Grundfos Hydro 2000 F Bedienungsanleitung

Hydro 2000 F

Installation and operating instructions

GRUNDFOS INSTRUCTIONS

Declaration of Conformity

We GRUNDFOS declare under our sole responsibility that the products

Hydro 2000 F, to which this declaration relates, are in conformity with the

Council Directives on the approximation of the laws of the EC Member States

relating to:

— Machinery (98/37/EC).

Standard used: EN 292.

— Electromagnetic compatibility (89/336/EEC).

Standards used: EN 61 000-6-2 and EN 61 000-6-3.

— Electrical equipment designed for use within certain voltage limits

(73/23/EEC) [95].

Standard used: EN 60 204-1.

Bjerringbro, 1st August 2003

Jan Strandgaard

Technical Manager

CONTENTS

Page

1. General 5

1.1 Scope of these instructions 5

1.2 Related documents 5

2. Product description 5

2.1 GRUNDFOS Hydro 2000 F 5

2.2 GRUNDFOS Control 2000 F 6

2.2.1 Examples of booster sets Hydro 2000 F 7

3. Functions 8

3.1 Control functions and settings 8

3.1.1 Monitoring functions 8

3.1.2 PFU 2000 RAM settings 8

3.1.3 Closed-loop control 9

3.1.4 Cascade control 9

3.1.5 Manual on/off and setting to max. or local 9

3.1.6 Water shortage monitoring 10

3.1.7 On/off mode at low flow 10

3.1.8 Automatic pump change 11

3.1.9 Test run 11

3.1.10 Clock functions 11

3.1.11 Standby pumps 11

3.1.12 Reduced operation 12

3.1.13 Pump priority 12

3.1.14 GRUNDFOS BUS 12

3.2 Control parameters 13

3.2.1 Allocation of pumps to zone 13

3.2.2 Zone type / control parameter 13

3.2.3 Priority of settings 13

3.2.4 Setpoint 14

3.2.5 Setpoint influences 14

3.2.6 On/off band 15

3.2.7 Measuring unit for control value 16

3.2.8 System time 16

3.2.9 Minimum switching sequence 16

3.2.10 Medium switching sequence 16

3.2.11 Control function 17

3.2.12 PFU 2000 analog input 1 configuration 17

3.2.13 PFU 2000 analog input 2 configuration 17

3.2.14 PFU 2000 analog input 3 configuration 17

3.2.15 PFU 2000 input 4 configuration 18

3.2.16 Ramp time 18

3.2.17 Minimum pump speed limit 19

3.2.18 Maximum limit (overpressure) 19

3.2.19 Minimum limit 19

3.2.20 Operation at minimum limit 19

3.2.21 Minimum pre-pressure 19

3.3 Pump parameters 19

3.3.1 Maximum head 20

3.3.2 Operating hours 20

3.3.3 Start time 20

4. Installation 20

4.1 Location 20

4.2 Hydraulic installation 20

4.3 Electrical connection 20

5. Start-up 21

5.1 Hydro 2000 F without a PMU 2000 21

5.1.1 Setting via a temporarily connected PMU 2000 21

5.2 Hydro 2000 F with a PMU 2000 21

5.3 Direction of rotation 21

5.4 Taking out of operation 22

6. Operation 22

6.1 Operation of PMU 2000 22

6.1.1 Display rules 23

6.1.2 Status display 23

6.2 Frequency converter settings 23

6.3 Configuration of the PFU 2000 23

6.3.1 PFU 2000 DIP switch settings 24

6.3.2 Configuration of PCU relays 25

7. Monitoring functions 25

7.1 Faults, general 25

7.2 Pump- and motor-related faults 26

7.2.1 Communication faults 26

7.2.2 Motor overtemperature 26

7.2.3 Frequency converter 26

7.3 Zone-related faults 26

7.3.1 Transmitter fault 26

7.3.2 Water shortage 26

7.3.3 Maximum limit of actual value 26

7.3.4 Minimum limit of actual value 26

7.3.5 Any fault in the zone 26

7.3.6 Fault in any motor 26

7.4 System-related faults 27

7.4.1 Voltage drop 27

8. Maintenance 27

8.1 Maintenance of booster set 27

8.1.1 Pumps 27

8.1.2 Motor bearings 27

8.1.3 Frost protection 27

8.2 Maintenance of the Control 2000 F 27

9. Operating and fault indications 28

10. Fault finding chart 29

11. Technical data 30

11.1 Hydraulic data 30

11.2 Operating conditions 30

11.3 Sound pressure level 30

11.4 Electrical data 31

12. Glossary 32

13. Display overviews 33

2. Product description

2.1 GRUNDFOS Hydro 2000 F

GRUNDFOS booster sets Hydro 2000 F consist of a number of

pumps with all necessary fittings and a GRUNDFOS Control 2000

F mounted on a common base frame, all ready for installation.

