Grundfos HURLEY ENGINEERING Hydro Multi-B Series Bedienungsanleitung

GRUNDFOS INSTRUCTIONS

Hydro Multi-B

Pressure boosting and tank fill applications

Installation and operating instructions

The Pacific Northwest's

premier Grundfos CBS

Manufacturer's Representative

for all Grundfos Booster

systems. Hurley Engineering

offers complete start up,

selection & installation

assistance, and has a full staff

of service technicians available

for preventive maintenance

programs. Hurley Engineering

is also the Pacific Northwest's

only Grundfos CBS Authorized

Service Partner.

English (US)

English (US) Installation and operating instructions

Original installation and operating instructions

These installation and operating instructions describe the

Grundfos Hydro Multi-B booster system.

Sections 1-5 give the information necessary to be able to unpack,

install and start up the product in a safe way.

Sections 6-17 give important information about the product, as

well as information on service, fault finding and disposal of the

product.

CONTENTS

Page

1. Limited Warranty

Products manufactured by GRUNDFOS PUMPS CORPORATION

(Grundfos) are warranted to the original user only to be free of

defects in material and workmanship for a period of 24 months

from date of installation, but not more than 30 months from date

of manufacture. Grundfos' liability under this warranty shall be

limited to repairing or replacing at Grundfos' option, without

charge, F.O.B. Grundfos' factory or authorized service station,

any product of Grundfos' manufacture. Grundfos will not be liable

for any costs of removal, installation, transportation, or any other

charges which may arise in connection with a warranty claim.

Products which are sold but not manufactured by Grundfos are

subject to the warranty provided by the manufacturer of said

products and not by Grundfos' warranty. Grundfos will not be

liable for damage or wear to products caused by abnormal

operating conditions, accident, abuse, misuse, unauthorized

alteration or repair, or if the product was not installed in

accordance with Grundfos' printed installation and operating

instructions.

To obtain service under this warranty, the defective product must

be returned to the distributor or dealer of Grundfos' products from

which it was purchased together with proof of purchase and

installation date, failure date, and supporting installation data.

Unless otherwise provided, the distributor or dealer will contact

Grundfos or an authorized service station for instructions. Any

defective product to be returned to Grundfos or a service station

must be sent freight prepaid; documentation supporting the

warranty claim and/or a Return Material Authorization must be

included if so instructed.

GRUNDFOS WILL NOT BE LIABLE FOR ANY INCIDENTAL OR

CONSEQUENTIAL DAMAGES, LOSSES, OR EXPENSES

ARISING FROM INSTALLATION, USE, OR ANY OTHER

CAUSES. THERE ARE NO EXPRESS OR IMPLIED

WARRANTIES, INCLUDING MERCHANTABILITY OR FITNESS

FOR A PARTICULAR PURPOSE, WHICH EXTEND BEYOND

THOSE WARRANTIES DESCRIBED OR REFERRED TO

ABOVE.

Some jurisdictions do not allow the exclusion or limitation of

incidental or consequential damages and some jurisdictions do

not allow limit actions on how long implied warranties may last.

Therefore, the above limitations or exclusions may not apply to

you. This warranty gives you specific legal rights and you may

also have other rights which vary from jurisdiction to jurisdiction.

1. Limited Warranty 2

2. Symbols used in this document 3

2.1 Warnings against hazards involving risk of death or

personal injury 3

2.2 Other important notes 3

3. Receiving the product 3

3.1 Transporting the product 3

4. Installing the product 3

4.1 Location 3

4.2 Mechanical installation 3

4.3 Electrical installation 5

5. Starting up the product 5

5.1 Positive inlet pressure startup procedure 5

5.2 Flooded suction and suction lift startup procedures 6

5.3 Handling the product 6

6. Product introduction 7

6.1 Product description 7

6.2 Applications 7

6.3 Identification 9

7. Control unit 10

8. Operating modes 12

8.1 Local mode, external stop not activated 12

8.2 Remote-controlled, external stop not activated 13

8.3 Remote-controlled, external stop activated 13

8.4 Adjusting the proportional-pressure setpoint 14

9. Functions 15

9.1 General functions 15

9.2 Functions for constant-pressure systems 15

9.3 Functions for tank-filling systems 17

10. Data communication 17

11. Servicing the product 17

11.1 Maintaining the product 17

12. Protecting the product against frost 17

13. Taking the product out of operation 17

14. Fault finding 18

15. Technical data 19

15.1 Pressure 19

15.2 Temperature 19

15.3 Relative humidity 19

15.4 Sound pressure level 19

15.5 Electrical data 19

16. Related documents 20

16.1 Service documentation 20

17. Disposing of the product 20

Read this document before installation. Installation

and operation must comply with local regulations and

accepted codes of good practice.

