reset or update the fault indication to the actual state
by switching the external on/off switch to OFF and then ON again (or by turning external potentiometer to OFF and ON
again), or
by switching the mains supply switch to OFF and then to ON again.
If automatic restarting was chosen and the cause of the fault has disappeared after the restarting attempt, the fault indication
will be reset automatically.
1.1.1 Fault finding
Fault finding should always start with a check that the external conditions for correct function are OK. Do this by checking:
that the mains supply is in accordance with the data on the nameplate,
that the installation was carried out according to the Installation and operating instructions,
that the external on/off switch has been connected correctly,
that the desired setpoint signal is available,
that the direction of rotation of the motor is correct,
that the required sensor signal is available.
1.1.2 Fault log
E-pumps feature a fault log function:
The fault log function memory can recall the five latest faults.
The fault log can be read out via R100 or PC Tool E-products.
The possible faults are shown in the tables in 1.2.2 Fault readings via R100 fault log or PC Tool E-products and 1.4.2 Fault
readings via R100 fault log or PC Tool E-products.
Note: The same fault can have different texts/designations in R100 and PC Tool E-products.
The fault log can only be reset via PC Tool E-products.
1.1.3 Fault reading via R100

Possible fault and log can be read via R100 in the GENI menu and/or in the OPERATION menu.
2 / 109
GENI menu
Reading out of faults in the GENI menu requires R100 to be set to service mode:
1. go to the menu SETTINGS
2. go to display Name and address
3. enter the service code 681400.
Now you can read out the fault log in the following display:
Class 2
ID:
Pos. A: Possible fault or 0 158
Pos. B: Fault log 1 159
Pos. C: Fault log 2 160
A B C
Pos. D: Fault log 3 161
Pos. E: Fault log 4 162
D E F Pos. F: Fault log 5 163
Fig. 1 R100 display showing the fault log
New E-pumps with MGE 71/80 model C and MMGE model A:

Pos. B will indicate fault code '40' (undervoltage) which is logged when the mains voltage is switched off after the final
production test.
MGE 90 - 132 model D:
Pos. B will not indicate undervoltage when the mains voltage is switched off.
A possible fault is indicated in pos. A and logged in pos. B.
When the fault disappears, pos. A is reset to '0', and the fault is kept logged in pos. B.
MGE 71/80 model C and MGE 90 - 132 model D:
The next fault occurring will be indicated in pos. A and logged in pos. B, and the fault log in pos. B will move to pos. C.
This will happen whether the next fault is a new type of fault or the same fault occurring again. (However, it is a precondition
that the motor has had no faults since the latest fault, meaning that the fault log will not be filled up during possible futile
restart attempts.)
MMGE:
Any new fault occurring, which differs from the fault logged in pos. B, will be indicated in pos. A and logged in pos. B, and the
fault log in pos. B will move to pos. C.
Note: This will only happen if the new fault is different from the fault logged in pos. B.
This process will be repeated for every new fault occurring.
If the number of faults exceeds five, the logs for the "oldest" faults will disappear.
3 / 109
1.1.4 Overview of R100 menus
CRE, CRIE, CRNE, CRKE, SPKE, MTRE, CHIE with and without sensor
The following is a complete overview of the R100 menu and displays applying to CRE, CRIE, CRNE, CRKE, SPKE, MTRE,
CHIE with and without sensor.
SETTINGS GENERAL OPERATION STATUS INSTALLATION GENI
4 / 109
TPE, TPED, NBE, NKE without sensor
The following is a complete overview of the R100 menu and displays applying to TPE and TPED Series 1000, NBE, NKE with-
out sensor.
5 / 109
TPE and TPED Series 2000
The following is a complete overview of the R100 menu and displays applying to TPE and TPED Series 2000.
6 / 109
1.1.5 Stop function
TM02 1608 1601
TM03 0200 4504
TM02 4495 1102

What is stop function?
One of the advantages of pump systems with speed controllable pumps is the possibility of maintaining a constant discharge
pressure independent of the flow and the inlet pressure. In order to avoid unnecessary energy consumption at low flow, the sys-
tem can be operated by means of an adjustable pressure hysteresis, H, which is a percentage of the setpoint. This facility is
called stop function.
How to activate the stop function
A built-in "low-flow detector" requires the following conditions to be fulfilled before the stop function will step into action:
The stop function must be set to Active. Do this by means of R100 or PC Tool E-products.
The pump must be equipped with a pressure sensor.
The pump must be equipped with a pressure tank.
Operation is based on constant-pressure control.
The use of the stop function in combination with a flow switch requires the following further condition to be fulfilled:
The flow switch must be connected to digital input 2(digital input).
How the stop function works
The complete stop function can be divided into two separate functions, A and B, which are to be seen as two consecutive steps
in a process:
B. Brief increase of pressure (boost) prior to

A. Detection of low flow
stop
Low flow can be detected in two ways:
1. Low-flow detector in the form of an electronic calculation. When the pump detects low flow, the speed will
2. Flow switch connected to the digital input. be increased briefly until the stop pressure
(actual setpoint + 0.5 x H) is reached and the
Ad 1: Low-flow detector
pump stops. When the pressure has fallen to the
At two-minute intervals (factory-setting which can be changed by start pressure (actual setpoint 0.5 x H), the
means of PC Tool E-products in "Max. Time Between Flow pump will restart.
Estimation") the pump will test the flow by reducing the speed by A start pressure and a stop pressure are defined
approx. 5%. on the basis of H. This value can be set as a
At the same time the two parameters described in 1a and 1b are percentage [%] of the actual setpoint, the
monitored. The one of the two which is detected first will be advantage of this being that pressure changes
followed. caused by an absolute change of pump speed are
1a: Low flow leading to a brief 1b: If the system pressure larger at a high setpoint than at a low setpoint. The
increase of pressure (boost) measured drops by 2% pressure is increased briefly by increasing the
is defined as the situation (cannot be changed!) of the setpoint so that it corresponds to the stop
where a "Flow Estimate"- setpoint, or if the counter pressure. The control loop, which was open during
counter exceeds a "Flow does not exceed the limit detection of low flow, is now closed. The pump will
Estimation Limit". The within 25 seconds, the pump remain stopped until the pressure reaches a value
counter and the limit are will "consider" this a flow and which is lower than the start pressure.
factory-set but can be re-establish constant If the stop pressure cannot be reached, a max.
adapted to specific pressure - i.e. normal period of time is defined stating how long time the
applications via PC Tool E- operation. controller may try to reach the stop pressure.
products. When this time has expired, the pump is stopped.
The process now continues in In a correctly adjusted system this situation will
step B. only arise in two situations, either because the flow
through the pump has risen since the detection of
Ad 2: Flow switch
low flow, or because the actual setpoint is too
The flow switch must be connected to the digital input. When the close to the upper limit for the pump performance.
input is activated for more than 5 secs., the stop function of the If the pump is stopped in a situation where the flow
pump will take over. Unlike the built-in low-flow detector, the flow has risen since the detection of low flow, the start
switch measures the minimum flow at which the pump must stop. pressure will be reached quickly and the pump will
The pump will not check the flow regularly by reducing the speed. restart.
The process now continues in step B.
See diagram on the next page.
7 / 109
The following figure is a diagrammatic representation of how the stop function works.
A B
Cut-out
pressure
Cut-in
pressure
High flow is Pump switches to

detected stop function
Pump switches back to
Low flow is
TM01 9092 1100

normal operation
detected
Time
Fig. 2 Operating principle of the stop function
A: Detection of flow.
B: After detection of low flow, pressure is increased briefly and pump switches to stop function.
How to adapt the built-in low-flow detector to a specific application
At regular intervals the pump will check the flow by reducing the speed for a short time and thus checking the pressure change.
The development of the pressure change is converted to the value "Flow integral" which can be read in the PC Tool E-prod-
ucts menu window "monitor". In case this value exceeds the flow integral value set in "5. Pump" in either the Stop function or
in Custom configuration, the stop function is activated. If the value is not exceeded, the pump remains in normal operation.
The "Flow integral" value is factory-set, and if the pump is connected to a diaphragm tank of the correct size, the stop function
will work correctly in most cases.
In case a special setting of the stop function is required, this must be done by means of PC Tool E-products using the function
Stop function or Custom configuration according to the following procedure:
Set the setpoint.
Set "Flow estimation limit" to 254.
Set pump flow to the value at which the pump is required to switch to stop function.
Wait till the pump has detected low flow.
Read the value for "Flow integral" in "monitor".
Set "Flow estimation limit" to the value stated.
Signals in the control panel
When the stop function has been activated, the green indicator light will be permanently on. If the operator stops the controller
in a normal way (for instance via R100), the green indicator light will start flashing.
8 / 109
1.2 Fault correction, single-phase E-pumps
1.2.1 Fault correction procedure
TM02 1608 1601

The fault correction procedure is based on indications from the two indicator lights in the MGE motor terminal box, see figure
below.
n
Green
Red
TM02 0838 0301
Fig. 3 Positions of the green and red indicator lights in the terminal box
The following two pages give a complete overview of the possible indicator light combinations. Remedy for some of the
situations is further elaborated on the five next pages (A1, A2, B1, C1, C2).
Legend for indicator lights:
= indicator light is off
= indicator light is permanently on
= indicator light is flashing
Indicator lights
Description Explanation Remedy/reference
Green Red
Power off
Pump is not running. Voltage supply to motor has been cut Re-establish correct voltage supply.
off.
Normal operation
1. Pump is running. Normal operational state. The pump
is keeping up the pressure according
to the setpoint set.
2. Pump is not running. Operational stop caused by ...
- the flow switch connected, or
- the stop function in the pump. See A1
3. Pump is running at Possible cause: Fault in installation,
unexpectedly high or setting or signal from setpoint/sensor. See A2
low speed.
9 / 109
Indicator lights
Green Red
Normal operational stop

Pump is not running. Pump has been stopped
by means of the operating button

via R100
via Grundfos GENIbus
by the motor start/stop-function.
(Input on terminal 2-3 is open.)
Fault
Pump is not running. Pump has been stopped due to:
1. External fault - manual restart. See B1
2. Motor winding temperature too Check ventilation.
high - automatic restart. Let motor cool.
3. Supply voltage outside speci-
fied range - automatic restart. Re-establish correct voltage supply.
4. Pump blocked or overloaded -
automatic restart. Remove blockage/reduce load.
5. Terminal box of the wrong type
- manual restart. Replace terminal box.
6. Configuration fault - manual
restart. Reconfigure the terminal box.
7. Fatal fault - motor must be
repaired - manual restart. Replace terminal box.
Normal operation + indication of previous fault
1. Pump running at Pump was stopped due to fault -
normal performance. pump has restarted automatically.
2. Pump running at max. Sensor signal is outside the set
speed. signal range or the sensor signal has
been set to max. by means of the "+"
-button. See C1
3. Pump running at min. Setpoint signal is outside the set
speed. signal range. See C2
Normal operational stop + indication of previous fault
by means of the operating
button
via R100
by the motor start/stop-function,
but the pump was stopped
previously due to a fault that has
now disappeared.
10 / 109
The following figure is a copy of the label fixed to the inside of the terminal box cover. The label gives an overview of terminals.
96048646 SUPPLY:
N PE L
SEE NAMEPLATE
FOR FURTHER DATA
A:RS485 A
Y:SHIELD
NC C NO
SIGNAL RELAY:
B:RS485 B
Max:250V/2A AC1
Min: DC 5V/1mA
0-10V STOP
+OUT
OUT 7: SENSOR INPUT

0/4-20mA + 4-20mA 2: RUN/STOP
-
8: +24V RUN
3: GND
9: GND
0-10V
4: SETPOINT
1: DIGITAL INPUT 0/4-20mA
0/1 +
TM02 1603 1601

- 10K 5: +10V
CONNECTION FOR 6: GND
GRUNDFOS SENSOR
CONNECTION
OPTIONAL FOR PC-TOOL
Fig. 4 Overview of terminals in the terminal box
A1
Description Explanation Check/remedy

Pump is not running. Low flow has caused ...
1. the flow switch to close, Check that the flow switch is working correctly:
NOT 5 VDC across terminals 1-9 = flow switch contact is
closed = pump is not running
5 VDC across terminals 1-9 = flow switch contact is
open = pump is running.
If flow switch is defective, it must be replaced.
Cut the connection between terminals 1 and 9.
Does the pump start?
YES: Pump is OK.

or
NO: Replace the terminal box.
2. the stop function to stop the pump. Increase the flow and/or reduce the pressure in the system.
YES: Pump is OK.

11 / 109
A2
Description Pump is running at unexpectedly high or low speed.
Explanation The cause may be fault in one of the following points. Proceed in consecutive order:
Check/Remedy 1. Is the correct setpoint type set in the motor?

(0-10 V, 0-20 mA, 4-20 mA)
NO: Correct the setting via R100.

YES: Proceed to point 2.
2. Is the external setpoint signal from potentio-

meter or external controller connected
TM02 1606 1601

4: SETPOINT
correctly? 0/4-20mA
+
0-10V
- 10K 5: +10V
NO: Connect the setpoint signal
6: GND
correctly.
3. Is the correct sensor type set in the motor?
(0-10 V, 0-20 mA, 4-20 mA)

4. Is the sensor connected correctly and does

the sensor signal correspond to the system
pressure? 0-10V
TM02 1604 0601

+OUT
OUT
7: SENSOR INPUT
0/4-20mA + 4-20mA
-
NO: Connect the sensor signal 8: +24V

correctly. 9: GND
YES: If the pump does not run correctly,
replace the terminal box.
If the sensor is defective, replace the sensor.
B1
Description Pump is not running.
Explanation External fault has been registered via the digital input.
Check/remedy 1. Is R100 set to external fault?
NO: Set correctly in R100.

2. Can 5 VDC be measured across terminals

1 - 9?
NO: Contact between terminals 1 and 9
9: GND
is closed. Seek cause of fault in
TM02 1605 0601
external signal transmitter. 0/1 1: DIGITAL INPUT

YES: Contact between terminals 1 and 9
is open. E-pump is OK. Proceed to
next fault possibility in the list.
12 / 109
C1
Description Pump is running at max. speed (and it was not set to max. manually by means of the "+"-button!).
Check/remedy 1. Does the sensor setting correspond to the sen-

sor type installed? (0-10 V, 0-20 mA, 4-20 mA)

2. Is the voltage to the sensor connection

24 VDC?
TM02 1606 1601

8: +24V
NO: Replace the terminal box. 9: GND
3. Is the sensor signal ...

- below 10 V (Type 0-10 V sensor),
- below 20 mA (Type 0-20 mA sensor),
- between 4 and 20 mA (Type 4-20 mA sensor)? 0-10V
TM02 1604 1601

+OUT
OUT
7: SENSOR INPUT
0/4-20mA + 4-20mA
-
8: +24V
NO: Replace the sensor. 9: GND
4. Is the sensor connected correctly and does the

sensor signal correspond to the system
pressure?
NO: Connect the sensor signal correctly. See diagram above.

13 / 109
C2
Description Pump is running at min. speed.
Check/remedy 1. Set the pump to "open loop" operation and con-

nect 10 V supply voltage to the setpoint input.
Does the pump switch to max. speed?
NO: Proceed to point 2.
YES: The pump is OK.
2. Does the setpoint setting correspond to the
setpoint type installed?
(0-10 V, 0-20 mA, 4-20 mA)

3. Is the voltage to the setpoint connection

10 VDC?
TM02 1607 1601

4: SETPOINT
0/4-20mA 0-10V
+ 10K 5: +10V
NO: Replace the terminal box. -
YES: Proceed to point 4. 6: GND
4. Is the setpoint signal ...

- between 4 and 20 mA (Type 4-20 mA sensor)?
NO: Check for fault in the external See diagram above.
setpoint signal. Re-establish correct
setpoint signal, if necessary.

14 / 109
1.2.2 Fault readings via R100 fault log or PC Tool E-products
In addition to the red indicator light on the pump indicating fault, the cause of a fault can be read out via a fault log code number
in the R100 operation menu, see the figure below.
(76): Fault log code number.

