Grundfos CR Series Bedienungsanleitung

CR, CRI, CRN

Installation and operating instructions

GRUNDFOS INSTRUCTIONS

English (GB)

English (GB) Installation and operating instructions

Original installation and operating instructions

CONTENTS

Page

1. Symbols used in this document

2. Handling

When lifting the entire pump with motor, follow these instructions:

• Pump with motor sizes 0.37 - 5.5 kW:

Lift the pump in the motor flange by means of straps or the

like.

• Pump with motor sizes 7.5 - 22 kW:

Lift the pump by means of the motor eyebolts.

• Pump with motor sizes 30-45 kW:

Lift the pump by means of the lifting brackets on the motor

flange.

• Pump with motor sizes 55-75 kW:

Lift the pump by means of the eyebolts on the motor side.

Fig. 1 Correct lifting of a CR pump

In case of CR, CRI and CRN pumps with other motors than MG or

Siemens, we recommend that you to lift the pump by means of

the straps in the motor flange.

1. Symbols used in this document 2

2. Handling 2

3. Type designation 3

3.1 Type key for CR, CRI, CRN 1s, 1, 3, 5, 10, 15 and 20 3

3.2 Type key for CR, CRN 32, 45, 64, 90, 120 and 150 3

4. Applications 3

5. Technical data 3

5.1 Ambient temperature and altitude 3

5.2 Liquid temperature 4

5.3 Maximum permissible operating pressure and liquid

temperature for the shaft seal 4

5.4 Minimum inlet pressure 4

5.5 Minimum inlet pressure 4

5.6 Minimum flow rate 5

5.7 Electrical data 5

5.8 Frequency of starts and stops 5

5.9 Dimensions and weights 5

5.10 Sound pressure level 5

6. Installation 5

6.1 Foundation 6

6.2 Vibration dampening 7

6.3 Outdoor installation 7

6.4 Hot or cold surfaces 7

6.5 Torques 7

6.6 Flange forces and torques 8

7. Electrical connection 9

7.1 Cable entry/screwed connection 9

7.2 Three-phase connection 9

7.3 Single-phase connection 10

7.4 Terminal box positions 10

7.5 Frequency converter operation 10

8. Startup 11

8.1 Shaft seal run-in 11

9. Maintenance 11

10. Frost protection 12

11. Service 12

11.1 Service kits and manuals 12

12. Fault finding 13

13. Disposing of the product 13

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.

Warning

If these instructions are not observed, it may lead to

electric shock with consequent risk of serious

personal injury or death.

Warning

The surface of the product may be so hot that it may

cause burns or 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.

TM04 0339 0608

TM04 0341 0608

TM05 9564 4113

TM04 0341 0608

0.37 - 5.5 kW 7.5 - 22 kW 30-45 kW 55-75 kW

Warning

Make sure that the pump remains in a stable position

during unpacking and installation by means of the

straps used for lifting the pump.

Note that typically the centre of gravity of the pump is

close to the motor.

English (GB)

3. Type designation

3.1 Type key for CR, CRI, CRN 1s, 1, 3, 5, 10, 15 and 20

3.2 Type key for CR, CRN 32, 45, 64, 90, 120 and 150

4. Applications

Grundfos multistage in-line centrifugal pumps, types CR, CRI and

CRN, are designed for a wide range of applications.

CR, CRI, CRN

CR, CRI and CRN pumps are suitable for liquid transfer,

circulation and pressure boosting of cold or hot clean liquids.

CRN

Use CRN pumps in systems where all parts in contact with the

liquid are made of high-grade stainless steel.

Pumped liquids

Thin, clean, non-flammable, non-combustible or non-explosive

liquids, not containing solid particles or fibres. The liquid must not

attack the pump materials chemically.

When pumping liquids with a density and/or viscosity higher than

that of water, use motors with correspondingly higher outputs, if

required.

5. Technical data

5.1 Ambient temperature and altitude

If the ambient temperature exceeds the above temperature

values or the pump is installed at an altitude exceeding the above

altitude values, the motor must not be fully loaded due to the risk

of overheating. Overheating may result from excessive ambient

temperatures or the low density and consequently low cooling

effect of the air.

In such cases, it may be necessary to use a motor with a higher

rated output.

Fig. 2 Motor output depends on temperature/altitude

Example

Figure 2shows that the load of an IE3 motor at an ambient

temperature of 70 °C must not be loaded more than 89 % of the

rated output. If the pump is installed 4750 metres above sea

level, the motor must not be loaded more than 89 % of the rated

output.