This appliance can be used by children aged from 8

years and above and persons with reduced physical,

sensory or mental capabilities or lack of experience

and knowledge if they have been given supervision

or instruction concerning use of the appliance in a

safe way and understand the hazards involved.

Children shall not play with the appliance. Cleaning

and user maintenance shall not be made by children

without supervision.

English (US)

2. Symbols used in this document

2.1 Warnings against hazards involving risk of death

or personal injury

2.2 Other important notes

3. Receiving the product

3.1 Transporting the product

The booster system is delivered in a recyclable packaging,

specially designed for transport by forklift truck or a similar

vehicle.

The forks of the forklift truck must be at least 6.6 ft (2 m) long.

4. Installing the product

Before installing the product, check the following:

• The booster system corresponds to the order.

• All visible parts are intact.

4.1 Location

Install the booster system in a well-ventilated room to ensure

sufficient cooling of the control cabinet and pumps.

Place the booster system with a 3.3 ft (1 m) clearance on all sides

for inspection and removal.

4.2 Mechanical installation

4.2.1 Pipes

Connect the pipes to the manifolds of the booster system. Either

end can be used. Apply sealing compound to the unused end of

the manifold, and fit the screw cap. For manifolds with flanges, fit

a blanking flange with gasket.

We recommend that you install pipe supports for the inlet and

outlet pipes. See figs 1and 2.

Noise and vibration are generated by the rotations in the motor

and pump and by the flow in pipes and fittings. The effect on the

environment is subjective and depends on correct installation and

the state of the other parts of the system.

If booster systems are installed in blocks of flats or the first

consumer on the line is close to the booster system, we

recommend that you fit expansion joints on the inlet and outlet

pipes to prevent that vibrations are transmitted through the pipes.

DANGER

Indicates a hazardous situation which, if not avoided,

will result in death or serious personal injury.

CAUTION

Indicates a hazardous situation which, if not avoided,

could result in minor or moderate personal injury.

SIGNAL WORD

Description of hazard

Consequence of ignoring the warning.

- Action to avoid the hazard.

If these instructions are not observed, it may result in

malfunction or damage to the equipment.

Tips and advice that make the work easier.

A red or grey circle with a diagonal bar, possibly with

a black graphical symbol, indicates that an action

must not be taken or must be stopped.

The booster system is designed for indoor

installation. Do not expose the product to direct

sunlight.

The pipes connected to the booster system must be

of adequate size.

English (US)

Fig. 1 Example showing the position of expansion joints, pipe

supports and machine shoes

Fig. 2 Example showing the position of expansion joints, pipe

supports and mounting bolts

Tighten all nuts before startup.

Fasten the pipes to parts of the building to ensure that they

cannot move or be twisted.

4.2.2 Foundation

Position the booster system on an even and solid surface, for

instance a concrete floor or foundation. The booster system must

be bolted to the floor or foundation.

4.2.3 Vibration dampers

To prevent the transmission of vibrations to buildings, it may be

necessary to isolate the booster system foundation from building

parts by means of vibration dampers.

The right damper varies from installation to installation, and a

wrong damper may increase the vibration level. Vibration

dampers must therefore be sized by the supplier. If the booster

system is installed on a base frame with vibration dampers,

always fit expansion joints on the manifolds. This is important to

prevent the booster system from "hanging" in the pipes.

4.2.4 Expansion joints

Fit expansion joints for these reasons:

• to absorb expansions or contractions in the pipes caused by

changing liquid temperature

• to reduce mechanical strains in connection with pressure

surges in the pipes

• to isolate mechanical structure-borne noise in the pipes (only

rubber bellows expansion joints).

Fit expansion joints at a distance of minimum 1 to 1 1/2 times the

nominal flange diameter from the manifold on the inlet as well as

on the outlet side. This prevents the development of turbulence in

the expansion joints, resulting in better inlet conditions and a

minimum pressure loss on the outlet side.

Fig. 3 Examples of rubber bellows expansion joints without

and with limiting rods

TM03 2154 3805

Pos. Description

1 Expansion joint (and good location for isolating valves)

2 Pipe support

3 Machine shoe

TM04 9900 0211

Pos. Description

1 Expansion joint (and good location for isolating valves)

2 Pipe support

3 Mounting bolt

Expansion joints, pipe supports as well as machine

shoes or mounting bolts shown in figs 1and 2

respectively are not included in a standard booster

system.