10h36min: Counter counting the time from the fault occurred till now.
Other fault: Fault reading in R100.
Fault reading
Code Grundfos Cause/Explanation Remedy
(fault log) R100 PC Tool
E-products
3 External External The digital input set to external fault has The fault reading can be reset by means of
fault fault been or is still closed. R100 when the digital input is no longer
closed.
Reset by pressing "+" or "".
4 Too many Too many The number of attempted restarts at 5- Seek the cause under the fault log code
restarts restarts minute intervals after a fault has exceeded numbers succeeding code 4 and 7 in this
16 within 24 hours. table.
The pump will automatically attempt restart
after 24 hours.
7 Too many Too many The number of attempted restarts at 10- Seek the cause under the fault log code
restarts restarts second intervals after a fault has exceeded numbers succeeding code 4 and 7 in this
4 within 1 minute. table.
See also code 4.
After these 4 attempts the pump will
automatically switch to restarting attempts
at 5-minute intervals.
32 Overvoltage Overvoltage The supply voltage exceeds 290 V RMS. Bring the supply voltage down to the
prescribed level (see nameplate).
40 Undervolt- Undervolt- The supply voltage is below 170 V RMS. Bring the supply voltage up to the
age age prescribed level (see nameplate).
49 Overload Overload The electronic module/motor very heavily
overloaded.
Cause:
Blocked pump. Remove the blockage.
Blocked rotor. Remove the blockage.
Continued overload. Reduce the load.
Incorrect configuration of terminal box. Re-configure the terminal box.
Fault in stator windings. Check the stator windings
(see WinCAPS or WebCAPS).
55 Overload Motor cur- The built-in motor current protection has
rent protec- detected a continued overload of more
tion than 125% of rated current for 60 seconds.
Cause:
Fault in stator windings Check the stator windings
65 Too high Motor tem- The PTC temperature sensor in the motor Reduce the load and improve cooling.
motor temperature has measured a winding temperature
perature protection above 140C.
73 Other fault Hardware Current limit of electronic module
shutdown exceeded.
Cause:
Incorrect terminal box type for the pump. Replace the terminal box.
Fault has occurred in the factory setting. Replace the terminal box.
15 / 109
Fault reading
E-products
76 Other fault Internal Internal communication error has occurred Try to reset the fault by
communica- in the pump. 1. Cutting off the supply voltage.
tion error 2. Waiting till all diodes are out.
3. Cutting in the supply voltage again.
If this does not remedy the fault,
85 Other fault Unrecovera- Fault has occurred in the factory setting. Replace the terminal box.
ble EEP-
ROM fault
88 Sensor sig- Sensor fault Sensor signal type 4-20 mA:
nal outside Signal below 2 mA or above 22 mA.
signal range Sensor signal type 0-20 mA:
Signal above 22 mA.
Sensor signal type 0-10 V: Signal above
11 V.
Signal range incorrectly set. Correct the signal range setting.
Sensor incorrectly connected. Connect sensor correctly.
Incorrect supply voltage to sensor. Check supply voltage from terminal box.
Sensor defective. If it is not 24 V, replace the terminal box.
Replace the sensor.
96 Setpoint sig- Reference Sensor signal type 4-20 mA:
nal outside input fault Signal below 2 mA or above 22 mA.
Signal above 22 mA.
Sensor signal type 0-10 V: Signal above
11 V.
Setpoint signal incorrectly connected. Connect setpoint signal correctly.
Incorrect supply voltage to setpoint. Check supply voltage from terminal box.
If it is not 10 V, replace the terminal box.
105 Overload Electronic Electronic module/motor very heavily over-
rectifier loaded; possibly combined with low supply
protection voltage.
Cause:
106 Overload Electronic Electronic module/motor very heavily over-
inverter loaded and electronics temperature ex-
protection ceeds 88C.
Cause:
Incorrect configuration of terminal box. Re-configure the terminal box
255 (255) The PC Tool has received an unknown Update the PC Tool E-products to the
Unknown fault signal. latest version.
16 / 109
1.3 Fault correction, three-phase E-pumps, 0.75 - 7.5 kW model B and C
TM02 1616 1701

The fault correction procedure is based on the combination of indications given by the indicator lights on the terminal box. The
indications of faults and/or disturbances listed in the table below are explained in detail in the tables on the following pages.
Indicator lights
State
Red Green
Off Off The pump is not operating (the electricity supply has been switched or cut
off).
Off Permanently - The pump is operating normally.
on - The pump has been stopped by the stop function (which is set to Active).
- The pump is operating at either too high or too low speed.
Off Flashing The pump has been stopped (e.g. via the control panel or R100).
Permanently Off
The pump has stopped due to fault.
on
Permanently Permanently
The pump is operating, but there has been a fault.
on on
Permanently Flashing The pump has been stopped (e.g. via the control panel or R100), but has
on been stopped earlier due to a fault.
17 / 109
Fault correction
Indicator lights State Cause Remedy

Red Green
Off Off The pump is not The electricity supply has been Check the electricity supply to the
operating. switched or cut off. terminals in the motor terminal box
and restore correct supply.
Off Permanently The pump is --- ---
on operating normally.
The pump has been GENERALLY:
stopped.
Read the expected speed via R100
or PC Tool E-products.
If the reading > 0 rpm:

1. Motor defective. 1. Check motor according to the
winding data. If winding data are
outside tolerances, replace the
motor.
2. Terminal box defective. 2. If motor is OK, replace the
terminal box (Remember the
configuration!).
CRE-N + CRE/CRNE:
By means of R100, check in menu

'Installation' whether stop function
has been set to Active:
A: Stop Function Active:
R100 menu 'Status' - "Operating

mode" reads:
'Stop - From - Stop func.'
The cause may be:
1. Internal flow test has detected low 1. No remedy - part of normal

flow = pump stopped. operation.
2. Stop function activated by signal 2. No remedy - part of normal
from external flow switch. operation.
3. Sensor defective. 3. Check that the sensor signal is in
accordance with the measured
value.
B: Stop Function Not active:
See above under 'Generally'.
18 / 109
Red Green
Off Permanently The pump is 1. Fault in external setpoint signal. 1. Check that the required external
on operating at too setpoint signal is available.
high speed. 2. Fault in setting of external set- 2. Via R100 menu 'Installation'
point signal. check that the "external setpoint
signal" setting is adapted to the
correct signal type.
3. Fault in sensor signal. 3. Check that the required sensor
signal is available.
4. Fault in setting of sensor input. 4. Via R100 menu 'Installation'
check that the "sensor in-put" set-
ting is adapted to the correct sen-
sor type.
5. Pump was set manually to max. 5.
speed by means of "+"-button.
The pump is 1. Fault in external setpoint signal. 1. a: Via R100 menu 'Installation'
operating at too low check that the "external setpoint
speed. signal" has been set to the correct
signal type.
b: Check that the required exter-
nal setpoint signal is available.
2. Fault in sensor signal. 2. Check that the sensor signal is in
accordance with the measured
value.
3. Speed has been reduced due to 3. Check motor temperature and
overload. remedy overload.
Overload is indicated in PC Tool

E-products status field by the
colour red.
Off Flashing The pump has been The pump has been stopped in one
stopped. of the following ways:
1. By means of the operating button 1. Start the pump by pressing the
"". operating button "+".
2. Via R100. 2. Start the pump via R100.
3. Via PMU 2000/BUS. 3. Start the pump via PMU 2000 or
the external control unit.
4. Via external start/stop. 4. Set the external on/off switch to
on. *)
With external switch on (closed
contact) voltage across terminals
2 and 3 should be DC 0 V.
With external switch off (open
contact) voltage across terminals
2 and 3 should be DC 5 V.
*)
Can be achieved temporarily by
choosing operation according to
max. curve by means of operating
buttons on the control panel or via
R100 (external forced-control signals
are ignored).
19 / 109
Red Green
Permanently Off The pump has been The pump has been stopped due to
on stopped. a fault. The cause may be influence
on the installation from external fac-
tors.
Read out the fault indication via

R100 or PC Tool E-products.
1. High ambient temperature or poor 1. Restore proper cooling.
cooling:
- Too high motor temperature.
2. Faulty electricity supply: 2. Check that the electricity supply

- Undervoltage, lies within the specified range.
- Overvoltage, If not, restore proper electricity
- Phase failure, supply.
- Mains supply failure,
- etc.
3. The pump is blocked: 3. Deblock the pump.

- Overload. If the above points are OK, try to
restart the pump by briefly press-
ing "+" or "" or via R100.

YES = Fault remedied.
NO = Check the winding resist-
ance. If OK, please replace
terminal box complete.
4. Other faults. 4. See 1.1.2 Fault log and
1.3.2 Fault readings via R100
fault log or PC Tool E-products
5. If no fault indication via R100 or 5. Replace the terminal box.
PC Tool E-products, then the (See Fitting Instructions for
terminal box is defective. service terminal box).
Permanently Permanently The pump is The cause of the fault can be read Reset the fault indication:
on on operating, but there out via R100 or PC Tool E-products.
has previously been by briefly pressing "+" or "" on the
a fault which has If the 4-20 mA sensor signal is cut control panel of the terminal box,
not been reset. out (falls below 4 mA) the pump or
switches to operation on the max.
via R100.
curve which is NOT indicated as
max. on the control panel.
If possible, take steps to try to avoid
recurrence of the fault.
If the 4-20 mA external setpoint sig-
nal is cut out (falls below 4 mA) the
pump switches to operation on the
min. curve which is NOT indicated as
min. on the control panel.
20 / 109
Red Green
Permanently Flashing The pump has been The cause of the fault can be read Reset the fault indication:
on stopped in one of out via R100 or PC Tool E-products.
the following ways: by briefly pressing "+" or "" on
1. Operating but- the control panel of the terminal
ton "". box, or
via R100.
2. R100.
If the red indicator light goes out and
3. PMU 2000/BUS. the green one starts flashing, the
pump is operational and ready for a
4. External on/off start command.
switch.
If any other indicator light combina-
There has previ- tion appears, start fault finding ac-
cording to that combination.
ously been a fault,
which has not been
reset. If possible, take steps to try to avoid
recurrence of the fault.
If the indicator lights do not change

indication, replace the terminal box
according to the Fitting Instructions
for service terminal box.
21 / 109
Fault reading
E-products
2 Phase fail- Phase - Check that all three mains phases are
ure (mains) failure within a 15 V window.
3 External External The digital input which has been set to No remedy - part of normal operation.
fault fault 'external fault' has been activated.
4 Too many Too many The number of permissible restarts within Reset by pressing "+" or "".
restarts restarts 24 hours has been exceeded.
(after faults)
7 Under- Too many HSD = hardware shut-down.
voltage HSD There has been a fault and the permissible
number of restarts for the fault type has
been exceeded.
Fault in mains supply. Restore mains supply.
Terminal box defective. Replace terminal box
32 Overvoltage Overvoltage Mains supply voltage is too high in the Bring voltage back to prescribed level.
starting moment.
40 Under- Under- Mains supply voltage is too low in the Bring voltage back to prescribed level.
voltage voltage starting moment.
42 Under- Cut-in fault Faulty mains supply voltage at the time of Restore proper mains supply.
voltage cutting in the terminal box.
48 Overload Overload Heavy overload has caused software shut- Check and possibly reduce the load.
down (SSD).
49 Overload Overcurrent Heavy overload. Deblock the pump.
Pump blocked.
50 Overload MPF MPF = motor protection function. The built- Check and possibly reduce load/
general in motor protection has detected a improve cooling.
shutdown sustained overload (MPF 60 sec. limit).
51 Overload Blocked Heavy overload (Imax. very high). Deblock the pump.
motor Pump blocked in the starting moment.
54 Overload Short time The built-in motor protection has Check and possibly reduce load/
overload detected a transitory overload (MPF 3 sec. improve cooling.
limit limit).
57 Dry running Underload Pump has been operating with too low Restore prescribed flow.
flow.
65 Too high Motor PTC sensor in the motor has Check and possibly reduce load/
motor temperature signalled overtemperature. improve cooling.
temperature
67 Too high Power Terminal box has indicated Check and possibly reduce load/
motor converter overtemperature. improve cooling.
temperature temperature (Temperature during operation can be read
via PC Tool E-products).
73 Undervolt- Hardware - Fall in mains supply. Restore proper mains supply.
age shutdown - Mains supply failure while motor is
running.
76 Other fault Internal Terminal box defective. Replace the terminal box.
communica-
tion error
83 Other fault Parameter Setting data not correct. Replace the terminal box.
area verifi-
cation error
88 Sensor Sensor fault Sensor specified for 4-20 mA but signal
signal out- received is below 4 mA:
side signal
range Signal range incorrectly set; Correct signal range setting;
Sensor incorrectly connected; Connect sensor correctly;
Sensor of an incorrect type; Connect correct sensor;
Sensor defective; Replace sensor;
Electricity supply failure. Restore proper electricity supply.
22 / 109
Fault reading
E-products
96 Setpoint sig- Reference External setpoint signal specified for 4-20
nal outside input fault mA but signal received is below 4 mA:
signal range Setpoint signal range incorrectly set; Correct signal range setting;
Setpoint signal incorrectly connected; Connect setpoint signal correctly;
Setpoint signal of an incorrect type. Provide correct setpoint signal.
255 - Unknown PC Tool E-products has received an unde- PC Tool E-products should be updated.
fined fault signal.
23 / 109
1.4 Fault correction, three-phase E-pumps, 0.55 - 7.5 kW model D
TM03 0200 4504

This fault correction procedure is based on indications from the two indicator lights in the terminal box and/or on the control
panel. For position of the indicator lights, see figures below.
Green
Red
TM02 9036 1504
TM02 8513 0304
TM03 0204 4504

Green Red
Green Red
Position of indicator lights in the terminal box Control panel of CRE with and Control panel of TPE/TPED
without sensor, TPE/TPED Series 2000
Series 1000, NKE and NBE
The following two pages give a complete overview of the possible indicator light combinations. Remedy for some of the situa-
tions is further elaborated on the five next pages (D1, D2, E1, F1, F2).
indicator light is flashing 5 times

=
per second
Indicator lights
Green Red
Power off
off.
Possibly faulty component in the

terminal box. Replace terminal box
Normal operation
1. Pump is running. Normal operational state.
- the stop function in the pump. See D1
unexpectedly high or setting, signal from setpoint/sensor
low speed. or sensor input is set to active. See D2
24 / 109
Indicator lights
Green Red

via R100
Fault
Pump is not running. Pump has been stopped due to: See fault reading in R100 or PC Tool
E-products.
1. Pump blocked or overloaded Remove blockage/reduce load.
2. Ambient temperature too high or
cooling insufficient Re-establish sufficient cooling.
3. Voltage supply fault:
- undervoltage Check that the mains supply is within
- overvoltage the voltage range stated on the
- phase failure nameplate. If not, re-establish correct
- mains supply fault. voltage supply.
4. External fault See E1
5. Other faults:
- wrong terminal box - replace the terminal box
- wrong configuration - reconfigure the terminal box
- fatal fault. - replace terminal box.
Fault
- Pump is not running; Fatal internal communication error in Try to reset the fault by
- communication with the pump. 1. Cutting off the supply voltage.
R100 is not possible; 2. Waiting till all diodes are out.
- no reaction when you
3. Cutting in the supply voltage
press the operating again.
buttons or .
1. Pump running at Communication error duty/standby. See fault code 77 1.4.2 Fault read-
normal performance. Duty/standby function of pump is ings via R100 fault log or PC Tool E-
activated, but no communication with products
the standby pump.
speed. signa range. See F1
speed. signal range. See F2
by means of operating button " "
via R100
previously due to a fault.
25 / 109
SUPPLY:
L1 L2 L3
96086116
SEE NAMEPLATE
FOR FURTHER DATA
A:RS485 A
Y:SHIELD
NC C NO
SIGNAL RELAY:
B:RS485 B
Max:250V/2A AC1
Min: DC 5V/1mA
0-10V STOP
+OUT
OUT
7: SENSOR INPUT
0/4-20mA + 4-20mA 2: RUN/STOP
-
8: +24V RUN
3: GND
9: GND
0-10V
4: SETPOINT
0/1 +
5: +10V
TM03 0269 4604

- 10K
GRUNDFOS SENSOR
CONNECTION
D1

- NOT 5 VDC across terminals 1-9 = flow switch contact is
closed = pump is not running.
- 5 VDC across terminals 1-9 = flow switch contact is open =
pump is running.
Check that the digital input works correctly by cutting the

connection between terminals 1 and 9.
or YES: Input is OK.
NO: Replace the pump I/O-module.
YES: Input is OK.
26 / 109
D2
Check/ 1. Is the correct setpoint type set in the motor?