In cases where both the maximum temperature and the maximum

altitude are exceeded, the derating factors must be multiplied

(0.89 x 0.89 = 0.79).

Example CR3-10X-X-X-X-XXXX

Type range: CR, CRI, CRN

Rated flow rate in m3/h

Number of impellers

Code for pump version

Code for pipework connection

Code for materials

Code for rubber pump parts

Code for shaft seal

Example CR 32- 2 1- X- X- X- X- XXXX

Type range: CR, CRN

Rated flow rate in m3/h

Number of stages

Number of impellers with reduced diameter

Code for pump version

Code for pipework connection

Code for materials

Code for rubber pump parts

Code for shaft seal

Warning

The pumping media is not suitable for the pump as it

can cause injury to persons or damage to the

equipment.

Motor

power

[kW]

Motor

make

Motor

efficiency

class

Maximum

ambient

temperature

[°C]

Maximum

altitude

above sea

level

[m]

0.37 - 0.55 Grundfos

MG - +40 1000

0.75 - 22 Grundfos

MG IE3 +60 3500

30-75 Siemens IE3 +55 2750

TM03 2479 4405

Pos. Motor power

[kW] Motor make

10.37 - 0.55 MG

0.37 - 22 MGE

20.75-22 MG

3 30-75 Siemens

Note

For motor bearing maintenance at ambient

temperatures above 40 °C, see section

9. Maintenance.

20 25 30 35 40 45 50 55 60 65 70 75 80

100

[%]

t [°C]

1000 2250 3500 4750 m

English (GB)

5.2 Liquid temperature

The table on page 16 states the relationship between liquid

temperature range and maximum permissible operating pressure.

5.3 Maximum permissible operating pressure and

liquid temperature for the shaft seal

CR, CRI, CRN 1s to 20 and CR, CRN 32 to 150

Fig. 3 Maximum permissible operating pressure and liquid

temperature

You can clean CRI and CRN pumps in place (CIP) with a type H

shaft seal with EPDM rubber parts, HxxE and liquids up to 150 °C

for maximum 15 minutes.

CR, CRI, CRN pumps are not suitable for the pumping of liquids

above 120 °C for long periods.

5.4 Minimum inlet pressure

Fig. 4 Schematic view of open system with a CR pump

Calculate the maximum suction lift "H" in metres head as follows:

H = pbx 10.2 - NPSH - Hf- Hv- Hs

pb= Barometric pressure in bar.

Barometric pressure can be set to 1 bar.

In closed systems, pbindicates the system pressure in

bar.

NPSH = Net Positive Suction Head in metres head.

To be read from the NPSH curve on page 14 at the

highest flow the pump will be delivering.

Hf= Friction loss in inlet pipe in metres head at the highest

flow the pump will be delivering.

Hv= Vapour pressure in metres head, see fig. E on page 19.

tm= liquid temperature.

Hs= Safety margin = minimum 0.5 metres head.

If the calculated "H" is positive, the pump can operate at a suction

lift of maximum "H" metres head.

If the calculated "H" is negative, an inlet pressure of minimum "H"

metres head is required. There must be a pressure equal to the

calculated "H" during operation.

Example

pb= 1 bar.

Pump type: CR 15, 50 Hz.

Flow rate: 15 m3/h.

NPSH (from page 14): 1.1 metres head.

Hf= 3.0 metres head.

Liquid temperature: +60 °C.

Hv(from fig. E, page 19): 2.1 metres head.

H = pbx 10.2 - NPSH - Hf- Hv- Hs [metres head].

H = 1 x 10.2 - 1.1 - 3.0 - 2.1 - 0.5 = 3.5 metres head.

This means that the pump can operate at a suction lift of

maximum 3.5 metres head.

Pressure calculated in bar: 3.5 x 0.0981 = 0.343 bar.

Pressure calculated in kPa: 3.5 x 9.81 = 34.3 kPa.

5.5 Minimum inlet pressure

The table on page 17 states the maximum permissible inlet

pressure. However, the actual inlet pressure + maximum pump

pressure (at no flow) must always be lower than the values stated

in fig. A, page 16.

The pumps are pressure-tested at a pressure of 1.5 times the

values stated in fig. B, page 17.

Note

The maximum permissible operating pressure and

liquid temperature ranges apply to the pump only.

Note

The diagram below applies to clean water and water

containing anti-freeze liquids.

TM03 8853 4907

Standard shaft seal Motor

[kW]

Max. temperature range

[°C]

HQQE 0.37 - 45 -40 - 120 °C

HBQE 55-75 0-120 °C

HQQV 0.37 - 45 -20 - 90 °C

HBQV 55-75 0-90 °C

Note

The pumping of liquids above +120 °C may result in

periodical noise and reduced pump life.

