Grundfos 2000 Series Bedienungsanleitung

GRUNDFOS MAGNA

Series 2000

MAGNA 40-120, 65-120, 65-60

GRUNDFOS INSTRUCTIONS

Installation and operating instructions

Grundfos.bk Page 1 Friday, January 15, 2010 3:23 PM

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 morethan 30 monthsfrom

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 orexclusions 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.

Grundfos.bk Page 2 Friday, January 15, 2010 3:23 PM

GRUNDFOS MAGNA

Series 2000

MAGNA 40-120, 65-120, 65-60

Installation and operating instructions 4

Notice d’installation et d’entretien 25

Grundfos.bk Page 3 Friday, January 15, 2010 3:23 PM

CONTENTS Page

1. Symbols used in this document 4

2. General description 4

3. Applications 4

3.1 Pumped liquids 4

4. Installation 5

4.1 Changing the control box position 5

4.2 Two pumps in parallel 5

4.3 Check valve 5

4.4 Frost protection 5

5. Electrical connection 6

5.1 Supply voltage 6

5.2 Connection diagram 7

6. Start-up 8

7. Functions 9

7.1 Control modes 10

7.2 Selection of control mode 11

7.3 Automatic night-time duty 12

7.4 Constant-curve duty 12

7.5 Max. or min. curve duty 12

7.6 Temperature influence 12

7.7 External start/stop 13

7.8 Signal relay 13

7.9 Indicator lights 13

7.10 Expansion modules 14

7.11 GENI module 14

7.12 LON module 14

8. Setting the pump 14

8.1 Factory setting 14

8.2 Control panel 15

8.3 R100 remote control 16

8.4 R100 display overview 17

8.5 Menu OPERATION 18

8.6 Menu STATUS 19

8.7 Menu INSTALLATION 20

8.8 Priority of settings 21

9. Fault finding chart 22

10. Megging 23

11. Technical data 24

12. Disposal 24

1. Symbols used in this document

2. General description

The GRUNDFOS MAGNA Series 2000 is a complete

range of circulator pumps with integrated differential

pressure control enabling adjustment of pump

performance to the actual system requirements.

In many systems, this will reduce the power

consumption considerably, reduce noise from

thermostatic valves and similar fittings, and improve

the control of the system.

The desired head can be set on the pump control

panel.

3. Applications

The GRUNDFOS MAGNA is designed for circulating

liquids in heating systems. The pump can also be

used in domestic hot-water systems.

The pump range is primarily used in

• systems with a variable flow.

The pump range can also be used in

• systems with a constant flow where it is

desirable to optimize the setting of the pump duty

point,

• systems with variable supply-pipe temperature.

GRUNDFOS MAGNA pumps can be used in snow-

melting applications. To avoid condensation in the

control box, the pump should not be installed on the

return side.

3.1 Pumped liquids

Thin, clean, non-aggressive and non-explosive liquids,

not containing solid particles, fibers or mineral oil.

In heating systems,the water should meet the

requirements of accepted standards on water quality

in heating systems.

In domestic hot-water systems, it is advisable to

use GRUNDFOS MAGNA pumps only for water with

a degree of hardness lower than approx. 17 grains/

gallon (14 °dH).

WARNING!

Prior to installation, read these

installation and operating instructions.

Installation and operation must comply

with local regulations and accepted

codes of good practice.

WARNING!

If these safety instructions are not

observed, it may result in personal

injury!

Caution

If these safety instructions are not

observed, it may result in malfunction

or damage to the equipment!

Note

Notes or instructions that make the job

easier and ensure safe operation.

WARNING!

The pump must not be used for the

transfer of inflammable liquids such as

diesel oil, petrol or similar liquids.

Grundfos.bk Page 4 Friday, January 15, 2010 3:23 PM

4. Installation

Arrows on the pump housing indicate the liquid flow

direction through the pump.

4.1 Changing the control box position

Change the control box position as follows:

1. Remove the inspection screw (1) and the four

Allen screws (6 mm) (2) in the stator housing, see

fig. 1.

2. Lift off the stator housing (3). Keep the rotor (4) in

place using a suitable tool, e.g. a T-key (M8) (5),

see fig. 2.