Remedy (0-10 V, 0-20 mA, 4-20 mA)

2. Is the external setpoint signal from
TM02 1606 1601

potentiometer or external controller connected 4: SETPOINT
0/4-20mA 0-10V
correctly? + 10K 5: +10V
-
NO: Connect the setpoint signal correctly. 6: GND
(0-10 V, 0-20 mA, 4-20 mA)


pressure? 0-10V
+OUT
OUT
7: SENSOR INPUT
NO: Connect the sensor signal correctly.
TM02 1604 0601

- 0/4-20mA + 4-20mA
8: +24V
YES: If the pump does not run correctly, 9: GND

replace the pump I/O-module or the
terminal box.
E1
Check/ 1. Is R100 set to external fault?

remedy

2. Can 5 VDC be measured across terminals 1 -

9?
NO: Contact between terminals 1 and 9 is
closed. Seek cause of fault in exter- 9: GND
nal signal transmitter.
TM02 1605 0601
0/1 1: DIGITAL INPUT

YES: Contact between terminals 1 and 9 is
open. E-pump is OK. Proceed to next
fault possibility in the list.
27 / 109
F1
Description Pump is running at max. speed (and it was not set to max. manually by means of the -button!).
Check/ 1. Does the sensor setting correspond to the sensor

remedy type installed? (0-10 V, 0-20 mA, 4-20 mA)

2. Is the voltage to the sensor connection 24 VDC?
TM02 1604 1601 TM02 1606 1601

8: +24V

- below 20 mA (Type 0-20 mA sensor), 0-10V
+OUT
OUT
- between 4 and 20 mA (Type 4-20 mA sensor)? 7: SENSOR INPUT
0/4-20mA + 4-20mA
-
8: +24V
9: GND
NO: Replace the sensor.
pressure?
See diagram above.
YES: If the pump does not run correctly, re-

place the pump I/O-module or the ter-
minal box.
28 / 109
F2
Check/ 1. Set the pump to "open loop" operation and

remedy connect 10 V supply voltage to the setpoint
input.
2. Does the setpoint setting correspond to the set-
point type installed? (0-10 V, 0-20 mA, 4-20 mA)

TM02 1607 1601

10 VDC? 4: SETPOINT
0/4-20mA 0-10V
+ 10K 5: +10V
-
6: GND

NO: Check for fault in the external setpoint
See diagram above.
signal. Re-establish correct setpoint
signal, if necessary.

29 / 109

Fault reading
E-products
3 External fault External fault The digital input set to external fault has The fault reading can be reset when the
been or is still closed. (terminal 1). digital input is no longer closed either by
means of R100 or by pressing or .
4 Too many Too many The number of attempted restarts at Seek the cause under the fault log code
restarts restarts 10-second intervals after a fault has numbers succeeding code 4 in this table.
exceeded 4 within 1 minute. The pump will automatically attempt
After this the number of attempted restart after 24 hours.
restarts at 5-minute intervals after a The fault reading can be reset either by
fault has exceeded 16 within 24 hours. means of R100 or by pressing or .
32 Overvoltage Overvoltage Voltage has exceeded the upper DC
voltage limit of the terminal box.
Mains voltage supply has been or is Bring the supply voltage down to the
too high. prescribed level (see nameplate).
40 Undervoltage Undervoltage Voltage has fallen below the lower DC
Mains voltage supply has been or is Bring the supply voltage up to the pre-
too low. scribed level (see nameplate).
49 Overload Overload The terminal box/motor very heavily over-
loaded. Cause:
Incorrect configuration of terminal box. Re-configure the terminal box with
correct configuration file.
Wrong terminal box. Replace terminal box.
Mains supply failure (phase failure). Re-establish correct mains supply.
55 Overload Motor current The built-in motor current protection has
protection detected a continued overload of more
than 125% of rated current for 60
seconds. Cause:
65 Too high Motor The temperature sensor in the motor has
motor temperature measured too high winding temperature
temperature protection (above 160C).
Cause:
Too high ambient temperature Improve cooling
PTC defective. Replace complete MGE motor.
shutdown exceeded.
Cause:
30 / 109
Fault reading
Code Grundfos
Cause/Explanation Remedy
E-products
76 Other fault Internal com- Internal communication error has Try to reset the fault by
munication occurred in the pump. 1. Cutting off the supply voltage.
error 2. Waiting till all diodes are out.
If this does not remedy the fault, replace
the terminal box.
77 Communica- Duty/standby Communication between the two pumps
tion error communica- set up for duty/standby function has been
duty/standby tion error cut.
Voltage supply to standby pump has Re-establish voltage supply.
been cut.
Communication cable has been cut. Check the communication cable.
ble EEP-
ROM fault
Signal above 22 mA.
Sensor signal type 0-10 V:
Signal above 11 V.
If it is not 24 V +/ 1 V, replace the
terminal box.
Sensor defective. Replace the sensor.
Sensor cable defective. Check the cable.
Signal above 22 mA.
Signal above 11 V.
105 Overload Electronic Electronic module/motor very heavily
rectifier pro- overloaded and the electronics
tection temperature is above 100C.
Cause:
Ambient temperature too high/cooling Improve cooling.
insufficient.
inverter overloaded and the electronics
protection temperature is above 100C.
Cause:
Ambient temperature too high/cooling
insufficient. Improve cooling.
155 Undervoltage Undervoltage Voltage limit of terminal box exceeded.
Mains supply failure. Re-establish mains supply.
Transients in the mains during
operation. Check the mains supply.
31 / 109
Fault reading
Code Grundfos
E-products
156 Other fault Hardware Internal communication error in the Terminal box defective.
shutdown pump. Replace the terminal box.
255 - Unknown The PC Tool E-products has received an Update the PC Tool E-products to the
unknown fault signal. latest version.
32 / 109
1.4.3 How to use PC Tool E-products on two pumps running duty/standby
The duty/standby function in E-pumps is set by means of R100. Before you start using PC Tool E-products on faulty E-pumps
you have to do this:
1. Contact one of the pumps by means of R100, set Duty/Standby to Not Active, see CRE, CRIE, CRNE, CRKE, SPKE,
MTRE, CHIE with and without sensor, menu INSTALLATION. The duty/standby function has now been cancelled.
2. Connect PC Tool E-products to the service port of the pump you want to communicate with.
3. Make the necessary service settings via PC Tool E-products.
4. Disconnect PC Tool E-products from the service port.
5. Contact one of the pumps by means of R100, set Duty/Standby to Active. The duty/standby function has now been set
again.
Note: It is important that you cancel the duty/standby function before you start on the abovementioned procedure. Otherwise
you may have one of the two fault situations described below.
The reason for this is that the two pumps communicate with each other via a GENIbus connection, and one pump is master and
the other pump is slave. This master-slave relation will make them react differently when you connect PC Tool E-products. You
cannot know in advance which of the two pumps is master and which is slave.
Fault situation 1:
If you connect PC Tool E-products to the master pump, you will see the following reactions:
Master pump Fault indication

Slave pump Fault indication
PC Tool E-products Unable to get Master status on GENIbus
1. PC Tool E-products will not be able to establish contact with any of the pumps and will display a window with the
abovementioned text. The reason is a communication conflict between two masters (PC Tool E-products and master pump).
2. Both pumps will give fault indication after approx. 8 seconds. The reason is that communication between the two pumps was
interrupted when PC Tool E-products was connected to the service port of the master pump.
Fault situation 2:
If you connect PC Tool E-products to the slave pump, you will see the following reactions:

Slave pump Ready indication
PC Tool E-products Ready indication
1. PC Tool E-products will establish contact with the pump. The reason is that PC Tool E-products is connected to the slave
pump; communication can take place.
2. The master pump will give a fault indication after approx. 8 seconds. The reason is that communication between the two
pumps was interrupted when PC Tool E-products was connected to the service port of the slave pump. The slave pump does
not indicate fault because being the slave pump, it will "mistake" PC Tool E-products for the master pump.
To remedy both fault situations:

1. disconnect PC Tool E-products from the pump
2. reset the fault indication by means of R100
3. go through the procedure described at the top of this page.
33 / 109
1.5 Fault correction, three-phase E-pumps, 11 - 22 kW model MMGE
TM02 4495 1102

Note: Before starting fault correction, always check that all wires and cables are securely in place and good connection is es-
tablished.
Fault diagnosing and fault correction are based on the following indications and procedures:
1.5.2 Indicator lights on the terminal box
1.5.4 Checking the terminal box main components
1.5.5 Dismantling and assembly of terminal box components
1.5.6 Diagrams
1.5.2 Indicator lights on the terminal box
Indicator lights
State
Red Green
Off Off The pump is not operating
The pump is not operating
The pump has been stopped by the stop function
Off Permanently on
The pump is operating at too high speed
The pump is operating at too low speed
Off Flashing The pump has been stopped via the control panel or via R100
Permanently on Off The pump has been stopped due to a fault
Permanently on Permanently on The pump is running, but has previously been stopped due to a fault
Permanently on Flashing The pump has been stopped and has previously been stopped due to a fault
Red Green
The pump is not operating
Off Off
Cause Remedy
1. Voltage supply has been switched or cut off. - Check that the voltage supply to the terminals in the motor terminal
box is according to the nameplate.
2. Terminal box defective (possibly due to internal - Restore correct voltage supply.
short circuit) A. If voltage supply is cut off again, there is an internal short circuit in
the terminal box.
- Replace the terminal box.
- Alternatively, carry out fault finding in the terminal box, see Check 0:
Mains supply.
B. Is the voltage supply now OK and are the indicator lights still off?
Can +5 V and +24 V be measured on the terminal box control
terminals?
YES:
- Alternatively, carry out fault finding in the terminal box, see Check 8:
Grundfos interface board.
NO:
- Check the fuse F101.
For position of F101, see illustration TM02 4557 1202.
The fuse is defective:
- Replace the fuse.
The fuse blows again:
- Alternatively, carry out fault finding in the terminal box, see Check
5: Control board.
34 / 109
Red Green The pump has been stopped by the stop function
Off Permanently on
Cause Remedy
GENERALLY:
Read whether R100 or PC Tool E-products indicates
revolutions of the pump?
Indicated speed > 0 rpm:
Motor or terminal box is defective. Check whether the motor terminals have voltage.
a. There is voltage to the terminals:
- Check the motor according to the winding data. If wind-
ing data are outside the tolerances, replace the motor.
b. There is not voltage to the terminals:
- Possibly carry out fault finding on the terminal box, see
Check 5: Control board
CRE-N + CRE/CRNE: By means of R100, check in menu 'Installation' whether stop
R100 or PC Tool E-products indicates: function has been set to Active:
Speed = 0 rpm:
A. Stop function Active:
R100 menu 'Status' - "Operating mode" reads:
'Stop - From - Stop func.
The cause may be:
1. Internal flow test has detected low flow = pump stopped. a. No remedy - part of normal operation.
2. Stop function activated by signal from external flow switch. b. No remedy - part of normal operation.
3. Sensor defective. c. Check that the sensor signal is in accordance with the
measured value.
B. Stop function Not active See above under 'Generally'.
Red Green
The pump is operating at too high speed
Off Permanently on
Cause Remedy
1. Fault in external setpoint signal. 1. Check that the required setpoint signal is available.
2. Fault in setting of external setpoint signal. 2. Via R100 menu 'Installation' check that the "external set
point signal" setting is adapted to the correct signal type.
3. Fault in sensor signal. 3. Check that the required sensor signal is available.
4. Fault in setting of sensor input. 4. Via R100 menu 'Installation' check that the "sensor input"
setting is adapted to the correct sensor type.
5. Pump was set manually to max. speed by means of "+"- 5. Correct the setting.
button (the top yellow light field is on).
Red Green
The pump is operating at too low speed
Off Permanently on
Cause Remedy
1. Fault in external setpoint signal. 1. a. Via R100 menu 'Installation' check that the "external
setpoint signal" is adapted to the correct signal type.
b. Check that the required external setpoint signal is
available.
2. Fault in sensor signal. 2. Check that the sensor signal is in accordance with the
measured value.
3. Speed has been reduced due to overload. 3. Check and reduce motor load.
PC Tool E-products will indicate Derating in the status line.
35 / 109
Red Green The pump has been stopped via the control panel or via
Off Flashing R100
Cause Remedy
The pump has been stopped in one of the following ways:
1. By means of the operating button "". 1. Start the pump by pressing the operating button "+".
2. Via R100. 2. Start the pump via R100.
3. Via PMU 2000/BUS. 3. Start the pump via PMU 2000 or the external control unit.
4. Via external start/stop. 4. Set the external on/off switch to on. *)
With external switch on (closed contact) voltage across
terminals 2 and 3 should be 0 VDC.
With external switch off (open contact) voltage across ter-
minals 2 and 3 should be 5 VDC.
*)
Can be achieved temporarily by choosing operation according
to max. curve by means of operating buttons on the control
panel or via R100 (external forced-control signals are ig-
nored).
Red Green
The pump has been stopped due to a fault
Permanently on Off
Cause Remedy
A. Internal factors:
Replace the terminal box.
If neither R100 nor PC Tool E-products indicates fault, the
Possibly carry out fault finding on the terminal box, see Check
terminal box is defective.
8: Grundfos interface board.
B. External factors:
1. High ambient temperature or bad cooling may cause too 1. Restore sufficient cooling.
high motor temperature.
2. Fault in voltage supply: 2. Check that the voltage supply is within the stated range.
- Undervoltage, If not, restore correct voltage supply.
- Overvoltage,
- Mains phase missing,
- Mains supply failure,
- etc.
3. The pump has seized up: 3. Remove the cause of the seizure.
- Overload.
If the abovementioned points are OK, try to restart the
pump by briefly pressing "+" or "" or via R100.