-60 -40 -20 020 40 60 80 100 120 140

p [bar]

HQQE/V

HBQE/V

t [°C]

TM02 0118 3800

HNPSH

English (GB)

5.6 Minimum flow rate

Due to the risk of overheating, do not use the pump at flows

below the minimum flow rate.

The curves below show the minimum flow rate as a percentage of

the rated flow rate in relation to the liquid temperature.

- - - - = air-cooled top.

Fig. 5 Minimum flow rate

5.7 Electrical data

See motor nameplate.

5.8 Frequency of starts and stops

5.9 Dimensions and weights

Dimensions: See fig. C, page 18.

Weights: See label on the packing.

5.10 Sound pressure level

See fig. D, page 19.

6. Installation

The pump must be secured to a horizontal, plane and solid

foundation by bolts through the holes in the base plate. When

installing the pump, follow the procedure below in order to avoid

damaging the pump.

TM01 2816 2302

Caution

The pump must not run against a closed outlet valve.

Motor size

[kW] Maximum number of starts per hour

≤2.2 250

3-4 100

5.5 - 11 50

18.5 - 22 40

30 90

37 50

45 80

55 50

75 50

Step Action

TM02 0013 3800

Arrows on the pump base show

the direction of flow of liquid

through the pump.

TM00 2256 3393

This information is stated on

page 18:

• port-to-port lengths

• dimensions of the base

• pipework connections

• diameter and position of

foundation bolts.

40 60 80 100 120 140 160 180t [°C]

Qmin

[%]

4 x ø

TM01 1241 4097

You can install the pump

vertically or horizontally. CR,

CRN 120 and 150, 75 kW, only

vertically. However, the motor

must neither fall below the

horizontal plane nor be

installed upside down.

Make sure that an adequate

supply of cool air reaches the

motor cooling fan.

Motors above 4 kW must be

supported.

TM05 7705 1013

Additional support. As the

centre of gravity on the pump is

relative high, we recommend

that pumps installed on ships,

in areas with risk of earth

quake or in systems which has

to be moved are equipped with

additional support brackets.

You can fit the bracket from the

motor stool to the bulkhead of

the ship, a rigid wall in a

building or to a rigid part.

TM02 0116 3800

To minimise possible noise

from the pump, we advise you

to fit expansion joints on either

side of the pump.

Carry out the foundation or

installation as described in

section 6.1 Foundation.

Fit the isolating valves on

either side of the pump to avoid

draining the system if the pump

needs to be removed for

cleaning, repair or

replacement.

Always protect the pump

against backflow by means of a

non-return valve.

TM02 0114 3800

Install the pipes so that air

locks do not occur, especially

on the inlet side of the pump.

TM02 0115 3800

Fit a vacuum valve close to the

pump if the installation has one

of these characteristics:

• The outlet pipe slopes

downwards away from the

pump.

• There is a risk of siphon

effect.

• Protection against backflow

of unclean liquids is needed.

Step Action

English (GB)

6.1 Foundation

Grundfos recommends that you install the pump on a concrete

foundation which is heavy enough to provide permanent and rigid

support to the entire pump. The foundation must be capable of

absorbing any vibration, normal strain or shock. The concrete

foundation must have an absolutely level and even surface.

Place the pump on the foundation, and fasten it. The base plate

must be supported on the whole area.

The following instruction applies when mounting the pump in

vertical or horizontal position.

Place the pump on the foundation, and fasten it. See fig. 6.

Fig. 6 Correct installation

Fig. 7 Foundation, vertical mounting

The recommended length and width are shown in fig. 7. Note that

the length and width of the foundation for pumps with motor size

below or equal to 30 kW must be 200 mm larger than the base

plate.

For pumps with motor size above or equal to 37 kW, the length

and width must always be 1.5 x 1.5 (Lfx Bf) metres.

Fig. 8 Foundation, horizontal mounting

The foundation length and width must always be 200 mm larger

than the length and width of the pump. See fig. 8.

The mass of the foundation must be at least 1.5 times the total

mass of the pump. The minimum height of the foundation (hf) can

then be calculated:

The density (δ) of concrete is usually taken as 2200 kg/m3.

In installations where noise-less operation is particularly

important, we recommend that you use a foundation with a mass

up to 5 times that of the pump.

The foundation must be provided with bolts for fixing the base

plate. See fig. 9.

Fig. 9 Bolt in foundation

When the foundation bolts are in position, place the pump on the

foundation. Then align the base plate using shims, if necessary,

so that it is completely horizontal. See fig. 10.

