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

These installation and operating instructions

describe Grundfos CR, CRI and CRN pumps, 0.37 -

75 kW.

Sections 1-4 give the information necessary to be

able to unpack, install and start up the product in a

safe way.

Sections 5-10 give important information about the

product, as well as information on service, fault

finding and disposal of the product.

CONTENTS

Page

1. General information

1.1 Hazard statements

The symbols and hazard statements below may

appear in Grundfos installation and operating

instructions, safety instructions and service

instructions.

The hazard statements are structured in the

following way:

1.2 Notes

The symbols and notes below may appear in

Grundfos installation and operating instructions,

safety instructions and service instructions.

1. General information 2

1.1 Hazard statements 2

1.2 Notes 2

2. Receiving the product 3

2.1 Transporting the product 3

2.2 Unpacking the product 3

2.3 Inspecting the product 3

2.4 Lifting the product 3

3. Installing the product 4

3.1 Mechanical installation 4

3.2 Electrical connection 10

4. Starting up the product 12

4.1 Shaft seal run-in 12

4.2 Frequency of starts and stops 13

4.3 Operating the product 13

5. Product introduction 14

5.1 Identification 14

5.2 Intended use of the product 15

6. Servicing the product 15

6.1 Contaminated products 16

6.2 Service documentation 16

6.3 Maintaining the product 16

7. Taking the product out of operation 18

7.1 Frost protection 18

7.2 Taking the product permanently out of

operation 18

8. Fault finding the product 19

9. Technical data 21

9.1 Operating conditions 21

9.2 Electrical data 23

9.3 Dimensions and weights 23

10. Disposing of the product 23

Read this document before installing the

product. Installation and operation must

comply with local regulations and accepted

codes of good practice.

DANGER

Indicates a hazardous situation which, if

not avoided, will result in death or serious

personal injury.

WARNING

Indicates a hazardous situation which, if

not avoided, could 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.

Observe these instructions for explosion-

proof products.

A blue or grey circle with a white graphical

symbol indicates that an action must be

taken.

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.

If these instructions are not observed, it

may result in malfunction or damage to the

equipment.

Tips and advice that make the work easier.

English (GB)

2. Receiving the product

2.1 Transporting the product

2.2 Unpacking the product

2.3 Inspecting the product

Before you install the product, do the following:

1. Check that the product is as ordered.

2. Check that no visible parts have been damaged.

If parts are damaged or missing, contact your local

Grundfos sales company.

2.4 Lifting the product

When lifting the entire product 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 Lifting points

In case of CR, CRI and CRN pumps with other

motors than MG or Siemens, we recommend that

you lift the pump by means of the straps in the motor

flange.

WARNING

Falling objects

Death or serious personal injury

- Keep the product in a stable and fixed

position during transportation.

- Wear personal protective equipment.

WARNING

Falling objects

Death or serious personal injury

- Keep the product in a stable position

during unpacking.

- Wear personal protective equipment.

WARNING

Falling objects

Death or serious personal injury

- Follow the lifting instructions.

- Use lifting equipment which is approved

for the weight of the product.

- Persons must keep a safe distance to

the product during lifting operations.

- Wear personal protective equipment.

Note that typically the centre of gravity of

the pump is close to the motor.

0.37 - 5.5 kW 7.5 - 22 kW

TM04 0339 0608

TM04 0341 0608

30-45 kW 55-75 kW

TM05 9564 4113

TM04 0341 0608

English (GB)

3. Installing the product

3.1 Mechanical installation

3.1.1 Lifting the product

For lifting instructions, see section 2.4 Lifting the

product.

WARNING

Contamination when pumping drinking

water

Death or serious personal injury

- Before the pump is used for supplying

drinking water, flush the pump

thoroughly with clean water.

- Do not use the pump for drinking water

if the internal parts have been in contact

with particles or substances not suitable

for water intended for human

consumption.

WARNING

Falling objects

Death or serious personal injury

- Follow the lifting instructions.

- Use lifting equipment which is approved

for the weight of the product.

- Persons must keep a safe distance to

the product during lifting operations.

- Wear personal protective equipment.

English (GB)

3.1.2 Installation guidelines

The pump must be secured to a horizontal, plane

and solid foundation with bolts through the holes in

the base plate. When installing the pump, be aware

of the information below in order to avoid damaging

the pump.

Illustration Information

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 in fig. 3in the appendix:

• port-to-port lengths

• dimensions of the base plate

• pipe connections

• diameter and position of anchor bolts.

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 of the pump is relatively

high, we recommend that pumps installed on ships, in areas with

risk of earth quake or in systems which can be moved, are

equipped with an additional support bracket. 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 recommend that you

fit expansion joints on either side of the pump.

Build a foundation and carry out mechanical installation as

described in section 3.1.3 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 pockets 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.