YES = Fault has been remedied.
NO = Check the winding resistance.
If OK, replace the terminal box complete.
4. Other faults. 4. Replace the terminal box.
See fitting instructions for terminal box.
36 / 109
Red Green The pump is running, but has previously been stopped
Permanently on Permanently on due to a fault
Cause Remedy
R100 or PC Tool E-products indicates:
A. "Sensor signal outside the signal range" Reset the fault indication
In case of fault in the sensor signal the pump automati- by briefly pressing either "+" or "" on the terminal box
cally switches to operation according to the MAX-curve control panel or
which is NOT indicated as MAX on the control panel. via R100.
Fault in the sensor signal may occur if... If possible, take steps to prevent recurrence of the fault.
- the sensor signal is interrupted,
- the sensor signal (4-20mA) falls below 2 mA, or
- the max.-value (4-20 mA or 0-10 V) is exceeded by 20%.
B. "Setpoint signal outside the signal range" Reset the fault indication
In case of fault in the setpoint signal the pump automati- by briefly pressing either "+" or "" on the terminal box
cally switches to operation according to the MIN-curve control panel or
which is NOT indicated as MIN on the control panel. via R100.
Fault in the setpoint signal may occur if... If possible, take steps to prevent recurrence of the fault.
- the sensor signal is interrupted,
- the sensor signal (4-20mA) falls below 2 mA, o r
- the max.-value (4-20 mA or 0-10 V) is exceeded by 20%.
Red Green The pump has been stopped and has previously been
Permanently on Flashing stopped due to a fault
Cause Remedy
R100 or PC Tool E-products indicates that the pump has been
stopped in one of the following ways:
1. By means of the operating button "". Reset the fault indication.
2. Via R100.
3. Via PMU 2000/BUS.
If possible, take steps to prevent recurrence of the fault.
4. Via external start/stop.
37 / 109
In addition to the indicator lights on the pump control panel, the cause of a fault can be read out via a fault log code number in
the R100 operation menu or in PC Tool E-products.
The following fault log code numbers are available:
2 3 4 7 32 40 42
48 49 50 51 54 57 65
67 73 76 83 88 96 255
The following is a description of causes of and suggested remedies for the individual fault situations:
Fault reading
Code
PC Tool Cause/Explanation Remedy
(fault log) R100
E-products
2 Phase failure Phase failure 1. Unbalance in the voltage supply. Check that all three mains phases lie
(mains) within a 15 V band.
2. One of the phases is missing. Connect the missing phase and check that
all three mains phases lie within a 15 V
band.
If this does not remedy the fault:
Replace the terminal box.
Carry out fault finding on the terminal
box, see Check 0: Mains supply.
3 External fault External fault The digital input set to external fault No remedy required - this is part of normal
has been activated. operation.
4 Too many Too many The number of permissible restarts Reset the fault reading by pressing "+" or
restarts (after restarts within 24 hours has been exceeded. "".
fault) Read the fault in the fault log and continue
fault finding according to the fault log code
numbers.
7 Undervoltage Too many HSD = Hardware shut-downs.
HSD 1. There has been repeated faults in the 1.Try to locate the cause of the unstable
voltage supply and the permissible voltage supply.
number of restarts for the fault type
has been exceeded. Read the fault in the fault log and con-
tinue fault finding according to the fault
log code numbers.
2. The terminal box is defective. 2. Replace the terminal box.
32 Overvoltage Overvoltage The voltage supply is or has been too Try to locate the cause of the unstable
high in the starting moment or during voltage supply.
operation. 700 VDC corresponds to 500 VAC.
The internal DC voltage measures See the motor nameplate.
> 700 V for 30 seconds.
40 Undervoltage Undervoltage Mains supply voltage is too low in the Try to locate the cause of the unstable
starting moment or during operation. voltage supply.
The internal DC voltage measures 400 VDC corresponds to 300 VAC.
< 400 V. See the motor nameplate.
The voltage supply may be under-
dimensioned.
42 Undervoltage Cut-in fault Faulty mains supply voltage at the time Restore proper mains supply.
of cutting in the terminal box. See the motor nameplate.
Possibly check whether the problem
recurs if the motor is restarted.
48 Overload Overload Heavy overload has caused software Check and possibly reduce the load.
shut-down (SSD).
49 Overload Overcurrent Heavy overload. Remove the cause of the seizure.
Pump seized up.
50 Overload MPF general MPF = Motor protection function. Check and possibly reduce the load/
shutdown The built-in motor protection has improve cooling.
detected a sustained overload for more
than 60 seconds.
The motor has been adjusted down to
min. frequency, and the max. current is
still above the limiting value.
51 Overload Blocked The pump is seized up in the starting Remove the cause of the seizure.
motor moment which causes heavy overload.
The input current is very high; motor
P > 120% for 60 seconds.
38 / 109
Fault reading
Code
(fault log) R100
E-products
54 Overload Short time The built-in motor protection has Check and possibly reduce the load/
overload limit detected a transitory overload for more improve cooling.
than 3 seconds.
57 Dry running Underload Pump has been operating with too low Restore prescribed flow.
flow.
65 Too high Motor Temperature sensor (PTC) in the motor Check whether:
motor temperature has signalled overtemperature. - the motor starts and stops too frequently?
temperature. - cooling is sufficient?
- the temperature sensor is OK?
Possibly carry out fault finding on the ter-
minal box, see Check 9: Motor tempera-
ture sensor (PTC).
67 Too high Power Terminal box has indicated temperature - Check terminal box ventilation and
motor converter > 80C. cooling.
temperature. temperature Possibly reduce the load.
- Possibly carry out fault finding on the
terminal box, see Check 7: Fan.
73 Undervoltage Hardware The motor has been stopped due to a
shutdown situation which may cause fatal fault.
The fault reading may be caused by:
1. Fluctuations in the voltage supply 1. Restore stable voltage supply.
during operation.
2. Heavy overload. 2. Check and reduce the overload.
3. Regenerative voltage from the motor. 3. Check whether the stopped motor is
being driven by some other driving
mechanism.
4. Short-circuited motor windings. 4. Meg the motor windings. Disconnect the
motor wires to the terminal box!
5. Motor windings with earth 5. See 4.
connection.
Possibly carry out fault finding on the
terminal box, see
Check 4: IPM module
Check 14: DC voltage
Check 6: Power board.
76 Other fault Internal com- Terminal box defective. A. Replace the terminal box.
munication B. Possibly carry out fault finding on the
error terminal box.
Does the fan run continuously?
YES: Check 5: Control board.
NO: Check the cable between the con-
trol board and the Grundfos interface
board.
Is the cable OK?
YES: Replace the terminal box.
NO: Replace the cable.
terminal box, see
- Check 8: Grundfos interface board
- Check 5: Control board.
83 Other fault Parameter Setting data are not correct. Re-configure the terminal box.
area Does this not solve the problem, replace
verification the terminal box.
error
terminal box, see Check 5: Control board.
39 / 109
Fault reading
Code
(fault log) R100
E-products
88 Sensor sig- Sensor fault Fault in the sensor signal may occur if:
nal outside - the sensor signal is interrupted,
signal range
- the sensor signal (4-20 mA) falls
below 2 mA, or
- the max.-value (4-20 mA or 0-10 V)
is exceeded by 20%.
1. Signal range incorrectly set. 1. Correct signal range setting.
2. Sensor incorrectly connected. 2. Connect sensor correctly.
3. Sensor of an incorrect type. 3. Connect correct sensor.
4. Sensor defective. 4. Replace sensor.
5. Voltage supply failure to the sensor. 5. Restore proper voltage supply to the
sensor.
terminal box, see Check 8: Grundfos inter-
face board.
96 Setpoint sig- Reference Fault in the setpoint signal may occur if:
nal outside input fault - the setpoint signal is interrupted,
signal range
- the setpoint signal (4-20 mA) falls
below 2 mA, or
- the max.-value (4-20 mA or 0-10 V)
is exceeded by 20%.
1. Setpoint signal range incorrectly set. 1. Correct setpoint signal range setting.
2. Setpoint signal incorrectly connected. 2. Connect setpoint signal correctly.
3. Setpoint signal of an incorrect type. 3. Connect correct setpoint signal.
terminal box, see Check 8: Grundfos inter-
face board.
255 Unknown PC Tool E-products has received an Update PC Tool E-products.
undefined fault signal.
40 / 109
1.5.4 Checking the terminal box main components
Terminal box nameplate
The terminal box data can be read from the nameplate beside the mains terminals in the terminal box.
Key to the nameplate information:
Type:
Example: EGF40 xxx 55CE
Type range
Rated current
Type identification
Serial number:
Example: 09101p / vv dddd mmmmmmm zzz
Rated motor power:

091015 = 11 kW
091016 = 15 kW
091017 = 18.5 kW
091018 = 22 kW
Version no.
Year and week of production
Manufacturing order no. of motor
Serial number
The checking of the terminal box main components falls in the following 15 individual procedures:
Check 0: Mains supply
Check 1: Resistor R1 (inrush)
Check 2: Relay K1 (inrush)
Check 3: Rectifier
Check 4: IPM module
Check 6: Power board
Check 7: Fan
Check 8: Grundfos interface board
Check 9: Motor temperature sensor (PTC)
Check 11: Electronic temperature sensor (PTC)
Check 15: DC capacitors
Set-up of control board after replacement
Power board switch setting
41 / 109
CAUTION:
Measurements inside the terminal box, with live power, should only be carried out by technicians who have
electrotechnical education and who have participated in an E-pump service-training seminar.
Otherwise, replace the complete terminal box!
Service tools required to carry out the checks and tests below.
Electrical tools: - Digital multimeter, type RMS, with diode test mode
- Switch box for control board setting
- Discharge resistor for discharging the capacitors.
Mechanical tools: - Hexagon key, ball-shaped, for the motor terminals
- Slotted screwdriver, 3.5 mm
- Slotted screwdriver, 5.5 mm
- Hexagon key, L-shaped, 5 mm
- Hexagon key, T-shaped, 2.5 mm
- Hexagon key, T-shaped, 3 mm
- Hexagon key, T-shaped, 4 mm
- Screw-holding screwdriver, 5 mm.
Disconnect the power supply and discharge the capacitors

This procedure will be referred to regularly from the individual checking procedures.
1. Disconnect the power supply

2. Discharge the capacitors
- Short-circuit DC+ and DC- for 5 seconds using the
discharge resistor.
- After discharging, check that the voltage is below
24 VDC.
TM02 4557 1202
Fig. 6 Terminal box three-phase E-motor
42 / 109
Check 0: Mains supply
Live wires during the check!
Check the mains supply according to the motor nameplate

(L1 - L2 - L3).
The mains fuses have blown.
- Replace the fuses.
The mains fuses are OK.
- Continue fault finding on the basis of the next LED or
R100 indication.
TM02 4557 1202

Fig. 7 Mains terminals in the terminal box
The mains fuses blow again.
- Proceed with further checks in the following order:
Check 3: Rectifier
Check 4: IPM module
The fault has still not been found after this:

- Replace the terminal box complete.
43 / 109
- Measure the resistance across the relay K1 bus bar:

Measuring result must be approx. 22 Ohm.
In case the resistance in R1 is outside the value, the relay

K1 must be checked too.
Note:
The resistor R1 is only used as a current limiter
during start-up.
After start-up, the current bypasses relay K1. If
relay K1 is defective, resistor R1 might be burnt.
TM02 4560 1202

See Wiring diagram
Fig. 8 Relay K1 bus bar in the terminal box
44 / 109
Check the contacts or simply replace the relay.

The inrush relay is activated approx. two seconds after the power has been switched on. This is indicated by a clearly audible
click.
1. The click is NOT audible: Remove the motor terminal DIN rail to access the contactor coil
Either the relay coil or the power board is defective. terminals.
Disconnect mains supply!
Check the relay coil:

- Resistance should be approx. 200 Ohm.
If the relay coil is OK, the power board is defective.
- See Check 6: Power board.
TM02 4560 1202

2. The click IS audible:
Disconnect mains supply!
The relay contacts ought to be open when mains sup-
ply is disconnected.
- Measure resistance across the contacts:
Approx. 22 Ohm = relay contacts are OK.
< 22 Ohm = relay contacts are defective. Fig. 9 Inrush Relay K1 in the terminal box
Moving the test button on the relay from position 0 to posi-

tion 1 will force-shift the position of the relay contacts.
- Measure resistance across the contacts:
Result < 1 Ohm = relay contacts are OK.
In case the relay is defective, the resistor R1 must also be

checked, see Check 1: Resistor R1 (inrush).
Fig. 10 Inrush resistor R1 in the terminal box TM02 4561 1202
Note:
The resistor R1 is only used as a current limiter during start-up.
After start-up, the current bypasses relay K1. If relay K1 is defective, resistor R1 might be burnt.
If the contact on the relay is hanging, this might damage the rectifiers.
45 / 109
Check 3: Rectifier
The rectifier supplies DC+ and DC to all functions of the terminal box.
Check the DC+ and DC voltage
Measure from DC to DC+
A The DC voltage > 500 VDC.

The rectifier is OK.
- Continue by...
Checking the fuse F101 on the power board.
1. The fuse has blown.
- Replace the fuse.
2. If the fuse blows again, the power board is
defective.
- Replace the power board.
B The DC voltage < 500 VDC
Disconnect the power supply and discharge the capacitors.
Carry out the following measurements by means of a

multimeter in diode test mode:
From mains terminal L1 to DC+: approx. 0.3 - 1.0 V
From mains terminal L1 to DC: Open circuit

TM02 4557 1202

Reversing the polarity of the multimeter will result in
the opposite measurements.
Fig. 11 Mains terminals in the terminal box

If the measurements are outside the values specified,
replace the rectifier and carry out the following checks
again:
46 / 109
Check 4: IPM module
IPM: Intelligent Power Module
1. Disconnect the motor wires U - V - W from the motor

terminals.
2. Check the inverter transistors by means of a multimeter in
diode test mode:
From motor terminal U to DC+: approx. 0.3 - 1.0 V
From motor terminal V to DC+: approx. 0.3 - 1.0 V
From motor terminal W to DC+: approx. 0.3 - 1.0 V
TM02 4557 1202

From motor terminal U to DC: Open circuit
From motor terminal V to DC: Open circuit
From motor terminal W to DC: Open circuit
Fig. 12 Motor terminals in the terminal box
Reversing the polarity of the multimeter will result in the
opposite measurements.
If the measurements are outside the values specified, replace the IPM module and carry out the following checks again:
Check 3: Rectifier
47 / 109
Control board failure is often indicated in one of the following ways:

there are no fault indications
there is no function at all
the pump behaves "strangely" immediately after power has been switched on
the relay K1 is not activated (no audible click is heard).
Replace the control board or check according to the following procedure:
After the power has been switched on, the fan is supposed to run for approx. 3 seconds, controlled by the control board, and
then stop.
A 1. The fan does not run after power has been switched Control board type 1:
on.
- Turn the mains supply off.
- Disconnect connectors X6 and X7 on the control x7
board.
- Turn the mains supply on.
2. The fan runs continuously. x6
- Replace the control board.
3. The fan does not run.
- See Check 3: Rectifier.
TM02 8505 0304

B The fan runs continuously, i.e. does not stop after
3 seconds. green diode
Fig. 13 Control board type 1
Control board type 2:

C The fan runs for approx. 3 seconds, then stops.
- Check the green LED on the control board. x7
1. Green LED is on, but operation is not normal:
x6
2. Green LED is off:
- Check the voltages +24 V, +15 V, -15 V and +5 V on
the control board. Measure from test pin TP1, see
Control board type 1 or Control board type 2 .
3. One of the above voltages is missing:
TM02 8506 0304
- See Check 6: Power board. green diode
See Set-up of control board after replacement. Fig. 14 Control board type 2
Note:
+5 V can be measured if one of the LEDs on the control board is on.
+24 V can be measured if communication with R100 is possible.
An easy way to check these two voltages is to measure on the Grundfos interface board terminal blocks.
48 / 109
Check 6: Power board
The power board is placed below the control board and its baseplate. To access the power board, disconnect and remove the
control board and its baseplate.
Note: Mark wires and cables and note their original position!
A Check the fuse F101 on the power board.
1. The fuse has blown.

- Replace the fuse.
The fuse blows again.
The power board is defective.

2. The fuse is OK.
- Continue to B.
B Turn the mains supply on (This is OK even if the

control board has been removed).
Check the DC voltage to the power board by
measuring from DC- to the power board fuse F101:
1. DC voltage is < 500 VDC.
- Go through the following checks:
TM02 4557 1202

Check 3: Rectifier
2. The DC voltage > 500 VDC.
- Continue to C. Fig. 15 Power board fuse F101 in the terminal box
C Check the voltages +15 V, -15 V, +24 V and +5 V on

the power board. Measure from N1 02 to the voltage
test points.
One or more of the above voltages is missing: See Power board
The power board is defective.

The power board is equipped with DIL-switches. After installing a new power board, make sure that the DIL-switch setting of
the new board is identical with the setting of the old board.
Note:
DC voltage = approx. mains AC phase-phase voltage multiplied by 1.4.
49 / 109
Check 7: Fan
The power board is placed below the control board and its baseplate. To access the power board, disconnect and remove the
control board and its baseplate.
Note: Mark wires and cables and note their original position!
After the power has been switched on the fan is supposed to run for approx. 3 seconds, controlled by the control board, and
then stop.
A The fan runs for 3 seconds and then stops.
The fan is OK.
B 1. The fan does not run immediately after power has

been switched on.
- Turn off the mains supply.
- Disconnect connectors X6 and X7 on the control
board.
TM02 4557 1202

Turn the mains supply on again.
Note: The fan should run continuously when X6
and X7 are disconnected.
2. The fan does not run.
- Disconnect the fan from power board terminal Fig. 16 Position of the connectors X6 and X7 in the
(marked Fan on the photo). terminal box
- Connect a new fan.
The new fan is operating.
- Replace the old fan.
The new fan is NOT operating.
- Check 24 VDC on the fan terminal.
- 24 VDC are not available.
- Check the fuse F101 on the power board
TM02 4559 1202

The fuse is OK.
3. The fan now runs continuously.
Fig. 17 Position of the fan in the terminal box
Technical note:
The voltage to the fan is 24 V.
Normally the fan is started when the temperature on the heat sink exceeds 60C and stopped again when the temperature
falls below 55C.
50 / 109
Check 8: Grundfos interface board
A All LEDs on the control panel are off.
- Check +5 V and +24 V on the terminal blocks, see

installation and operating instructions in chapter 2.
1. Voltages are OK.
- Replace the Grundfos interface board.
2. Voltages are not OK.
- Check and make sure that the cable connecting
the Grundfos interface board to the control
board is properly fitted.
TM02 4556 1202

The cable is properly fitted.
- Proceed with Check 5: Control board.
Fig. 18 Position of interface board in the terminal box
B One or more of the LEDs on the control panel are on or

flashing.
- Check 24 V on the terminal blocks:
1. 24 V not measured. 8: +24 V
- Proceed with Check 5: Control board. 7: Sensor input
6: GND (frame)
2. 24 V are OK. 5: +5 V
4: Setpoint input
a. Communication to/from R100 or PC Tool MGE 3: GND (frame)
is NOT possible. 2: Start/stop
Group 1
1: Digital input
b. Communication to/from R100 or PC Tool MGE A: RS-485A
IS possible but there are still malfunctions. Y: Screen
B: RS-485B
There are still problems. NC
Group 2
- Proceed with Check 5: Control board . NO
C
TM02 1952 2601

Fault signal relay
Fig. 19 Interface board
Note:
After replacing the Grundfos interface board, download a new configuration file (gsc file) via the PC Tool E-products.
51 / 109
Check 9: Motor temperature sensor (PTC)
Check that the wire guard protecting the fan, the fan blades and the heat sink are free from dirt and objects obstructing the free
air flow.
Make sure the fan or fans can operate. Possibly go through Check 7: Fan.
A Disconnect the temperature sensor wires from the termi-

nals on the power board
B Measure the resistance in the temperature sensor
(It is assumed that the temperature in the temperature
sensor is within the motor temperature range).
1. The resistance measured is within the 20 - 2000 Ohm
range.
The temperature sensor is OK.
2. The resistance measured is
> 2000 Ohm or < 20 Ohm.
The temperature sensor is defective.
- Replace the motor
TM02 4558 1202

- Alternatively, short circuit the two motor temperature
sensor terminals.
Note: The motor might suffer a fatal burn-out! Fig. 20 Position of motor PTC in the terminal box
52 / 109
Check 11: Electronic temperature sensor (PTC)
Check that the wire guard protecting the fan, the fan blades and the heat sink are free from dirt and objects obstructing the free
air flow.
Make sure the fan or fans can operate. Possibly go through Check 7: Fan.
A Disconnect the temperature sensor wires from the

terminals on the power board marked "Electronics
temperature" in the photo.
B Measure the resistance in the temperature sensor
1. The resistance is within the 1 - 50 kOhm range.