Fig. 10 Alignment with shims

Warning

To avoid personal injury, make sure that the pump is

mounted securely in all conditions.

Warning

Carry out the foundation or installation in accordance

with the following instructions.

TM04 0342 0608TM04 0343 0608

TM05 9579 4113

hf= mpump ×1.5

Lf×Bf×δconcrete

TM03 4589 2206TM04 0362 0608

Shims

English (GB)

6.2 Vibration dampening

If you use vibration dampers, install them under the foundation.

Pumps with motor size below or equal to 30 kW can use vibration

dampers as shown in fig. 11.

For pumps with motor sizes above or equal to 37 kW, use a

Sylomer®plate as shown in fig. 12.

Fig. 11 Pump on vibration dampers

Fig. 12 Pump on Sylomer®plate

6.3 Outdoor installation

When installed outdoors, we recommend that you provide the

motor with a rain cover. We also recommend that you open one of

the drain holes in the motor flange.

6.4 Hot or cold surfaces

Figure 13 shows which pump parts get as hot or cold as the

pumped liquid.

Fig. 13 Hot or cold surfaces on a CR, CRI, CRN pump

6.5 Torques

The table shows the recommended torques for bolts in base and

flanges.

The bolt quality must be minimum 8.8.

TM04 1691 1008TM04 1692 1008

Vibration dampers

Sylomer®plate

Warning

When pumping hot or cold liquids, make sure that

persons cannot accidentally come into contact with

hot or cold surfaces.

TM04 0361 0608

Caution

To minimize risk of damage to the equipment, make

sure to tighten bolts according to recommendations.

CR, CRI, CRN Base

[Nm]

Flange [Nm]

DIN, JIS, ANSI Oval

1s-5 40 M10 - 50-60

10-20 50 M12 60 60-70

32-150 70 M16 100 70-80

M20 150 -

M24 200 -

Pump head

Pump sleeve

Base

English (GB)

6.6 Flange forces and torques

If not all loads reach the maximum permissible value stated in the

tables below, one of these values may exceed the normal limit.

Contact Grundfos for further information.

Fig. 14 Flange forces and torques

Forces

The following tables represent values that applies according to

the material quality.

TM04 0346 2013

Y-direction: Inlet/outlet

Z-direction: Direction of chamber stack

X-direction: 90 ° from inlet/outlet

Force limits for CR cast-iron pump housing

Flange, DN

[mm]

Force, Y-direction

[N]

Force, Z-direction

[N]

Force, X-direction

[N]

25/32 1s-5 338 394 319

40 10 413 469 375

50 15 and 20 563 581 506

65 32 694 788 638

80 45 938 769 844

100 64 and 90 1256 1013 1125

125/150 120 and 150 1256 1013 1125

Torque limits to CR cast-iron pump housing

Flange, DN

[mm]

Torque, Y-direction

[Nm]

Torque, Z-direction

[Nm]

Torque, X-direction

[Nm]

25/32 1s-5 300 175 125

40 10 400 275 200

50 15 and 20 450 325 250

65 32 500 350 300

80 45 325 400 550

100 64 and 90 375 475 625

125/150 120 and 150 375 475 625

Force limits for CRI, CRN stainless-steel pumps housing

Flange, DN

[mm]

CRI, CRN

Force, Y-direction

[N]

Force, Z-direction

[N]

Force, X-direction

[N]

25/32 1s-5 675 788 638

40 10 825 938 750

50 15 and 20 1125 1163 1013

65 32 1388 1575 1275

80 45 1875 1538 1688

100 64 and 90 2513 2025 2250

125/150 120 and 150 2513 2025 2250

Torque limits to CRI, CRN stainless steel pump housing

Flange, DN

[mm]

CRI, CRN

Torque, Y-direction

[Nm]

Torque, Z-direction

[Nm]

Torque, X-direction

[Nm]

25/32 1s-5 600 350 250

40 10 800 550 400

50 15 and 20 900 650 500

65 32 1000 700 600

80 45 650 800 1100

100 64 and 90 750 950 1250

125/150 120 and 150 750 950 1250

English (GB)

7. Electrical connection

The electrical connection must be carried out by an authorised

electrician in accordance with local regulations.

The operating voltage and frequency are marked on the motor

nameplate. Make sure that the motor is suitable for the power

supply on which it will be used and the motor terminal connection

is correct. You will find a wiring diagram in the terminal box.

7.1 Cable entry/screwed connection

All motors are supplied without screwed cable entries. The table

below shows the numbers and sizes of cable entry holes of the

terminal box (standard EN 50262).