A diaphragm tank must be included in the installation.

Fig. 1

TM01 1521 1799

PRESSURE

TRANSMITTER

VALVE

PFU 2000

PRESSURE GAUGE

NON-RETURN

VALVE

ISOLATING

PUMP

Control 2000

GRUNDFOS booster set Hydro 2000 F

1. General

1.1 Scope of these instructions

These installation and operating instructions apply to GRUND-

FOS booster sets Hydro 2000 F.

GRUNDFOS booster sets Hydro 2000 F are designed for the

transfer and pressure boosting of clean water in waterworks,

blocks of flats, hotels, industry, hospitals, schools, etc.

The Hydro 2000 F range includes two types of systems, i.e. MF,

and MFH.

1.2 Related documents

For some booster sets, the detailed information can be found in

the related documents.

• List of Control Parameters (factory configuration).

• Wiring diagram.

• Installation and operating instructions.

• Installation and operating instructions for the frequency con-

verter.

• Data booklet.

System

type System function

Hydro 2000 F

All pumps are full-size pumps.

One pump is operated via a frequency con-

verter. The other pumps are mains-operated

(on/off).

All pumps will be controlled by the frequency

converter in rotation.

MFH

Two pumps are half-size pumps. The other

pumps are full-size pumps.

The two half-size pumps are controlled by the

frequency converter in rotation, and the full-size

pumps are mains-operated (on/off).

Fig. 2

Fig. 3

PFU 2000 front cover

Reset

TM00 2721 2397

PMU 2000 front cover

TM00 7023 1302

2.2 GRUNDFOS Control 2000 F

The GRUNDFOS Control 2000 F controls a number of pumps,

some are operated via a frequency converter and some are

mains-operated.

The Control 2000 F always includes the PFU 2000 with applica-

tion-optimized software, but it is also available with a PMU 2000.

The operating conditions and factory settings can be optimized

via a temporarily connected PMU 2000.

If the Control 2000 F includes the PFU 2000 only, it will be placed

in the front cover. If the Control 2000 F includes both the

PFU 2000 and the PMU 2000, the PMU 2000 will be placed in the

front cover and the PFU 2000 inside the cabinet.

The Control 2000 F is factory-assembled and tested with the con-

trol parameters mentioned in the “List of Control Parameters”,

which is delivered with the booster set.

The Control 2000 F offers the following functions:

• Closed-loop control.

• On/off operation at low flow.

• Automatic pump changeover to mains operation in case of

damage to the frequency converter.

• Automatic cascade control of pumps.

• Selection of switching sequences, automatic pump change

and pump priority.

• Manual operation.

• Possibility of various analog setpoint influences:

– friction loss compensation (flow-dependent setpoint

control with or without flow measurement),

– temperature-dependent setpoint control,

– setpoint adjustment.

• Possibility of various digital remote-control functions:

– system on/off,

– reduced operation,

– setpoint control with two-point switch,

– setpoint control with three-point switch,

– alternative setpoint,

– fire-fighting operation,

– switching off individual pumps.

• Pump and system monitoring functions:

– minimum and maximum limits of actual value,

– pre-pressure,

– motor protection,

– BUS communication.

• Display and indication functions:

– 2 x 24 character LCD display,

– green indicator light for operating indications and

red indicator light for fault indications,

– potential-free changeover contacts for operation and fault.

• Clock functions.

• GRUNDFOS BUS communication.

2.2.1 Examples of booster sets Hydro 2000 F

Example:

GRUNDFOS Hydro 2000 MF.

Four pumps and a diaphragm tank.

Example:

GRUNDFOS Hydro 2000 MFH.

Two half-size pumps, two full-size pumps

and a diaphragm tank.

One pump in operation via frequency con-

verter. One half-size pump in operation via fre-

quency converter.

One pump in operation via frequency con-

verter and two pumps on mains operation. One half-size pump in operation via fre-

quency converter and one full-size pump on

mains operation.

GRUNDFOS Hydro 2000 MF maintains a

constant pressure through continuously vari-

able adjustment of the speed of one pump.

The other pumps are mains-operated

(on/off) according to the demand thus

achieving a system size corresponding to

the consumption.

The frequency-converter controlled pump

will always start first.

Pump changeover is automatic and

depends on load, time and fault. Besides, all

pumps will be controlled by the frequency

converter in rotation.

GRUNDFOS Hydro 2000 MFH maintains a

constant pressure through continuously vari-

able adjustment of the speed of one half-

size pump. The rest of the pumps are mains-

operated.