The temperature sensor is OK.
2. The resistance is > 50 kOhm or < 1 kOhm

The temperature sensor is defective.
- Replace the temperature sensor.
- Alternatively, replace the control board.
TM02 4559 1202

Fig. 21 Position of the temperature sensor wires in the
terminal box
Note:
Resistance at approx. 20C = 15 kOhm
Resistance at approx. 55C = 3 kOhm
Resistance at approx. 80C = 1.5 kOhm
If the temperature exceeds 80C, the motor will stop and indicate fault.
53 / 109
Measure the voltage on the DC capacitors:

DC value calculation:
Mains voltage phase L1 - phase L2 x 1.41.
Example: 400 VAC x 1.41 = 564.
No voltage can be measured or voltage is below 500 VDC:
TM02 4557 1202

Check 3: Rectifier
Fig. 22 Position of DC capacitors in the terminal box
54 / 109
Checking the DC capacitors:

1. Remove the wires from DC+ and DC-.
2. Remove the connection between the capacitors.
3. Measure across each capacitor:
Values should be the following:
Resistance: R > 10 kOhm
Capacitance: C > 1000 F
If one or both values are out of range, replace the
capacitor.
TM02 4587 1302

Fig. 23 Position of DC capacitors in the terminal box
55 / 109
Set-up of control board after replacement
1. Control board type 1 (the original control board).
1. Set the motor to the correct kW size

2. Configure the motor to the relevant pump type
Ad 1: Set the motor to the correct kW size
Use the switch box service tool

1. Insert the flat-cable connector into connector X3 on
the control board.
2. Set the switch to the position corresponding to the
motor size:
Switch Motor size

position [kW]
0 11
1 15
2 18.5
TM02 4557 1202

3 22 Fig. 24 Position of connector X3 on the control board
3. Turn on mains supply again.

4. Wait for five seconds.
5. Turn off the mains supply.
6. Disconnect the switch box from X3.
Ad 2: Configure the motor to the relevant pump type

Use PC Tool E-products
2. Control board type 2

Control board type 2 is used since the end of 2003.
Control board type 2 is configured from factory and consequently does NOT have to be set or configured.
When ordering, please state the product number corresponding to the kW size of the motor. See WinCAPS or WebCAPS,
section Service parts.
56 / 109
Power board switch setting
The terminal box is available in two physical frame sizes:

frame size "small" covering 11 and 15 kW
frame size "large" covering 18.5 and 22 kW.
Consequently, it is possible to...

change an 11 kW controller into a 15 kW
controller and vice versa
change an 18.5 kW controller into a 22 kW
controller and vice versa.
Follow the procedures A, B and C below.
A: Power board switch setting of motor power size
Set the motor power size on the power board

switches S721 and S701.
Note: Give both switches the same setting!

Set the mains voltage on the power board switch
S601.
TM02 4588 1302

Fig. 25 Power board switches (S601, S701, S721)
Examples of power board switch settings:
Setting for 22 kW Setting for 11 kW
22 ON 22 OFF
18.5 OFF 18.5 OFF
S721 S721
15 OFF 15 OFF
11 OFF 11 ON
22 ON 22 OFF
18.5 OFF 18.5 OFF
S701 S701
15 OFF 15 OFF
11 OFF 11 ON
OFF OFF
S601 S601
OFF OFF
B: Adapt the control board to the chosen power size, see Set-up of control board after replacement.
C: Download the Grundfos configuration file by means of PC Tool E-products and set up according to the pump application.
57 / 109
1.5.5 Dismantling and assembly of terminal box components
Dismantling and assembly of terminal box components consists of ten different procedures which are all explained in the follow-
ing.
1. Grundfos interface unit
2. Control board
3. Baseplate for control board
4. Power board
5. Baseplate for power board
6. Rectifier
7. IPM module
8. Relay K1 (inrush relay)
9. Resistor R1 (inrush)
10. Capacitors
58 / 109
1. Grundfos interface unit
The Grundfos interface unit is an integrated part of the complete terminal box cover.
Dismantling: Assembly:
1. Lift the flat cable out of the cable relief. 1. Fit the two screws for fastening the interface unit.
2. Carefully pull the flat-cable plug straight out of the socket. 2. Carefully press the flat-cable plug home into the socket.
3. Remove the interface unit and remove the two screws Note: The flat-cable positioning pins must fit into the slots
from the terminal box frame. of the cable relief.
TM02 4589 1302

Fig. 26 Grundfos interface unit
59 / 109
2. Control board
The control board was changed at the end of 2003. So there are now two control boards:
Control board type 1 (the original control board)
Control board type 2 (used after the end of 2003).
The difference between the two control boards can be seen in the illustration below.
Control board type 1: Control board type 2:
TM02 8507 0304

Fig. 27 Control board type 1 and control board type 2
Consequently, when the control board needs to be replaced, you can have three different situations:
A: Replacement of control board type 1 with control board type 1
B: Replacement of control board type 1 with control board type 2
C: Replacement of control board type 2 with control board type 2.
60 / 109
2A Replacement of control board type 1 with control board type 1
1. Remove 1. Place the new control board in the plastic fixing

- three flat-cable plugs from the board holes.
- five plastic screws (rings) 2. Fit
- one hexagon socket head screw (triangle). - one hexagon socket head screw (triangle)
- five plastic screws (rings)
2. Remove the board.
- three flat-cable plugs, mind the positioning pins!
TM02 4590 1302

Fig. 28 Position of plastic screws for removal of the control board type 1
61 / 109
2B Replacement of control board type 1 with control board type 2
1. Remove control board type 1. See 2A Replacement of control board type 1 with control board type 1.
2. Remove the baseplate for control board. See 3. Baseplate for control board.
3. Move the existing metal spacer and three black plastic spacers M3 x 10 as shown in the illustration below.
Note: Remove one cable clip that covers a tapping.
4. Fit new plastic spacers (two white ones and a black one M4 x 10) as shown in the illustration below. New spacers are sup-
plied with the new control board.
TM02 8508 0304

Fig. 29 Spacers to remove to dismantle the control board
5. Fit the baseplate for control board. See 3. Baseplate for control board.
6. Fit control board type 2 as shown in the illustration on the following page by means of
- three plastic screws M3 x 6 (rings)
- one plastic screw M4 x 6 (square)
- one hexagon socket head screw (triangle).
TM02 8509 0304
Fig. 30 Screws for the control board
62 / 109
2C Replacement of control board type 2 with control board type 2
1. Remove ... 1. Place the new control board as shown in the illustration
- three flat cables from the board below.
- three plastic screws (rings) 2. Fit ...
- one plastic screw (square) - one hexagon socket head screw (triangle)
- one hexagon socket head screw (triangle). - one plastic screw (square)
- three plastic screws (rings)
2. Remove the board.
- three flat cables, mind the positioning pins!
TM02 8509 0304

63 / 109
3. Baseplate for control board
Condition: The control board must be removed first.
1. Remove 1. Before placing the baseplate, carefully pull the flat cables
from the power board out through the slot in the baseplate.
- four plastic screws (rings)
- two hexagon socket head screws (triangles).
2. Remove the baseplate. Be careful not to damage the flat 2. Fit
cables from the power board. - two hexagon socket head screws (triangles)
- four plastic screws (rings).
3. Place the flat cables in the guides.
TM02 4591 1302

64 / 109
4. Power board
Condition: The control board and the baseplate for the control board must be removed first.
1. Remove 1. Switch the multiple plug to the new power board.

- the two flat-cable plugs (cannot be mistaken) 2. Carefully place the new power board while at the same
- the two wires to the temperature sensor, pos. 2 time guiding the multiple plug to its position in the IPM
- the two wires to relay K1, pos. 3 module.
- the fan wires, pos. 4 3. Fit
- the small black plug, pos. 5
- the four plastic spacers (squares)
- the big black 6-poled plug, pos. 6
- the two hexagon socket head screws (triangles)
- the 3-poled plug, pos. 7.
- the nine plastic screws (rings).
2. Mark the three motor wires passing over the power print 4. Fit the three motor wires according to their markings.
and note which of them is passing through the current Pass two of the wires through the current transformers,
transformers. see photo below.
3. Dismantle the wires from the motor terminal block, pos. 8, 5. Fit
and pull the wires back through the current transformers.
- the 3-poled plug, pos. 7
4. Remove - the big black 6-poled plug, pos. 6
- the nine plastic screws (rings) - the small black plug, pos. 5
- the two hexagon socket head screws (triangles) - the fan wires, pos. 4
- the four plastic spacers (squares). - the two wires to relay K1, pos. 3
- the two wires to the temperature sensor, pos. 2
- the two flat-cable plugs (cannot be mistaken).
5. Leave the big multiple plug in the middle of the power
board.
Note: The multiple plug is connected to the IPM module
below the baseplate by means of a plug.
6. Carefully remove the power board from its position and the
multiple plug from its socket.
TM02 4592 1302
Fig. 33 Screws for the power board
65 / 109
5. Baseplate for power board
Condition: The control board and its baseplate must be removed first.
1. Remove 1. Carefully place the new baseplate.

- three hexagon socket head screws (triangles). 2. Fit
2. Remove the baseplate. - three hexagon socket head screws (triangles).
TM02 4593 1302

Fig. 34 Screws for the baseplate
66 / 109
6. Rectifier
Conditions: The control board and its baseplate must be removed first.
The power board and its baseplate must be removed first.
1. Mark the positions of the wires on the rectifier as well as 1. Make sure the aluminium plate underneath the rectifier is
the orientation of the rectifier. clean.
2. Remove the wires and the bridge connector. 2. Place the new rectifier in correct position. Refer to photo
and note the orientation. Tighten the two hexagon socket
head screws firmly.
3. Remove the two hexagon socket head screws and remove 3. Fit the wires and the bridge connector according to the
the rectifier. marking.
TM02 4594 1302

Fig. 35 Position of rectifier
67 / 109
7. IPM module
1. Mark the positions of the wires on the module as well as 1. Make sure the aluminium plate underneath the module is
the orientation of the module. clean.
2. Remove wires and connecting bars. 2. Place the new IPM module in correct position.
Refer to photo and note the orientation. Tighten the four
hexagon socket head screws firmly.
3. Remove the four hexagon socket head screws in the 3. Fit wires and connecting bars according to the marking.
power board.
4. Remove the IPM module.
TM02 4595 1302
Fig. 36 Position of IPM module
68 / 109
8. Relay K1 (inrush relay)
Conditions: The terminal block for the motor terminals must be removed first.
1. Remove wires from the relay terminals A1 and A2. 1. Fit the connecting bar on terminals L1, L2, L3 and L4 of the
new relay.
2. Mark and remove the wires from the connecting bars of the
main contacts. 2. Place the new relay in correct position.
3. Remove the connecting bar from terminals T1, T2, T3 and 3. Fit the two fastening screws.
T4.
4. Fit the connecting bar on terminals T1, T2, T3 and T4 of the
4. Remove the two fastening screws. new relay.
5. Remove the relay. 5. Fit the wires on the relay according to the marking.
6. Remove the connecting bar from terminals L1, L2, L3 and
L4.
TM02 4596 1302
Fig. 37 Relay K1 (Inrush relay)
69 / 109
9. Resistor R1 (inrush)
Condition: The terminal block for the motor terminals must be removed first.
1. Remove the motor terminal block. 1. Place new inrush resistor R1 in its correct position.
2. Remove the two spade terminals - push off by means 2. Re-fit the mains terminals. Tighten the screws at both ends
of a large screwdriver. of the resistor firmly.
3. Remove the screw under the spade terminals. 3. Re-fit the two spade terminals.
4. Loosen the screw at the opposite end of the resistor. 4. Re-fit the motor terminal block.
Possibly remove the mains terminals.
5. Remove the inrush resistor R1.
TM02 4596 1302
TM02 4597 1302

Fig. 38 Relay K1 (Inrush relay) Fig. 39 Resistor R1 (Inrush)
70 / 109
10. Capacitors
1. Remove terminal block for motor, incl. DIN rail. 1. Fit the new capacitors to the common baseplate.
2. Remove terminal block for mains supply, incl. DIN rail. 2. Fit capacitors and baseplate to the bottom of the terminal
box.
3. Remove the bridge connector to IPM module. 3. Refit the various wires correctly to the capacitors.
4. Remove the remaining wires from the capacitors. 4. Refit the bridge connector to the IPM module.
5. Remove the three nuts from the baseplate under the 5. Refit the terminal blocks for motor and mains supply incl.
capacitors. their DIN rails.
6. Remove the capacitors and their common baseplate.
7. Note the polarity of the capacitors (+).
8. Remove the capacitors from the baseplate.
TM02 4598 1302
TM02 4557 1202

Fig. 40 Polarity of the capacitors Fig. 41 Position of capacitors in the terminal box
71 / 109
1.5.6 Diagrams
Control board type 1
+5 VDC +24 VDC -15 VDC +15 VDC
TP1
TM02 4573 1202
72 / 109
Control board type 2
+5 VDC +24 VDC
TP1
+15 VDC
-15 VDC
TM02 8510 0304
73 / 109
U4
Wiring diagram
EMODR I VE X6 X6
U1 X8
4, 5 X7 X7 F D U C ONT ROL BOA RD
sc r e w
PO WER BRD
s c r ew
s c r ew X1 X2 X3 X5 X4 C
SMP S
C
X1 2
X1 : B1
X1 : B2
X1 : B3
X1 : A1
X1 : A3
X5 : 1
X5 : 2
X3 : 1 ( + )
X3 : 2 ( - )
X4 : 1 ( A1 )
X4 : 2 ( A2 )
X2 : 3
X2 : 2
X2 : 1
X9 : 1
X9 : 2
X8 : 1 - 2 5
GN D
GN D
U2 X
r ed
r ed
bl u e
+ A1
GR UN DF O S
bl a c k
USE RI N T ER F A CE
E1 K1
- A2
R2
P T C1
P T C2
1
K12
3. 6 /
3. 6 /
3 4
5 6
R1 DC+ DC+ P
Fig. 44 Wiring diagram of the terminal box

1 2
L1
C1 C3
-
~ XXX Xu 10 0N
1 kV
~ - / +
C5
~ 3 30n F
1 kV
74 / 109
+
C2 C4
-
XXX Xu 10 0N CT R 1/ 1 6
1 kV
-
V02
DC- DC- N
E B U V W
U5 V0 1
I N VER T ER I PM
AS SEMBL Y T2
3. 4
3. 4
U4
+ M -
( PA RT OF T1
PT C 1 /
PT C 2 /
S MPS P WBR D)
+ M - 4 5 6
R
X1 L1 L2 L3 PE MOT OR
P TC X2 U V W E
MAI NS VO L T A GE MO T O R
TM02 4574 1202

Power board
F101
N1 02
+5 VDC
+15 VDC
-15 VDC
+24 VDC
TM02 4575 3702
Fig. 45 Power board
75 / 109
1.6 Fault correction, three phase E-pumps, 11-22 kWmodel F
The operational state of the motor incl. possible faults can be read via the indicator lights on the control panel.
If an R100 remote control is available, we recommend you to start fault finding via the R100 fault code.
See section 1.6.1 Fault finding using alarm and warning codes .
In case of certain faults in the electronics, the indicator lights on the control panel may indicate
differently from the indicator lights on the control board. In these cases, the indicator lights on
the control board indicate the current operating and alarm condition.
Indicator lights
Condition/cause Remedy
Green Red
On On Normal operation + indication of previous fault

1. The pump is running at a) Has the power supply to the standby pump been switched off?
normal performance. YES: Re-establish the power supply.
The pump's duty/ NO: Proceed to point b).
standby function has
b) Has the communication cable been disconnected?
been activated, but
there is no YES: Check the communication cable.
NO: Contact Grundfos Service.
communication with the
standby pump.
2. The pump is running at a) Does the sensor setting correspond to the sensor type installed?
maximum speed. (0-10 V, 0-20 mA, 4-20 mA)
The sensor signal is
outside the set signal
range.
NO: Correct the setting using the R100.