7.2 Three-phase connection

1) 60 Hz motors, 0.37 - 1.1 kW: 220-277/380-440 V.

Fig. 15 Delta connection

Fig. 16 Star connection

If the motor is provided with PTC sensors or PTO contacts, the

connection must be in accordance with the wiring diagram in the

terminal box.

Connect three-phase motors to a motor-protective circuit breaker.

Warning

Connect the CR pump to an external mains switch

placed close to the pump and to a motor-protective

circuit breaker or a CUE frequency converter. Make

sure you can lock the mains switch in OFF position

(isolated). Type and requirements as specified in EN

60204-1, 5.3.2.

Warning

Before removing the terminal box cover and before

removing or dismantling the pump, make sure that

the power supply has been switched off and that it

cannot be accidentally switched on.

Caution

Consider whether it is necessary to install an

emergency stop switch.

Motor

[kW]

Number and size

of cable entries Description

0.25 - 0.55 2 x M20 x 1.5

The holes have precast

threads and are closed with

knock-out cable entries

0.75 - 3.0 2 x M20 The holes are closed with

knock-out cable entries

4.0 - 7.5 4 x M25 The holes are closed with

knock-out cable entries

11-22 2 x M20

4 x M40

The holes are closed with

knock-out cable entries

30-45 2 x M50 x 1.5 Blanking plug

55-75 2 x M63 x 1.5 Blanking plug

Mains supply [V]

Delta connection Star connection

50 Hz 220-240 / 380-415

380-415 / 660-690

60 Hz 220-277 / 380-4801)

380-480 / 660-690

TM02 6656 1305TM02 6655 1305

W2 U2 V2

U1 V1 W1

W2 U2 V2

V1 W1

English (GB)

7.3 Single-phase connection

Fig. 17 Connection, "low voltage", 0.37 - 0.75 kW

Fig. 18 Connection, "high voltage", 0.37 - 0.75 kW

Fig. 19 Connection, "low voltage", 1.1 - 2.2 kW

Fig. 20 Connection, "high voltage", 1.1 - 2.2 kW

Single-phase Grundfos motors incorporate a thermal switch and

require no additional motor protection.

7.4 Terminal box positions

You can turn the terminal box to four positions, in 90 ° steps.

Follow this procedure:

1. If necessary, remove the coupling guards. Do not remove the

coupling.

2. Remove the bolts securing the motor to the pump.

3. Turn the motor to the required position.

4. Replace and tighten the bolts.

5. Replace the coupling guards.

Carry out the electrical connection as shown in the diagram

inside the terminal box cover.

7.5 Frequency converter operation

You can use 3-phase motors for frequency convertor operation

following the conditions below. This section applies to motors

defined in IEC 60034.

7.5.1 General conditions

Protect all motors used with frequency converters against voltage

peaks and dU/dt according to IEC 60034-17. Grundfos

recommends that you use insulated bearings for motors from

frame size 225 (45 kW/2-pole, 30 kW/4-pole and 22 kW/6-pole).

Mains voltage dependent conditions

200-240 V

No output filters are required for frequency converter operated

motors with mains voltages up to 240 V.

380-500 V

For frequency converter operated motors with motor cable length

less than 25 metres and mains supply up to 460 V. No additional

motor protection against voltage peaks is required. For frequency

converter operated motors with motor cable length of more than

25 metres or mains supply higher than 460 V, sine-wave filters

are required.

500 V and higher

Always use sine-wave filters for motors marked with 500 V or

higher voltages. *

Exception

• Protect Grundfos motors types MG 71 and MG 80 (up to 1.1

kW/2-pole and up to 0.75 kW/4-pole) for supply voltages up to

and including 440 V without phase insulation against voltage

peaks above 650 V between the supply terminals.

• If you use MG 71 and MG 80 without phase insulation for input

voltages above 240 V, it requires that you use sine save filters

at the output of the frequency converter.

• MG 71 and MG 80 with phase insulation for use with variable

frequency drives are available as standard products.

* Motors with reinforced insulation can be supplied as an option.

These motors are according to IEC 60034-25 and therefore there

is no need for sine-wave filters. This do not eliminate the

requirement for insulated bearings from frame size 225.

7.5.2 Motors supplied by Grundfos

You can connect all three-phase MG motors with phase insulation

to a frequency converter.

Mains supply [V]

"Low voltage" "High voltage"

50 Hz 220-230 / 240

TM04 1693 1008TM04 1694 1008TM04 0345 0608TM04 0344 0608

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