The weight of a concrete foundation must be 1.5

times the weight of the booster system.

Do not install expansion joints to compensate for

inaccuracies in the pipes such as center

displacement of flanges.

TM02 4981 1902 - TM02 4979 1902

English (US)

Expansion joints with limiting rods can be used to minimise the

forces caused by the expansion joints. We always recommend

that you use expansion joints with limiting rods for flanges larger

than ANSI 4" (DN 100).

Anchor the pipes so that they do not stress the expansion joints

and the pump. Follow the supplier’s instructions and pass them

on to advisers or pipe installers.

4.2.5 Prefilling of diaphragm tank, if applicable

If a diaphragm tank is connected to the system, prefill the tank

with nitrogen to a pressure of 0.7 times the setpoint.

4.3 Electrical installation

• The electrical installation of the booster system must comply

with enclosure class UL type 3R.

• Check that the power supply and frequency correspond to the

values stated on the nameplate.

• Make sure that the conductor cross-section meets the

specifications in the wiring diagram.

5. Starting up the product

After having carried out the mechanical, electrical and hydraulic

installation described in sections 4.2 Mechanical installation,

4.3 Electrical installation, proceed as follows:

5.1 Positive inlet pressure startup procedure

1. Check that the precharge pressure in the diaphragm tank is

0.7 times the required outlet pressure (setpoint).

2. Close all pump outlet isolation valves on the Multi B system.

3. Open the outlet valve on one pump and turn the tap on the

outlet side of the system allowing water to pass through the

pump. Once complete, close the isolation valve.

4. Repeat step 3 for all remaining pumps in the system. Once

complete, open the outlet isolation valve on all pumps after all

pumps have been vented.

5. Switch on the main switch.

6. Turn the system on by pressing [On/Off] and adjust the

setpoint to the desired setpoint value by pressing arrow up or

arrow down on the controller.

Use nitrogen to avoid corrosion.

CAUTION

Electric shock

Minor or moderate personal injury

- The electrical installation must be carried out by an

approved person in accordance with local

regulations and the relevant wiring diagram.

- Switch off the power supply and lock the main

switch with a padlock to ensure that the power

supply cannot be accidentally switched on.

See the wiring diagram supplied with the booster

system. Tighten all wire terminals in the panel before

switching on power to the panel.

If the system cannot be installed with the supply

disconnecting device located minimum 2 ft (0.6 m)

above service level according to EN 60204-1

paragraph 5.3.4, install the system with an external

"supply disconnecting device" made according to EN

60204-1, paragraph 5.3.2. The system must be

provided with a means permitting it to be locked in

the OFF (isolated) position.

A positive inlet pressure is required before startup

and during operation.

Do not start the pumps until they have been fully

primed.

Set the precharge pressure on the diaphragm tank

with zero pressure on the tank.

Measure the precharge pressure in the diaphragm

tank while the system is not pressurized.

English (US)

5.2 Flooded suction and suction lift startup

procedures

1. Check that the precharge pressure in the diaphragm tank is

0.7 times the required outlet pressure (setpoint).

Note: Set the precharge pressure with zero pressure on the

tank.

2. Switch off the main switch on the cabinet front.

3. Switch off the circuit breakers of all pumps. The circuit

breakers are located inside the cabinet.

4. Set the "Emergency/Normal" switch for all pumps to

"Emergency". The switch is located on the front of the control

cabinet.

5. Close all pump outlet valves and prime all pumps. Prime the

pumps by opening the cap on the port of the check valve

positioned closest to the pump and filling water into the port.

Prime the pump when water no longer is able to fill into the

pump. Reinstall the cap on the check valve port and repeat

the procedure for all pumps.

6. Switch on the relevant circuit breaker of the pump to be

started.

7. Switch on the main switch; this will start the pump with the

relevant circuit breaker on.

8. Vent the pump by slowly opening the outlet valve. This will

also allow gradual filling of the outlet pipes.

9. Set the "Emergency/Normal" switch for the relevant pump to

"Normal".

10. Switch off the main switch.

11. Repeat steps 6, 7, 8, 9 and 10 for the other pumps in the

system.

12. Switch on the main switch.

13. Adjust the required setpoint via the CU 323 by pressing arrow

up or arrow down.