YES: Proceed to point b).
b) Is the voltage to the sensor connection 24 VDC?
TM04 2072 1908 TM02 1606 1601

8: +24V
9: GND
12: ANALOG OUTPUT

0/4-20mA
0-10V
13: GND
14: SENSOR INPUT 2
15: +24V (2)
16: GND
NO: Replace the I/O module.

YES: Proceed to point c).
c) Is the sensor signal
below 10 V (type 0-10 V sensor)?
below 20 mA (type 0-20 mA sensor)?
between 4 and 20 mA (type 4-20 mA sensor)?
TM04 2072 1908 TM02 1604 1601
0-10V
+OUT
OUT
7: SENSOR INPUT
0/4-20mA + 4-20mA
-
8: +24V
9: GND
12: ANALOG OUTPUT

0/4-20mA
0-10V
13: GND
14: SENSOR INPUT 2
15: +24V (2)
16: GND

YES: Proceed to point d).
d) Has the sensor been connected correctly, and does the sensor
signal correspond to the system pressure?
YES: Replace the I/O module or the terminal box.
If the sensor is defective, replace it.
[To be continued on the next page]
76 / 109
Indicator lights
Green Red
On On 3. The pump is running at a) Set the pump to "open loop" operation, and connect 10 V supply to
minimum speed. the setpoint input.
The setpoint signal is Does the pump switch to maximum speed?
outside the set signal NO: Proceed to point b).
range. YES: The pump is OK.
b) Does the setpoint setting correspond to the setpoint type
installed?
(0-10 V, 0-20 mA, 4-20 mA)

c) Is the voltage to the setpoint connection 10 VDC?
TM02 1607 1601

4: SETPOINT
0/4-20mA 0-10V
+ 10K 5: +10V
-
6: GND

d) Is the setpoint signal
below 10 V (type 0-10 V sensor)?
below 20 mA (type 0-20 mA sensor)?
between 4 and 20 mA (type 4-20 mA sensor)?
NO: Check for fault in the external setpoint signal.
YES: Re-establish the correct setpoint signal, if necessary.
If the pump still does not run correctly, replace the
terminal box.
77 / 109
Indicator lights
Green Red
On Off Normal operation

1. The pump is running.
Normal operational
state.
On Off 2. The pump is not running. a) The flow switch is closed.
Operational stop which
may be caused by
the flow switch
connected
the pump stop function.
The connection of a flow switch depends on the MGE functional

modules. See the wiring diagrams in figs 8 to 11.
Is there 5 VDC across terminals 1-9?
(If an extended I/O module is installed, the flow switch may be
connected to DI3 (terminals 9-10) or DI4 (terminals 9-11)).
NO: Flow switch closed = Pump is not supposed to run.
YES: Flow switch open = Pump must be running.
If the flow switch is defective, replace it.
Does the pump start when the connection between the flow switch
terminals is cut?
NO: Replace the I/O module.
YES: The digital input is OK.
The flow switch is defective. Replace it.
b) The stop function has stopped the pump.
Does the pump start when you increase the flow and/or reduce the
pressure in the system?
NO: If the sensor is OK, replace the terminal box.
YES: The input is OK.
78 / 109
Indicator lights
Green Red
On Off 3. The pump is running at a) Has the correct setpoint type been set in the motor?
unexpectedly high or low (0-10 V, 0-20 mA, 4-20 mA)
speed.
Can be caused by fault
in installation, setting or
signal from setpoint/
sensor or that the
sensor input has been
set to "active".

b) Has the external setpoint signal from potentiometer or external
controller been connected correctly?
TM02 1606 1601

4: SETPOINT
0/4-20mA 0-10V
+ 10K 5: +10V
-
6: GND
NO: Connect the setpoint signal correctly.

c) Has the correct sensor type been set in the motor?
(0-10 V, 0-20 mA, 4-20 mA)

d) Has the sensor been connected correctly, and does the sensor
signal correspond to the system pressure?
TM04 2072 1908 TM02 1604 0601

0-10V
+OUT
OUT
7: SENSOR INPUT
0/4-20mA + 4-20mA
-
8: +24V
9: GND
G U
12: ANALOG OUTPUT
0/4-20mA
0-10V
13: GND
14: SENSOR INPUT 2
15: +24V (2)
16: GND

YES: If the pump does not run correctly, replace the I/O module
or the terminal box.
If the sensor is defective, replace it.
Off Off The pump is not running
1. The power supply to the Re-establish correct power supply.
motor has been cut.
2. The control panel or one Switch off the power supply. Then remove the control panel and the
of the functional modules functional modules, one at a time, and switch on the power supply every
is defective. time a component has been removed. When the fault has disappeared
after switching on the power supply, the defective component has been
localised and can be replaced.
3. The terminal box is Replace the terminal box, or contact Grundfos Service.
defective.
79 / 109
Indicator lights
Green Red
Off On The pump has stopped due to a fault

The pump has been stopped See the fault indication on the R100 or
due to one of the following PC Tool E-products.
causes:
1. The pump is blocked or Remove the blockage, or reduce the load.
overloaded.
2. The ambient temperature Re-establish sufficient cooling.
is too high, or the cooling
is insufficient.
3. Power supply fault: Check that the supply voltage is within the stated voltage range.
undervoltage If not, re-establish correct power supply.
overvoltage
phase failure
mains supply failure.
4. External fault. a) Has the R100 been set to external fault?

b) Can 5 VDC be measured across terminals 1-9?
TTM02 1605 0601

9: GND
NO: Contact between terminals 1 and 9 is closed.

Seek the cause of fault in external signal transmitter.
YES: Contact between terminals 1 and 9 is open.
The E-pump is OK. Proceed to the next fault possibility.
5. Other faults:
wrong terminal box Replace the terminal box.
wrong configuration Reconfigure the terminal box.
fatal fault. Replace the terminal box.
Flashing, Off Normal operational stop
1 Hz
The pump has been stopped
with the button
with the R100
using the Grundfos GENIbus
by the motor start/stop function. (Input on terminal 2-3 is open).
Flashing, On Normal operational stop + indication of previous fault
1 Hz
The pump has been stopped
with the button
with the R100
using the Grundfos GENIbus
by the motor start/stop function, but was previously stopped
due to a fault which has now disappeared.
Flashing, On The pump has been stopped due to a fault in the product
5 Hz
Pump is not running and Try resetting the fault by
communication with the disconnecting the power supply.
R100 is not possible. waiting until all diodes are off.
no reaction when you re-establishing the power supply.
press or .
fatal internal
communication fault in the
pump.
If this does not remedy the fault, the terminal box is defective. Replace
the terminal box.
80 / 109
1.6.1 Fault finding using alarm and warning codes
Apart from being indicated by the indicator lights on the control panel, alarms, warnings and their fault codes can be
read using the R100.
1.6.2 Alarm and warning list
The list below gives you an overview of the possible alarms and warnings and a description of their causes and
suggestions for remedy.
These abbreviations are used in the column "Fault type":
W: Warning.
A: Alarm.
1): The alarm can be configured to Warn/Max/Min/Stop/User using the PC Tool E-products.
Fault code Fault reading in the R100 Fault reading in PC Tool E-products Fault type
Explanation/cause Remedy
3 External fault External fault signal A

The digital input set for "External fault" was or is When the digital input is no longer closed, the fault indication can be reset
closed (terminal 1, 10 or 11). either with the R100 or by pressing or .
4 Too many restarts Too many restarts (from standby mode per 24 hours) A
The number of attempted restarts at 10-second Seek the cause under the fault log code numbers in the R100.
intervals after a fault has exceeded four within The pump will automatically attempt to restart after 24 hours.
one minute. The fault indication can be reset either with the R100 or by
The number of attempted restarts at five-minute pressing or .
intervals after a fault has exceeded 16 within
24 hours.
30 Replace motor bearings Motor bearings need change (service information) W
The motor has reached the number of operating hours Replace the bearings. See section 4.2 Replacement of motor bearings.
for the bearing service life that is stated in the
configuration.
31 Replace varistor Motor varistor(s) need change (service information) W
The varistor has been exposed to the allowable Contact Grundfos Service.
number of transients and needs replacing.
32 Overvoltage Overvoltage A
The supply voltage has been or is too high. Reduce the voltage to the specified level (see the nameplate).
40 Undervoltage Undervoltage A
The supply voltage has been or is too low. Increase the voltage to the specified level (see the nameplate).
41 Undervoltage Undervoltage transient A
There has been a voltage drop in the supply voltage
caused by one of the following:
Supply cable too small.
Another big user is supplied from the same
panel.
45 Mains voltage asymmetry Voltage asymmetry A
The supply voltage has been or is asymmetric. Check the supply voltage while the motor is loaded.
49 Overload Overcurrent (i_line, i_dc, i_mo) A
The terminal box or the motor is heavily overloaded.
Cause:
Incorrect configuration of the terminal box. Contact Grundfos Service.
Wrong terminal box. Contact Grundfos Service.
Fault in stator windings. Contact Grundfos Service.
Power supply failure (phase failure). Re-establish correct power supply.
51 Overload Blocked motor/pump A
The pump is blocked during start-up which causes Remove the blockage.
a heavy overload. The input current is very high;
the motor P > 120 % for 60 seconds.
81 / 109
55 Overload Motor current protection activated (MCP) A

The built-in motor-current protection function has
registered a continued overload of more than 125 % of
rated current for 60 seconds.
Cause:
Continued overload. Reduce the load by limiting the pump flow.
56 Underload Underload A
The motor is underloaded.
Cause:
Incorrect configuration of the terminal box. Check the settings of the terminal box.
The pump has run dry. Make sure that all valves in the piping system are open and that there
is water in the piping system.
57 Dry running Dry running A
The pump has run dry. Make sure that all valves in the piping system are open and that there is
water in the piping system.
65 Too high motor temperature Motor temperature A
The temperature sensor in the motor has measured a
too high winding temperature.
Cause:
Dust and dirt in the cooling fins. Clean the cooling fins.
Too high ambient temperature. Improve the cooling.
73 Undervoltage Hardware shutdown (HSD) A
The current limit of the electronic module has been
exceeded.
Cause:
Terminal box defective. Contact Grundfos Service.
77 Duty/standby, Communication fault Twin pump communication fault W
Communication between the two pumps which have
been set to duty/standby function has been
interrupted.
Cause:
Power supply to standby pump has been cut. Re-establish the power supply.
Communication module defective. Replace communication module.
85 Other fault Freq. conv. parameter verification error (EEPROM) A
The EEPROM has lost its contents. Contact Grundfos Service.
General sensor signal fault / feedback sensor signal
88 Sensor 1 signal outside signal range 1)
fault
Sensor signal type 4-20 mA: signal below 2 mA or
above 22 mA.
Sensor signal type 0-20 mA: signal above 22 mA.
Sensor signal type 0-10 V: signal above 11 V.
Signal range set incorrectly. Correct the signal range setting.
Sensor incorrectly connected. Connect the sensor correctly.
Incorrect power supply to sensor. Check the power supply from the terminal box. If it is not 24 V 1 V,
Sensor cable defective. Check the sensor cable.
Temperature sensor 1 signal outside
91 Temperature sensor 1 signal fault 1)
signal range
The sensor signal has been short-circuited or cut. Replace the temperature sensor.
93 Sensor 2 signal outside signal range Sensor 2 signal fault 1)
Same as fault 88. Same as fault 88.
82 / 109
96 Setpoint signal outside signal range Reference input signal fault 1)

Sensor signal type 4-20 mA: signal below 2 mA or
above 22 mA.
Sensor signal type 0-20 mA: signal above 22 mA.
Sensor signal type 0-10 V: signal above 11 V.
Signal range set incorrectly. Correct the signal range setting.
Setpoint signal incorrectly connected. Connect the setpoint signal correctly.
Incorrect supply voltage to the setpoint. Check the supply voltage from the terminal box. If it is not 10 V,
105 Overload Electronic rectifier protection activated (ERP) A
The electronic module/motor is heavily overloaded,
and the temperature of the electronics is above
100 C.
The measured temperature can be read via PC Tool
E-products.
Cause:
Temperature sensor defective. Contact Grundfos Service.
The ambient temperature is too high, or Improve the cooling.
the cooling is insufficient.
106 Overload Electronic inverter protection activated (EIP) A
The electronic module/motor is heavily overloaded,
and the temperature of the electronics is above
100 C.
The measured temperature can be read via PC Tool
E-products.
Cause:
Temperature sensor defective. Contact Grundfos Service.
The ambient temperature is too high, or Improve the cooling.
the cooling is insufficient.
Motor drive-end (DE) bearing temp. warning limit W
148 DE bearing temperature high
Motor drive-end (DE) bearing temp. alarm limit A
The drive-end motor bearing has become too hot.
Cause:
The bearing is worn. Replace the bearing. See section 4.2 Replacement of motor bearings.
The motor is dirty. Check and clean, if necessary,
the fan
the motor cooling fins.
Motor non-drive-end (NDE) bearing temp. warn. limit W
149 NDE bearing temperature high
Motor non-drive-end (NDE) bearing temp. alarm limit A
The non-drive-end motor bearing has become too hot.
Cause:
The bearing is worn. Replace the bearing. See section 4.2 Replacement of motor bearings.
The motor is dirty. Check and clean, if necessary,
the fan
the motor cooling fins.
155 Undervoltage Inrush fault A
The terminal box voltage is outside the alarm limit.
Cause:
Fault in the voltage supply. Re-establish the voltage supply.
Transients in the voltage supply during Contact Grundfos Service.
operation.
83 / 109
156 Other fault Internal communication failure in frequency converter A

Internal communication fault in the pump due to defect Contact Grundfos Service.
in the terminal box.
Temperature sensor 2 signal outside
175 Temperature sensor 2 signal fault 1)
signal range
Same as fault 91. Same as fault 91.
190 Limit 1 exceeded Limit 1 exceeded
1)
191 Limit 2 exceeded Limit 2 exceeded
This is a monitoring function offering information, The function can be set to monitor
alarm or warning if a low or high limit is exceeded. sensor 1 or 2
The function can only be set with the PC Tool Pt100 sensor 1 or 2
E-products. external setpoint
the feedback signal.
The limit set has been exceeded either upwards or Procedure:
downwards. 1. Using PC Tool E-products, check which function is being monitored.
2. Check in the pump system whether the alarm or warning is real. If it is
real, remedy the fault.
3. If the alarm or warning seems to be wrong for the pump system,
troubleshoot according to the selected sensor using these service
instructions.
240 Relubricate motor bearings Motor bearings need lubrication (service information) W
The motor has reached the number of operating hours Lubricate the bearings. See section 4.1 Lubrication of motor bearings.
stated in the configuration for the bearing lubrication.
84 / 109
1.7 Fault correction, three-phase E-pumps, 0.55 - 7.5 kW model G
TM03 0200 4504

This fault correction procedure is based on indications from the two indicator lights in the terminal box and/or on the control
panel. For position of the indicator lights, see figures below.
Green
Red
TM02 9036 1504
TM02 8513 0304
TM03 0204 4504

Green Red
Green Red
Position of indicator lights in the terminal box Control panel of CRE with and Control panel of TPE/TPED
without sensor, TPE/TPED Series 2000
Series 1000, NKE and NBE
The following two pages give a complete overview of the possible indicator light combinations. Remedy for some of the situa-
tions is further elaborated on the next pages (D1, D2, E1, F1, F2).
indicator light is flashing 5 times