3. Check that the O-ring (6) is intact.

A defective O-ring must be replaced.

4. Hold the stator housing/control box (3) in the

desired position.

5. Lower the stator housing over the rotor.

Keep the rotor in place as described in point 2.

6. Fit and tighten the four screws, torque

14-17.5 Nm, and the inspection screw, torque

8-10 Nm.

Fig. 1 Removing the control box

Fig. 2 Changing the control box position

4.2 Two pumps in parallel

Two pumps in parallel can be controlled via the

optional GENI module. Both pumps should have a

GENI module installed in the control box. The

modules are connected with a wire. The modules

determine the pump operating mode, see section

7.11 GENI module.

4.3 Check valve

If a check valve is fitted in the pipe system, see fig.

3, it must be ensured that the set minimum discharge

pressure of the pump is always higher than the

closing pressure of the valve. This is especially

important in proportional-pressure control mode

(reduced head at low flows).

Fig. 3 Check valve

4.4 Frost protection

If the pump is not used during periods of frost,

necessary steps must be taken to prevent frost

bursts.

WARNING!

Before any dismantling of the pump,

the system must be drained or the

isolating valves on either side of the

pump must be closed as the pumped

liquid may be scalding hot and under

high pressure.

TM03 8910 2707

TM03 8911 2707

Pos. Description

1 Inspection screw

2Screw

3 Stator housing/control box

4 Rotor

5 T-key (not provided with the pump)

6 O-ring

TM02 0640 0301

Note

Additives with a density and/or

kinematic viscosity higher than those/

that of water will reduce the hydraulic

performance.

Grundfos.bk Page 5 Friday, January 15, 2010 3:23 PM

5. Electrical connection

The electrical connection and protection should be

carried out in accordance with local regulations.

• The pump requires no external motor protection.

• The operating voltage and frequency are marked

on the pump nameplate. Please make sure that

the motor is suitable for the electricity supply on

which it will be used.

Open the control box cover as shown in fig. 4.

Fig. 4 Opening the control box

If the control box cover cannot be lifted sufficiently, it

can be removed as shown in fig. 5.

Fig. 5 Removing the control box cover

5.1 Supply voltage

1 x 230 V ±10 %, 50/60 Hz.

WARNING!

Never make any connections in the

pump control box unless the electricity

supply has been switched off for at

least 5 minutes.

The ground terminal of the pump must

be earthed.

The pump must be connected to an

external mains switch with a contact

separation of at least 1/8 inch (3 mm) in

each pole.

Grounding or neutralization can be

used for protection against indirect

contact.

Megging must be carried out as

described in section 10. Megging.

If the pump is connected to an electric

installation where an earth leakage

circuit breaker (ELCB) is used as

additional protection, this circuit

breaker must trip out when earth fault

currents with DC content (pulsating

DC) occur.

The earth leakage circuit breaker must

be marked with the symbol shown:

Step Action

TM02 0456 3503

TM02 0457 3503

Step Action

TM02 7441 3503

TM02 7442 3503

Grundfos.bk Page 6 Friday, January 15, 2010 3:23 PM

5.2 Connection diagram

Fig. 6 Wiring diagram

Concerning demands on signal wires and signal

transmitters, see section 11. Technical data.

A connection example can be found on page 49.

Note:

• If no external on/off switch is connected, the

connection across terminals STOP and should

be maintained.

• All cables used must be heat-resistant up to

+185 °F (+85 °C).

• All cables used must be installed in accordance

with NEC or applicable local codes and

regulations.

• If a GENI module is fitted, the screen must be

connected to . See page 50.

TM02 0235 1007

NC NO C

213

Supply connection Signal output Start/stop input

NC NO C

WARNING!

•Wires connected to

– supply terminals,

– outputs NC, NO, C and

– start/stop input

must be separated from each other

and from the supply by reinforced

insulation.

•All wires connected to a terminal

block must be tied up at the

terminals.

Grundfos.bk Page 7 Friday, January 15, 2010 3:23 PM

6. Start-up

Do not start the pump until the system has been filled

with liquid and vented. Furthermore, the required

minimum inlet pressure must be available at the

pump inlet, see section 11. Technical data.

The system cannot be vented through the pump.

The pump can be vented by slackening the

inspection screw.