14. Set the system to "On" by pressing [On/Off].

15. Increase the setpoint to the desired setpoint value.

Hydro Multi-B is now in automatic mode and ready for operation.

5.3 Handling the product

Lift the booster systems with CM and CME pumps as shown in

fig. 4.

During handling, the lifting point must always be above the center

of gravity of the booster system.

Fig. 4 Correct lifting of Hydro Multi-B with CM and CME

pumps

When lifting the booster system, only use suitable lifting

equipment that is in good condition and approved for the weight.

The weight is stated on the nameplate of the booster system.

Measure the precharge pressure in the diaphragm

tank while the system is not pressurized.

If you change the outlet pressure, change the

diaphragm tank precharge pressure accordingly.

The initial setpoint pressure value for the system is 0

psi, and the maximum pressure is 22 psi above the

setpoint value.

This may cause a "Maximum pressure exceeded"

alarm condition after startup is complete. Increase

the setpoint pressure value to the desired pressure

and, if necessary, bleed off the pressure on the outlet

to clear the "Maximum pressure exceeded" fault.

TM05 0221 0911

CAUTION

Overhead load

Minor or moderate personal injury

- When lifting the booster system, do not use the

eyebolts of the motors.

- Do not lift the booster system by the manifolds.

- Do not stand on the manifolds.

CAUTION

Crushing of feet

Minor or moderate personal injury

- When lifting the booster system, do not use the

eyebolts of the motors.

- Do not lift the booster system by the manifolds.

- Do not stand on the manifolds.

English (US)

6. Product introduction

6.1 Product description

Hydro Multi-B is a range of factory-assembled pump systems,

ready for installation and operation.

As standard, the booster systems consist of two and three pumps

connected in parallel and mounted on a common base frame with

a control cabinet and all necessary fittings.

Fig. 5 Front view of Hydro Multi-B booster system with three

CM(E) pumps

Fig. 6 Rear view of Hydro Multi-B booster system with three

CM(E) pumps

6.2 Applications

The booster systems are suitable for the following application

types:

• constant-pressure boosting

• tank filling.

6.2.1 Booster system for constant-pressure applications

The booster system for constant-pressure applications is

designed to maintain a constant pressure on the outlet side of the

pumps. The booster systems for constant-pressure applications

adjust the performance according to the demand and keep a

constant pressure in the following ways:

• by cutting the required number of pumps in and out

• through continuous adjustment of the speed of the running

pumps.

Operating principle

The user enters the required pressure of the system (setpoint) via

the user interface of the CU 323 control unit. CU 323 adjusts the

system performance according to the feedback received from the

pressure transmitter installed in the outlet manifold.

TM04 9898 0211TM04 9899 0211

Pos. Description Quantity

1 Control cabinet 1

2 Inlet manifold 1

3 Outlet manifold 1

4 Diaphragm tank (not included) 1

5 Isolating valve 2 per pump

6 Non-return valve 1 per pump

7Pump 2-4

8 Base frame 1

9 Pressure transmitter and pressure gauge 1

10 Pressure switch or inlet pressure sensor 1

11 Oval flange (CME 3-10) 2 per pump

Intermediate adapter (CME 15-25) 1 per pump

12 Screw cap or blanking flange 2



Control variant E

Two to three electronically speed-controlled pumps

TM03 0993 0905

One speed-controlled pump in operation.

TM00 7995 2296

Three speed-controlled pumps in operation.

TM00 7996 2296

• Control variant E for constant-pressure applications

maintains a constant pressure through continuous

adjustment of the speed of the pumps.

• The system performance is adjusted to the demand by

cutting the required number of pumps in and out and

through parallel control of the pumps in operation.

Hset

English (US)

6.2.2 Booster system for tank-filling applications

The booster system for tank-filling applications is designed to fill

a tank such as a roof tank or a break tank in a controlled manner.

The booster system controls the filling either via level switches, a

level sensor, or a ball cock valve.

• Operating principle

The system has three methods of operation, one based on

level switches, one based on a level sensor and the other

based on a ball cock valve.

• Operation with level switches

The user adjusts the switches in the tank to the desired stop

and start levels.

• Operation with level sensor

The user adjusts the setpoint so it corresponds to the real tank

height, measured from the bottom of the tank to the top, via

the user interface of the CU 323 control unit.

• Operation with ball cock valve

The user adjusts the ball cock valve in the tank to the desired

start and stop levels.