=
per second
Indicator lights
Green Red
Power off
off.
Possibly faulty component in the

terminal box. Replace terminal box
Normal operation
1. Pump is running. Normal operational state.
- the stop function in the pump. See D1
unexpectedly high or setting, signal from setpoint/sensor
low speed. or sensor input is set to active. See D2
85 / 109
Indicator lights
Green Red

via R100
Fault
Pump is not running. Pump has been stopped due to: See fault reading in R100 or PC Tool
E-products.
1. Pump blocked or overloaded Remove blockage/reduce load.
2. Ambient temperature too high or
cooling insufficient Re-establish sufficient cooling.
3. Voltage supply fault:
- undervoltage Check that the mains supply is within
- overvoltage the voltage range stated on the
- phase failure nameplate. If not, re-establish correct
- mains supply fault. voltage supply.
4. External fault See E1
5. Other faults:
- wrong terminal box - replace the terminal box
- wrong configuration - reconfigure the terminal box
- fatal fault. - replace terminal box.
Fault
- Pump is not running; Fatal internal communication error in Try to reset the fault by
- communication with the pump. 1. Cutting off the supply voltage.
R100 is not possible; 2. Waiting till all diodes are out.
- no reaction when you
3. Cutting in the supply voltage
press the operating again.
buttons or .
1. Pump running at Communication error duty/standby. See fault code 77 1.4.2 Fault read-
normal performance. Duty/standby function of pump is ings via R100 fault log or PC Tool E-
activated, but no communication with products
the standby pump.
speed. signa range. See F1
speed. signal range. See F2
by means of operating button " "
via R100
previously due to a fault.
86 / 109
SUPPLY:
L1 L2 L3
96086116
SEE NAMEPLATE
FOR FURTHER DATA
A:RS485 A
Y:SHIELD
NC C NO
SIGNAL RELAY:
B:RS485 B
Max:250V/2A AC1
Min: DC 5V/1mA
0-10V STOP
+OUT
+ OUT 7: SENSOR INPUT

0/4-20mA 4-20mA 2: RUN/STOP
-
8: +24V RUN
3: GND
9: GND
0-10V
4: SETPOINT
0/1 +
5: +10V
TM03 0269 4604

- 10K
GRUNDFOS SENSOR
CONNECTION
D1

- NOT 5 VDC across terminals 1-9 = flow switch contact is
closed = pump is not running.
- 5 VDC across terminals 1-9 = flow switch contact is open =
pump is running.
Check that the digital input works correctly by cutting the

connection between terminals 1 and 9.
or YES: Input is OK.
NO: Replace the pump I/O-module.
YES: Input is OK.
87 / 109
D2
Check/ 1. Is the correct setpoint type set in the motor?

Remedy (0-10 V, 0-20 mA, 4-20 mA)

2. Is the external setpoint signal from
TM02 1606 1601

potentiometer or external controller connected 4: SETPOINT
0/4-20mA 0-10V
correctly? + 10K 5: +10V
-
NO: Connect the setpoint signal correctly. 6: GND
(0-10 V, 0-20 mA, 4-20 mA)


pressure? +OUT 0-10V
OUT
7: SENSOR INPUT
TM02 1604 0601

0/4-20mA + 4-20mA
-
8: +24V
YES: If the pump does not run correctly, 9: GND

replace the pump I/O-module or the
terminal box.
E1
Check/ 1. Is R100 set to external fault?

remedy

2. Can 5 VDC be measured across terminals 1 -

9?
NO: Contact between terminals 1 and 9 is
closed. Seek cause of fault in exter- 9: GND
nal signal transmitter.
TM02 1605 0601

YES: Contact between terminals 1 and 9 is
open. E-pump is OK. Proceed to next
fault possibility in the list.
88 / 109
F1
Description Pump is running at max. speed (and it was not set to max. manually by means of the -button!).
Check/ 1. Does the sensor setting correspond to the sensor

remedy type installed? (0-10 V, 0-20 mA, 4-20 mA)

2. Is the voltage to the sensor connection 24 VDC?
TM02 1604 1601 TM02 1606 1601

8: +24V

- below 20 mA (Type 0-20 mA sensor), 0-10V
+OUT
OUT
- between 4 and 20 mA (Type 4-20 mA sensor)? 7: SENSOR INPUT
0/4-20mA + 4-20mA
-
8: +24V
9: GND
pressure?
See diagram above.
YES: If the pump does not run correctly, re-

place the pump I/O-module or the ter-
minal box.
89 / 109
F2
Check/ 1. Set the pump to "open loop" operation and

remedy connect 10 V supply voltage to the setpoint
input.
2. Does the setpoint setting correspond to the set-
point type installed? (0-10 V, 0-20 mA, 4-20 mA)

TM02 1607 1601

10 VDC? 4: SETPOINT
0/4-20mA 0-10V
+ 10K 5: +10V
-
6: GND

NO: Check for fault in the external setpoint
See diagram above.
signal. Re-establish correct setpoint
signal, if necessary.

90 / 109

Fault reading
E-products
3 External fault External fault The digital input set to external fault has The fault reading can be reset when the
been or is still closed. (terminal 1). digital input is no longer closed either by
means of R100 or by pressing or .
4 Too many Too many The number of attempted restarts at Seek the cause under the fault log code
restarts restarts 10-second intervals after a fault has numbers succeeding code 4 in this table.
exceeded 4 within 1 minute. The pump will automatically attempt
After this the number of attempted restart after 24 hours.
restarts at 5-minute intervals after a The fault reading can be reset either by
fault has exceeded 16 within 24 hours. means of R100 or by pressing or .
30 Replace mo- Motor bear- The motor has reached the number of Replace the bearings. See section 4.2
tor bearings ings need operating hours for the bearing service Replacement of bearings.
change lifethat is stated in the configuration.
32 Overvoltage Overvoltage Voltage has exceeded the upper DC
Mains voltage supply has been or is Bring the supply voltage down to the
too high. prescribed level (see nameplate).
40 Undervoltage Undervoltage Voltage has fallen below the lower DC
Mains voltage supply has been or is Bring the supply voltage up to the pre-
too low. scribed level (see nameplate).
45 Mains volt- Voltage The supply voltage has been or is Check the supplyvoltage whilethe motor
age asym- asymmetry asymmetric is loaded.
metry
49 Overload Overload The terminal box/motor very heavily over-
loaded. Cause:
Wrong terminal box. Replace terminal box.
Mains supply failure (phase failure). Re-establish correct mains supply.
51 Overload Overcurrent The pump is blocked during start-up Remove the blockage.
(i_line, i_dc, which causes a heavy overload. The
i_mo) input current is very high: the motor P
> 120 % for 60 secunds.
55 Overload Motor current The built-in motor current protection has
protection detected a continued overload of more
than 125% of rated current for 60
seconds. Cause:
91 / 109
Fault reading
Code Grundfos
E-products
56 Underload Underload The motor is underloaded. Cause:
Incirrect configuration of the terminal Check the setting at the terminal box.
box. Make sure that all valves in the piping
The pump has run dry. system are open and that there is water
in the piping system.
57 Dry running Dry running the pump has run dry Make sure that all valves in the piping
system are open and that there is water
in the piping system.
65 Too high Motor The temperature sensor in the motor has
motor temperature measured too high winding temperature
temperature protection (above 160C).
Cause:
Too high ambient temperature Improve cooling
PTC defective. Replace complete MGE motor.
shutdown exceeded.
Cause:
76 Other fault Internal com- Internal communication error has Try to reset the fault by
munication occurred in the pump. 1. Cutting off the supply voltage.
error 2. Waiting till all diodes are out.
If this does not remedy the fault, replace
the terminal box.
77 Communica- Duty/standby Communication between the two pumps
tion error communica- set up for duty/standby function has been
duty/standby tion error cut.
Voltage supply to standby pump has Re-establish voltage supply.
been cut.
ble EEP-
ROM fault
Signal above 22 mA.
Signal above 11 V.
If it is not 24 V +/ 1 V, replace the
terminal box.
Sensor cable defective. Check the cable.
Signal above 22 mA.
Signal above 11 V.
92 / 109
Fault reading
Code Grundfos
E-products
rectifier pro- overloaded and the electronics
tection temperature is above 100C.
Cause:
Ambient temperature too high/cooling Improve cooling.
insufficient.
inverter overloaded and the electronics
protection temperature is above 100C.
Cause:
Ambient temperature too high/cooling
insufficient. Improve cooling.
155 Undervoltage Undervoltage Voltage limit of terminal box exceeded.
Mains supply failure. Re-establish mains supply.
Transients in the mains during
operation. Check the mains supply.
156 Other fault Hardware Internal communication error in the Terminal box defective.
shutdown pump. Replace the terminal box.
255 - Unknown The PC Tool E-products has received an Update the PC Tool E-products to the
unknown fault signal. latest version.
93 / 109
1.7.3 How to use PC Tool E-products on two pumps running duty/standby
The duty/standby function in E-pumps is set by means of R100. Before you start using PC Tool E-products on faulty E-pumps
you have to do this:
1. Contact one of the pumps by means of R100, set Duty/Standby to Not Active, see CRE, CRIE, CRNE, CRKE, SPKE,
MTRE, CHIE with and without sensor, menu INSTALLATION. The duty/standby function has now been cancelled.
2. Connect PC Tool E-products to the service port of the pump you want to communicate with.
3. Make the necessary service settings via PC Tool E-products.
4. Disconnect PC Tool E-products from the service port.
5. Contact one of the pumps by means of R100, set Duty/Standby to Active. The duty/standby function has now been set
again.
Note: It is important that you cancel the duty/standby function before you start on the abovementioned procedure. Otherwise
you may have one of the two fault situations described below.
The reason for this is that the two pumps communicate with each other via a GENIbus connection, and one pump is master and
the other pump is slave. This master-slave relation will make them react differently when you connect PC Tool E-products. You
cannot know in advance which of the two pumps is master and which is slave.
Fault situation 1:
If you connect PC Tool E-products to the master pump, you will see the following reactions:

Slave pump Fault indication
PC Tool E-products Unable to get Master status on GENIbus
1. PC Tool E-products will not be able to establish contact with any of the pumps and will display a window with the
abovementioned text. The reason is a communication conflict between two masters (PC Tool E-products and master pump).
2. Both pumps will give fault indication after approx. 8 seconds. The reason is that communication between the two pumps was
interrupted when PC Tool E-products was connected to the service port of the master pump.
Fault situation 2:
If you connect PC Tool E-products to the slave pump, you will see the following reactions:

Slave pump Ready indication
PC Tool E-products Ready indication
1. PC Tool E-products will establish contact with the pump. The reason is that PC Tool E-products is connected to the slave
pump; communication can take place.
2. The master pump will give a fault indication after approx. 8 seconds. The reason is that communication between the two
pumps was interrupted when PC Tool E-products was connected to the service port of the slave pump. The slave pump does
not indicate fault because being the slave pump, it will "mistake" PC Tool E-products for the master pump.
To remedy both fault situations:

1. disconnect PC Tool E-products from the pump
2. reset the fault indication by means of R100
3. go through the procedure described at the top of this page.
94 / 109
1.8 Fault correction, Hydro Multi-E
Grundfos Hydro Multi-E booster system consists of two, three or four CRE pumps mounted on a common base frame, dia-
phragm tank, pressure gauge and a breaker or control cabinet with main switch and back-up fuses.
Hydro Multi-E with single-phase E-pumps
Hydro Multi-E systems with single-phase E-pumps are controlled by a Multi-E control unit incorporated in the terminal box of
pump no. 1. Pumps 2, 3 and 4 are standard CRE pumps with built-in GENIbus connection, but without control panel.
Hydro Multi-E with three-phase E-pumps model B and C
Hydro Multi-E systems with three-phase E-pumps are controlled by a PC 410 controller incorporated in the control cabinet.
Pumps 1, 2, 3 and 4 are standard CRE pumps with built-in GENIbus connection.
Hydro Multi-E with three-phase E-pumps model D
Hydro Multi-E systems with three-phase E-pumps are controlled by a Multi-E control unit incorporated in the terminal box of
Hydro Multi-E with three-phase E-pumps model G
Hydro Multi-E systems with three-phase E-pumps are controlled by a Multi-E control unit incorporated in the terminal box of
95 / 109
This general procedure applies to both Hydro Multi-E booster systems with single-phase E-pumps and with three-phase E-
pumps.
The main purpose is to isolate which pump is faulty or possibly if PC 410 is faulty.
Carry out fault finding of the individual pump by following these steps:
1: Installation and operating instructions
See section 9 "Setting by means fo R100". Make all settings according to the installation and opeating instructions.
2: Fault management
General description
A Hydro Multi-E booster system is set to keep up a set setpoint. In case of fault in one pump, the pump work will be taken over
by one of the other pumps.
Current fault is the latest occurring fault. Fault is indicated by the red indicator light on the control panel.
The system is equipped with a sensor. In case of fault in the sensor this will be indicated on the control panel, but it is only when
the system is in operating mode Normal that the controller will react to this fault.
Distinction is made between system fault and pump fault. Pump fault causes Warning and not Fault, see product information
Hydro Multi-E (PI-046), section 11.1 System conditions.
Fault types
Hydro Multi-E has the following main fault types:
motor protection fault
communication fault in Grundfos GENIbus, see product information Hydro Multi-E (PI-046), section 8.10 Start-up after dis-
connection
sensor fault, see product information Hydro Multi-E (PI-046), section 8.5 Registration of sensor fault
dry running.
See also product information Hydro Multi-E (PI-046), section 11.1 System conditions.
Fault log
Hydro Multi-E has a fault log function:
the five latest occurring faults are stored in the fault log
the fault log is stored in the EEPROM
a fault log contains...
fault code for either pump or system fault
time since the fault occurred.
The fault log can be read out by means of R100 or via GENI-bus.
If two consecutive faults have the same fault code, the latest fault will be stored in the fault log if in the meantime the system
has been in condition Ready.
The fault log can be reset via GENIbus.
A fault is registered in the fault log as soon as it occurs and not only when it is reset or a new fault occurs.
Note: The fault log is stored even if Hydro Multi-E has been switched off.
Resetting of faults
When Hydro Multi-E is in system condition Warning or Fault due to fault in one or more of the pumps, the built-in automatic
restart functions of the pumps will - at intervals - try to switch the system to system condition Ready again.
While the pump/pumps try to restart automatically (0 - 25 sec.), the user may try to restart the pump/pumps manually by either
pressing one of the buttons of the control panel or by means of R100/GENIbus.
96 / 109
3: Fault correction procedure
Hydro Multi-E booster systems with single-phase E-pumps or three-phase E-pumps model D
Fault situations are indicated by the indicator lights on pump no. 1.
Indicator lights
Green Red
Power off
No pumps are running. Voltage supply to motors has Re-establish correct voltage supply.
been cut off.
Normal operation
1. At least one pump is Normal operational state. YES: OK
running. Is the pump keeping up the NO: check system configuration
pressure according to the set- replace terminal box of pump
point? no. 1
check sensor installation, setting
and signal. If sensor is defective,
replace the sensor.
2. No pumps are running. Operational stop caused by stop
function. -
3. One or more pumps Jumper on terminals 2 and 3 in Fit a jumper on terminals 2 and 3.
never run. terminal box not fitted.
4. One or more pumps Possible cause: Fault in ...
are operating at unex- 1. sensor installation, setting or 1. Check sensor installation, setting and sig-
pectedly high or low signal nal.
speed. If sensor is defective, replace the sensor.
2. terminal box on pump no. 1. 2. replace terminal box.
3. More pumps in opera- Possible cause: Defective non- Set the system to max.operation.
tion than expected for return valve. Stop the pumps one by one - remove the
the actual consump- jumper between terminals 2 and 3.
tion. If one of the pumps is running backwards,
this pumps non-return valve is defective.
Replace the non-return valve.
No pumps are running. Pumps have been stopped... -
by means of a control button
via R100
via GENIbus.
Fault
No pumps are running. Pumps have stopped due to...
1. external fault 1. The fault indication will be reset automati-
- the digital input is closed cally when the fault has disappeared
due to the external fault.
2. sensor fault 2. check sensor and wiring
3. fault in all motors 3. check the internal LEDs in the motors and
correct any fault according to fault correc-
tion procedure
4. communication fault. 4. replace the terminal box on pump no. 1.
97 / 109
Indicator lights
Green Red