Fig. 7 Venting the pump

WARNING!

If the inspection screw is to be

loosened, see fig. 7, care should be

taken to ensure that the escaping,

scalding hot liquid does not cause

personal injury or damage to

components.

TM03 8912 2707

Inspection screw

Grundfos.bk Page 8 Friday, January 15, 2010 3:23 PM

7. Functions

Most functions can be selected on the pump control panel. However, some functions can only be selected with

the R100 or via expansion modules.

On the pump control panel, see fig. 13, page 15:

•AUTOADAPT (factory setting)

Recommended for most heating installations.

During operation, the pump automatically makes the necessary adjustment to the actual system

characteristic. This setting ensures minimum energy consumption and noise level which reduces operating

costs and increases comfort.

•Proportional-pressure control

The pump head is changed continuously in accordance with the water demand in the system. The desired

setpoint can be set on the pump control panel.

•Constant-pressure control

A constant head is maintained, irrespective of water demand. The desired setpoint can be set on the pump

control panel.

•Automatic night-time duty

The pump changes automatically between normal duty and night-time duty depending on the supply-pipe

temperature. Automatic night-time duty can be combined with the above-mentioned control modes.

Further functions:

Via the digital input:

•External start/stop

The pump can be started or stopped via the digital input.

With the R100 remote control:

•Constant-curve duty

The pump runs at a constant speed, on or between the max. and min. curves.

•Temperature influence

The head varies depending on the liquid temperature.

•External fault and operating signal

The pump controls an external fault or operating signal device via a potential-free output.

Via expansion modules:

GENI module

•External analog control of head or speed via a signal from an external 0-10 V signal transmitter.

•External forced control via inputs for:

- Max. curve,

- Min. curve.

•Bus communication via GENIbus

The pump can be controlled and monitored by a GRUNDFOS Pump Management System 2000,

a building management system or another type of external control system.

•Control of two pumps in parallel

The control of two pumps in parallel is described in section 7.11.

LON module

•Bus communication via LON

This module enables connection to a network based on LonWorks®technology and to other units which

are based on this communication standard.

Grundfos.bk Page 9 Friday, January 15, 2010 3:23 PM

7.1 Control modes

A GRUNDFOS MAGNA pump can be set to the

control mode which is most suitable for the individual

system.

Possible control modes:

•AUTO

ADAPT (factory setting)

• Proportional pressure

• Constant pressure.

Each of the control modes can be combined with

automatic night-time duty, see section 7.3 Automatic

night-time duty.

AUTOADAPT

To be set on the control panel or with the R100, see

section 8. Setting the pump.

The control mode AUTOADAPT continuously adapts

the pump performance.

The setpoint (Hset1) of the pump has been factory-

set as follows and cannot be changed manually:

• MAGNA 40-120, 65-120 to 21 feet (6.5 m).

• MAGNA 65-60 to 11.5 feet (3.5 m).

When the pump registers a lower pressure on the

max. curve, A2, the AUTOADAPT function

automatically selects a correspondingly lower control

curve, Hset2, thus reducing the energy consumption.

Fig. 8 AUTOADAPT

A1: Original duty point.

A2: Lower registered pressure on the max. curve.

A3: New duty point after AUTOADAPT control.

Hset1: Original setpoint.

Hset2: New setpoint after AUTOADAPT control.

Hfac.: Factory-set setpoint.

The AUTOADAPT function can be reset by pressing

the button for approx. 10 seconds until the control

mode is back to the starting point (AUTOADAPT or

AUTOADAPT with automatic night-time duty).

Proportional-pressure control

To be set on the control panel or with the R100, see

section 8. Setting the pump.

The pump head is reduced as the water demand

declines and increased as the water demand rises,

see fig. 9.

Constant-pressure control

To be set on the control panel or with the R100, see

section 8. Setting the pump.

The pump maintains a constant pressure,

irrespective of water demand, see fig. 9.

Fig. 9 Pressure control

TM02 0251 4800

Hmax.

Hfac.

A3A2Hset2

Hset1

TM00 5546 4596

Proportional

pressure Constant

pressure

Hset Hset

Hset

Grundfos.bk Page 10 Friday, January 15, 2010 3:23 PM

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