• Factory setting

Start level: 15 % of setpoint

Stop level: 85 % of setpoint

High-level alarm: 95 % of setpoint.

The Multi-B systems configured for tank filling applications work as described below.

The CU323 will display the tank level graphically. For

assistance contact Grundfos.

The PC tool is required to adjust the start and stop

level setting. For assistance contact Grundfos.

Control variant E

E: Two to three electronically speed-controlled pumps

TM05 0222 0911

Fig. 7 Example of tank filling

• In tank-filling applications, the booster system fills the tank with focus on protecting the piping and preventing water hammer. When

low level in the tank is reached, a speed-controlled pump starts by running approximately 70 % of maximum speed to slowly and

safely fill the pipes. After a while, it increases the speed to 100 %, and the next pump is started. When the tank is full, the pumps

stop.

• Systems with more than two pumps will as default set one pump as standby pump.

• Changeover among the mains-operated pumps is automatic and depends on load, time and fault.

First pump starts Second pump starts First pump stops

Second pump stops

Time

Pump speed

100 %

70 %

English (US)

6.3 Identification

6.3.1 Nameplate

The nameplate of the booster system is fitted on the base frame.

Fig. 8 Nameplate

6.3.2 Type key

* The control cabinet can be placed up to 6.6 ft (2 m) from the pumps.

TM06 9434 2317

Pos. Description

1 Type designation

2 Model

3 Serial number

4 Supply voltage

5 Maximum operating pressure in psi

6 Liquid temperature

7 Panel part number

8 Weight in lb

9 Country of origin

10 Company logo

11 Maximum flow rate in GPM

12 Nominal head in ft

13 Approval mark, cULus (Category QCZJ)

14 Approval mark

15 QR code

Type: HYDRO MULTI-B 3 CME10-3

Model: A

Serial No.: 10000001

Mains supply: 3 x 460 V, 60 Hz

pMax: 145 PSI Q Nom / Max: 159 / 240

H Nom / Max: 127 / 225Liq. temp.: 32-140

Panel PN: 91148011

Weight: 840 Ib

ASSEMBLED IN US

GPM

code Packet Pumping system 38PK

DK - 8850 - Bjerringbro - Denmark

Code Example Hydro Multi-B -E 3 CME 10-3 A 3 x 460 V, 60 Hz

Type range

System type

All pumps, E-motor or CUE

Number of pumps with integrated frequency drive and pump type

Pump material

Cast iron (EN-GJL-200)

Supply voltage, frequency

English (US)

7. Control unit

The booster system incorporates a CU 323 control unit which enables manual setting and monitoring of the system.

Figure 9shows the user interface for a system with four pumps.

Fig. 9 User interface of control cabinet and CU 323

TM05 0479 1111

Off

RESET

OFF AUTO

CU 323

system run

alarm

10 11

Off

RESET

OFF AUTO

CU 323

system run

alarm

Pos. Buttons Description

1 [On/Off]: Changes the system operating mode between "Normal" and "Stop".

2 [Up]: Increases the setpoint value.

3 [Down]: Decreases the setpoint value.

4 [RESET]: Resets all alarms.

5[>]: Changes the operating mode of the individual pumps between "AUTO" and "OFF". Each pump in

the system has an Auto/Off button.

Enables "Emergency/Normal" operation.

Note: If a pump is set to "Emergency" operation, it will run at 100 % speed, and the power supply to

CU 323 will be switched off. There is a delay of 30 seconds before the pumps are set to "Emergency"

operation.

7 Switches the power supply to the control cabinet on or off.

"Setpoint" Shows the setpoint. After unlocking CU 323, the setpoint will flash.

Proportional-pressure control. "PPP" flashes for one second followed by the current setpoint for four

seconds. This function is only available for E-pump systems.

The tank symbol appears in tank-filling mode with float switches.

or "Setpoint" Alternates between the tank symbol and the setpoint in tank-filling mode with analog input.

External stop: Indicates that the system has been stopped externally via a digital input.

Indicates that the system has been set to "OFF".

Indicates that the system has been set from "OFF" to "On". "On" is only shown for 3 seconds after

which the setpoint is shown.

Indicates that the buttons on CU 323 have been locked automatically. To unlock the buttons, press

[RESET] and arrow up or [RESET] and arrow down simultaneously.

Indicates that the system is remotely controlled.

Local: Appears if attempts to change local settings are made while the system is remotely controlled.

Off

RESET

1___!

E.St

OFF

0-N

bUS

LOC

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