At least one pump is run- The situation is...
ning or stopped due to 1. external fault 1. Check that contacts in terminals 1-3 are
the stop function. open
2. sensor fault 2. check wiring to sensor
3. communication fault 3. check that the pump can communicate
4. voltage to the pump inter- 4. check the automatic circuit breaker of the
rupted pump
5. one or more pumps are not 5. carry out fault correction of the motor, see
ready for operation or have section 1.2 , 1.3 or 1.4
been faulty
6. communication to pump no. 6. restore voltage to the pumps and check
2, 3 or 4 interrupted. the communication wiring.
No pumps are running. The pump has been stopped via
the Grundfos GENIbus:
The situation is...
1. external fault 1. Check that contacts in terminals 1-3 are
open
rupted pump
ready for operation or have section 1.2, 1.3 or 1.4
been faulty
6. communication to pump no. 6. restore voltage to the pumps and check
2, 3 or 4 interrupted. the communication wiring.
98 / 109
Hydro Multi-E booster systems with three-phase E-pumps model B and C
Fault situations are indicated by the indicator lights on PC 410.
Indicator lights
Green Red
Power off
No pumps are running. Voltage supply to motors has Re-establish correct voltage supply.
been cut off.
Normal operation
1. At least one pump is Normal operational state. YES: - OK
running. Is the pump keeping up the NO: check system configuration
pressure according to the set- replace PC 410
point?
2. No pumps are running. Operational stop caused by stop -
function.
3. One or more pumps Jumper on terminals 2 and 3 in Fit a jumper on terminals 2 and 3.
never run. terminal box not fitted.
4. One or more pumps Possible cause: Check sensor installation, setting and signal.
are operating at unex- Fault in sensor installation, set- If sensor is defective, replace the sensor.
pectedly high or low ting or signal
speed.
5. More pumps in opera- Possible cause: Set the system to max.operation.
tion than expected for Defective non-return valve. Stop the pumps one by one - remove the
the actual consump- jumper between terminals 2 and 3.
tion. If one of the pumps is running backwards,
this pumps non-return valve is defective.
Replace the non-return valve.
No pumps are running. Pumps have been stopped... -
by means of a control button
via R100
via GENIbus.
Fault
No pumps are running. Pumps have stopped due to...
1. external fault 1. The fault indication will be reset automati-
- the digital input is closed cally when the fault has disappeared
due to the external fault.
2. sensor fault 2. check sensor and wiring
3. fault in all motors 3. check the internal LEDs in the motors and
correct any fault according to fault correc-
tion procedure
4. communication fault. 4. replace the PC 410
99 / 109
Indicator lights
Green Red

At least one pump is run- The situation is...
ning or stopped due to 1. external fault 1. Check that contacts in terminals 1-3 are
the stop function. open
rupted pump
ready for operation or have section 1.2 , 1.3 or 1.4
been faulty
6. communication to pumps in- 6. restore voltage to the pumps and check
terrupted. the communication wiring.
No pumps are running. The pump has been stopped via
the Grundfos GENIbus:
The situation is...
1. external fault 1. Check that contacts in terminals 1-3 are
open
rupted pump
ready for operation or have section 1.2, 1.3 or 1.4
been faulty
6. communication to pumps in- 6. restore voltage to the pumps and check
terrupted. the communication wiring.
100 / 109
4: Fault readings via R100 fault log or PC Tool E-products
In addition to the indicator lights on the control panel of pump no. 1 or on PC 410, fault is indicated via a fault log code number,
see the R100 menu "Operation" - 1.1.4 Overview of R100 menus.
Fault reading
Code
(fault Grundfos Cause/Explanation Remedy
log) R100 PC Tool
E-products
03 External fault - The digital input has been activated. No remedy. This is part of normal op-
The contacts of terminals 1-9 are eration.
closed. Possibly check the external signal
transmitter.
88 Sensor fault - The sensor has been outside its Check the connections to the sensor
measuring range, short-circuited or and measure sensor values by means
disconnected. of a multimeter.
10 Communication - Communication to one or more of the
fault pumps has been cut.
The cause may be:
1. Supply voltage to one or more of 1. Re-establish correct voltage supply
the pumps has been disconnected to the pump
2. the communication cable has been 2. check the communication cable.
disconnected.
101 / 109
1.8.2 Configuration of Hydro Multi-E
A Hydro Multi-E booster system is configured from factory.
This description explains how to configure a Hydro Multi-E booster system if you have replaced a motor or a terminal box.
To be able to carry out the configuration you need the "PC Tool E-products" program and a "PC Tool link" for the physical con-
nection between terminal box and PC.
Configuration of a Hydro Multi-E falls in two procedures:
A. Configuration of the Multi-E pump (P1) involves:
1. System configuration
2. Pump configuration
B. Configuration of the other pumps (P2, P3, P4) involves:
1. Pump configuration
A. 1. Multi-E system configuration
1. Connect your PC to the Multi-E pump terminal box GENIbus plug A-Y-B via the PC Tool Link.
2. Start PC Tool E-products.
3. When communication has been established, the PC Tool 'Network list' will display the icons for Hydro Multi-E sys-
tem and the pumps installed.
4. Select the Multi-E icon.
5. Select the PC Tool function 'Standard configuration'.
6. Go to section 'Search by'
If the configuration file number is available, see 1.8.3Multi-E pumps GSC-file numbers:
- select 'Number'
- type the Configuration No.
- click Search now.
If the configuration file number is NOT available:
- select 'Application'
- in 'Application search' select the correct settings for your application
- Click 'Search now'.
7. Select the relevant file from the 'Configuration files' list and click 'Send' to transfer the system file to the Multi-E
pump.
102 / 109
A.2. Multi-E pump configuration
1. In the PC Tool go to 'Network list' and select the Multi-E pump.

If the motor or the terminal box is new (has not been configured before), the pump no. is marked (-) MGE

If you are going to reconfigure an existing pump, the pump no. is marked (P1) MGE
If the configuration file number is available, see 1.8.3 Multi-E pumps GSC-file numbers:
- select 'Number'
- click Search now.
4. Select the relevant file from the 'Configuration files' list and click 'Send' to transfer the pump type file to the Multi-E
pump (P1).
B.1. Configuration of pumps 2, 3 and 4
If a PC with PC Tool E-products is already connected via the Multi-E GENIbus plug A-Y-B, start at point 4. We recom-
mend you to configure pumps 2, 3, 4 in this way as access to the terminal box of pumps 2, 3, 4 is made difficult by
the control cabinet.
If a PC is not connected via the Multi-E pump, start from point 1.
1. Connect your PC to the pump to be configured via the PC Tool Link
either to the pump terminal box Genibus plug A-Y-B
or to the TTL plug (situated to the left on the lower board in the terminal box).
3. When communication has been established, the PC Tool 'Network list' will display the icons for the pumps installed.
4. Select the Pump you want to configure in the 'Network list'.
If the configuration file number is available, see 1.8.3 Multi-E pumps GSC-file numbers:
- select 'Number'
- click Search now.
Select the relevant file from the 'Configuration files' list and click 'Send' to transfer the system file to the relevant
7.
pump (P2, P3, P4 ).
103 / 109
PC 410
Set system size
1. Connect your PC to the PC 410 terminals A-Y-B via the PC Tool Link.
When communication has been established, the PC Tool 'Network list' will display the icons for Hydro Multi-E sys-
3.
tem and the pumps installed.
4. Select the Multi-E icon.
If the configuration file number is available:
- select 'Number'
- click Search now.
7. Select the relevant file from the 'Configuration files' list and click 'Send' to transfer the system file to the PC 410.
104 / 109
1.8.3 Multi-E pumps GSC-file numbers
GSC file GSC file GSC file GSC file

Emergency run Phases Power [kW]
pump 1 pump 2 pump 3 pump 4
0.37 96264517 96264518 96264519 96264520
0.55 96264525 96264526 96264527 96264528
No
0.75 96264533 96264534 96264535 96264536
1-phase 1.1 96264541 96264542 96264543 96264544
Model C 0.37 96264521 96264522 96264523 96264524
0.55 96264529 96264530 96264531 96264532
Yes
0.75 96264537 96264538 96264539 96264540
1.1 96264545 96264546 96264547 96264548
1.5 96264588 96264589 96264590 96264591
2.2 96264592 96264593 96264594 96264595
3-phase
No 3 96264596 96264597 96264598 96264599
Model B/C
4 96264600 96264601 96264602 96264603
5.5 96264604 96264605 96264606 96264607
1.5 96275070 96275116 96275139 96275162
2.2 96275071 96275117 96275140 96275163
No 3 96275072 96275118 96275141 96275164
4 96275073 96275119 96275142 96275165
3-phase 5.5 96275074 96275120 96275143 96275166
Model D 1.5 96275093 96275185 96275208 96275231
2.2 96275094 96275186 96275209 96275232
Yes 3 96275095 96275187 96275210 96275233
4 96275096 96275188 96275211 96275234
5.5 96275097 96275189 96275212 96275235
1.5 97845685 97845689 97845691 97845693
2.2 97845721 97845725 97845727 97845729
No 3 97845749 97845753 97845755 97845757
4 97845765 97845769 97845771 97845773
5.5 97845793 97845797 97845799 97845801
3-phase 7.5 97845823 97845824 97845825 97845829
Model G 1.5 97845687 97845695 97845697 97845699
2.2 97845723 97845731 97845733 97845735
3 97845751 97845759 97845761 97845763
Yes
4 97845767 97845775 97845777 97845779
5.5 97845795 97845803 97845805 97845807
7.5 97845826 97845827 97845828 97845836
1.8.4 Multi-E system GSC-file numbers
Emergency run Phases Number of pumps GSC file Multi-E

2 96484809
No 3 96484830
1 4 96497640
Model C 2 96264581
Yes 3 96264582
4 96264583
2 96484831
No 3 96484832
3
4 96497646
Model D
2 96275252
and G
Yes 3 96275253
4 96275254
1.8.5 PC 410 GSC-file numbers
Emergency run Phases Number of pumps GSC file Multi-E

2 96484831
No 3 3 96484832
4 96497646
Product no. PC 410: 96484763
105 / 109
1.8.6 Emergency operation (optional)
Emergency operation deals with the reaction of the Hydro Multi-E booster system if fault occurs in
the Hydro Multi-E add-on board
the pressure transmitter
the signal cable.
In the standard version the reaction to any of the abovementioned faults is to stop all pumps - just as it was in the original con-
cept. It is the same basic reaction as in a Hydro 2000 booster system.
The emergency operation is an option. Emergency operation must be configured like this:
Pressure switches to be fitted on the discharge manifold
One pressure switch will be connected to the terminal boxes of all CRE pumps
This table shows the reaction of Hydro Multi-E to the two fault types mentioned above and what to do.
Fault type System reaction

All active pumps will automatically switch to "Local operation"
Multi-E add-on board
Speed = Stop or max. (set via PC Tool E-products)
Sensor fault
Cut in/cut-out via pressure switch
This solution will both safeguard the water supply and prevent the risk of any of the pumps operating against closed valve if the
Hydro Multi-E add-on board should fail.
Setting of pressure switch

H
Setpoint Cut-out pressure
Differential pressure
Cut-in pressure, switch 1
Cut-in pressure, switch 2 Cut-in pressure
Cut-in pressure, switch 3
One pump in max. Two pumps in Three pumps in
TM02 9400 2504

operation max. operation max. operation
Q
Fig. 47 Setting of pressure switch
Pressure switch settings and number of pumps in emergency operation

Connection of pressure switches
The pressure switches for emergency operation must be connected to terminals 4, 5 and 6 for each Hydro Multi-E pump.
Stop Max.
TM02 9301 2304
6 5 4 3 2
6: GND
5: + 10 V
4: Setpoint input
Fig. 48 Connection of pressure switches
Wiring of each pressure switch for emergency operation to pump terminals.

See also the wiring diagram on page 109.
Note: If one of the pressure switches becomes defective when the Hydro Multi-E is in emergency operation, the inlet pressure
and the pump pressure will be the total pressure.
This means that the maximum permissible pressure for the pipe system might be exceeded. It should then be considered to
install a pressure relief valve in the pipe system. A relief valve is not an option - nor an accessory.
106 / 109
TM02 5674 3802
Fig. 49 Fuse box, single-phase, 0-8.2 A 3 x 400/230 V
107 / 109
TM02 5675 3802
Fig. 50 Fuse box, three-phase, 1.5-2.5 kW, 0-16 A 3 x 400 V
108 / 109
0 1 2 3 4 5 6 7 8 9
Wiring diagram
2 2 2
S1 S2 S3
3 3 3
PE1 PE1 PE1

1 1 1
Pump1 Pump2 Pump3
PE PE
1 N PE 1 N 1 N
Q2 Q3 Q4
2 N 2 N 2 N
M1 M2 M3
JP6 JP3 JP6 JP3 JP6 JP3
4 5 3 2 6 NC NO C L N PE 4 5 3 2 6 NC NO C L N PE 4 5 3 2 6 NC NO C L N PE
Fig. 51 Wiring diagram of the fuse box

JP1 JP1 JP1
Speed
Speed
Speed
10 VDC
GND
ON/OFF
GND
10 VDC
GND
ON/OFF
GND
10 VDC
GND
ON/OFF
GND
Alarm Alarm Alarm

MGE1.B MGE1.B MGE1.B
1 9 8 7 A1 Y B1 A Y B A Y B A Y B
Motor 1 Motor 2 Motor 3
T1 T2 T3 N
white
brown
white
brown
white
brown
P
Q1
L1 L2 L3 N +24V
109 / 109
X0 PE1 PE2
If an earth leakage current

breaker shall be installed
in the mains supply, it must
be marked
water shortage
protection
Sensor
4-20 mA
+
1 3
Datum 11.Feb.2004 =
S-Fuse Box Single Phase 3 Pumps NETZANSCHLUSS 96461119
Bearb. MME +
LEISTUNGSTEIL
Gepr. 08.Mr.2004 IP 54 Bl. 2
nderung Datum Name Norm Urspr. Ers.f. Ers.d. 3 Bl.
TM03 1135 1105

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Service instructions

1.1.3 Fault reading via R100

Fig. 1 R100 display showing the fault log

New E-pumps with MGE 71/80 model C and MMGE model A:

SETTINGS GENERAL OPERATION STATUS INSTALLATION GENI

SETTINGS GENERAL OPERATION STATUS INSTALLATION GENI

SETTINGS GENERAL OPERATION STATUS INSTALLATION GENI

TM02 1608 1601

TM03 0200 4504

TM02 4495 1102

B. Brief increase of pressure (boost) prior to

See diagram on the next page.

High flow is Pump switches to

TM01 9092 1100

Fig. 2 Operating principle of the stop function

1.2.1 Fault correction procedure

TM02 1608 1601

TM02 0838 0301

Legend for indicator lights:

= indicator light is off

= indicator light is permanently on

= indicator light is flashing

Normal operational stop

OUT 7: SENSOR INPUT

TM02 1603 1601

Fig. 4 Overview of terminals in the terminal box

Description Explanation Check/remedy

YES: Pump is OK.

YES: Pump is OK.

Description Pump is running at unexpectedly high or low speed.

Check/Remedy 1. Is the correct setpoint type set in the motor?

NO: Correct the setting via R100.

2. Is the external setpoint signal from potentio-

TM02 1606 1601

NO: Correct the setting via R100.

4. Is the sensor connected correctly and does

TM02 1604 0601

NO: Connect the sensor signal 8: +24V

Description Pump is not running.

Check/remedy 1. Is R100 set to external fault?

NO: Set correctly in R100.

2. Can 5 VDC be measured across terminals

external signal transmitter. 0/1 1: DIGITAL INPUT

Check/remedy 1. Does the sensor setting correspond to the sen-

NO: Correct the setting via R100.

2. Is the voltage to the sensor connection

TM02 1606 1601

3. Is the sensor signal ...

TM02 1604 1601

4. Is the sensor connected correctly and does the

YES: If the pump does not run correctly,

Description Pump is running at min. speed.

Check/remedy 1. Set the pump to "open loop" operation and con-

NO: Correct the setting via R100.

3. Is the voltage to the setpoint connection

TM02 1607 1601

YES: Proceed to point 4. 6: GND

4. Is the setpoint signal ...

YES: If the pump does not run correctly,

(76): Fault log code number.

1.3.1 Fault correction procedure

TM02 1616 1701