4 x ø

English (GB)

3.1.3 Foundation

We recommend that you install the pump on a

concrete foundation which is heavy enough to

provide permanent and rigid support for 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 both vertical and horizontal position. Place

the pump on the foundation, and fasten it. See fig. 2.

Fig. 2 Correct installation

The recommended length and width of the

foundation are shown in fig. 3. Note that for pumps

with motor size below or equal to 30 kW, the length

and width of the foundation must be 200 mm larger

than the base plate.

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

the length and width must always be 1.5 x 1.5 (Lf x

Bf) m.

Fig. 3 Foundation, vertical mounting

WARNING

Falling objects

Death or serious personal injury

- Keep the product in a stable and fixed

position before installing it.

- Make sure that the foundation is

suitable for the weight of the product.

TM04 0342 0608

TM04 0343 0608

English (GB)

The foundation length and width must always be 200

mm larger than the length and width of the pump.

See fig. 4.

Fig. 4 Foundation, horizontal mounting

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 anchor bolts

for fixing the base plate. See fig. 5.

Fig. 5 Bolt in foundation

When the anchor 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. 6.

Fig. 6 Alignment with shims

3.1.4 Vibration dampening

Elimination of noise and vibrations is best achieved

by means of a concrete foundation, vibration

dampers and expansion joints.

If you use vibration dampers, install them under the

foundation. For pumps with motor size below or

equal to 30 kW, you can use vibration dampers as

shown in fig. 7.

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

use a Sylomer®plate as shown in fig. 8.

Fig. 7 Pump on vibration dampers

TM05 9579 4113

hf = Mpump ×1.5

Lf ×Bf ×δconcrete

TM03 4589 2206

TM04 0362 0608TM04 1691 1008

Shims

Vibration dampers

English (GB)

Fig. 8 Pump on Sylomer®plate

3.1.5 Outdoor installation

When the pump is 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.

3.1.6 Tightening torques

The table shows the recommended torques for base

plate anchor bolts and flange bolts.

The bolt quality must be minimum class 8.8.

3.1.7 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. 9 Flange forces and torques

The following tables represent the values that apply

according to the material quality.

TM04 1692 1008

WARNING

Flange gasket blowout

Death or serious personal injury

- Tighten flange bolts according to the

torque values stated in the installation

and operating instructions.

CR,

CRI,

CRN

Base

[Nm]

Flange bolts [Nm]

Bolt

size

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 -

Sylomer®plate

TM04 0346 2013

Y-direction: Inlet or outlet

Z-direction: Direction of chamber stack

X-direction: 90 ° from inlet or outlet

English (GB)

Force limits

Torque limits

3.1.8 Positioning the terminal box

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.

Flange,

DN [mm] Type

CR -

Cast iron pump housing

CRI, CRN -

Stainless steel pump housing

Force, Y-

direction

[N]

Force, Z-

direction

[N]

Force, X-

direction

[N]

Force, Y-

direction

[N]

Force, Z-

direction

[N]

Force, X-

direction

[N]

25/32 1s-5 338 394 319 675 788 638

40 10 413 469 375 825 938 750

50 15 and 20 563 581 506 1125 1163 1013

65 32 694 788 638 1388 1575 1275

80 45 938 769 844 1875 1538 1688

100 64 and 90 1256 1013 1125 2513 2025 2250

125/150 120 and 150 1256 1013 1125 2513 2025 2250

Flange,

DN [mm] Type

CR -

Cast iron pump housing

CRI, CRN -

Stainless steel pump housing

Torque, Y-

direction

[Nm]

Torque, Z-

direction

[Nm]

Torque, X-

direction

[Nm]

Torque, Y-

direction

[Nm]

Torque, Z-

direction

[Nm]

Torque, X-

direction

[Nm]

25/32 1s-5 300 175 125 600 350 250

40 10 400 275 200 800 550 400

50 15 and 20 450 325 250 900 650 500

65 32 500 350 300 1000 700 600

80 45 325 400 550 650 800 1100

100 64 and 90 375 475 625 750 950 1250

125/150 120 and 150 375 475 625 750 950 1250

English (GB)

3.2 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 is used and

that the motor terminal connection is correct. You will

find a wiring diagram in the terminal box.

3.2.1 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

according to the standard EN 50262.

3.2.2 Three-phase connection

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

Fig. 10 Delta connection

Fig. 11 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.

Follow the instructions for the motor when

carrying out the electrical connections.

WARNING

Electric shock

Death or serious personal injury

- Before starting any work on the product,

make sure that the power supply has

been switched off and that it cannot be

accidentally switched on.

- Connect the pump to an external main

switch close to the pump and to a

motor-protective circuit breaker or a

CUE frequency converter. Make sure

you can lock the main switch in OFF

position (isolated). Type and

requirements as specified in EN 60204-

1, 5.3.2.

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

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