The half-size pump controlled by the fre-

quency converter will always start first.

Changeover among the half-size pumps,

which can both be controlled by the fre-

quency converter, as well the full-size

pumps is automatic and depends on load,

time and fault.

TM00 2680 0294

PFU 2000

TM00 2677 0294

PFU 2000

sætH

Hset

TM00 2753 0294

sætH

Hset

TM00 2777 0294

sætH

Hset

TM00 2755 0294

sæt

Hset

TM00 2779 0294

3. Functions

3.1 Control functions and settings

The display numbers mentioned in the following refer to the dis-

play overviews in section 13. Display overviews.

In the PFU 2000, two sets of control parameter settings are

stored:

• PFU 2000 EPROM settings, which are default values.

• PFU 2000 RAM settings, which are configuration values.

(These values can be changed.)

The PFU 2000 RAM settings are configured and displayed in the

PMU 2000.

Operation with PFU 2000 EPROM settings or PFU 2000 RAM

settings can be changed by means of the DIP switches in the

PFU 2000.

The PFU 2000 EPROM default settings and the PFU 2000 RAM

settings are listed in the “List of Control Parameters”. This list

should be updated after each change of setting.

PFU 2000 EPROM settings should not be used for continuous op-

eration. It is preferable to operate the booster set with PFU 2000

RAM settings.

3.1.1 Monitoring functions

The following functions are available:

• Red indicator light (LED) for indication of fault condition.

• Green indicator light (LED) for indication of operating condi-

tion.

• PFU 2000 fault signal relay for indication of fault condition.

• PFU 2000 operating signal relay for indication of operating

condition.

• PMU 2000 fault signal relay for indication of fault condition

(if a PMU 2000 is installed).

• PMU 2000 operating signal relay for indication of operating

condition (if a PMU 2000 is installed).

• GRUNDFOS BUS communication.

See also section 9. Operating and fault indications.

Fig. 4

Fig. 5

PFU 2000 front cover

Reset

TM00 2721 1302

PMU 2000 front cover

TM00 7023 1302

3.1.2 PFU 2000 RAM settings

The PMU 2000 maintains the PFU 2000 RAM settings as long as

the units are connected via the GRUNDFOS BUS.

If a PMU 2000 is to be connected or replaced, please note the fol-

lowing:

To enter data from a PMU 2000 into the PFU 2000 RAM:

Fig. 6

1. Connect the GRUNDFOS BUS between the PMU 2000 and

the PFU 2000.

2. Switch on the electricity supply to the PMU 2000.

3. Switch on the electricity supply to the PFU 2000.

4. The settings from the PMU 2000 will be entered into the

PFU 2000 RAM. This operation will take about 1 minute.

During this period, the PMU 2000 will display “Master”.

To enter data from a PFU 2000 RAM into the PMU 2000:

Fig. 7

1. Connect the GRUNDFOS BUS between the PMU 2000 and

the PFU 2000.

2. Switch on the electricity supply to the PFU 2000.

3. Switch on the electricity supply to the PMU 2000.

4. The settings from the PFU 2000 RAM will be entered into the

PMU 2000. This operation will take about 1 minute. During this

period, the PMU 2000 will display “Slave”.

For further information, see section

3.1 Control functions and settings.

PMU 2000

PFU 2000

GRUNDFOS BUS

TM00 8462 2896

PMU 2000

PFU 2000

GRUNDFOS BUS

TM00 8461 2896

3.1.4 Cascade control

Cascade control ensures automatic matching of the performance

to the system demand by cutting in/out the required number of

pumps.

The controller will operate the system with as few pumps as pos-

sible.

The frequency of starts and stops is limited by the setting of mini-

mum and medium switching sequences.

For further information, see sections

3.2.9 Minimum switching sequence,

3.2.10 Medium switching sequence and

3.2.17 Minimum pump speed limit.

3.1.5 Manual on/off and setting to max. or local

Operation with PFU 2000 RAM / PMU 2000 settings:

Fig. 10

In the start/stop menu, the “On/Off” button on the PMU 2000

gives quick access to:

• manual on/off of zone and setting to max. or local,

• manual on/off of individual pumps.

In this menu, the zone and the pumps allocated to this zone ap-

pear one by one when the arrow buttons are pressed.

The operating condition of the zone or pump in question is dis-

played in the top line. In the bottom line, a new status can be se-

lected.

Start/stop of zones (display 300):

•“on”

All pumps in the zone are ready for operation.

•“off”

All pumps in the zone are switched off.

•“max.”

All pumps in the zone are operating at maximum performance.

• “local”

The controller has been set to local mode and will operate ac-

cording to the local control parameter settings.

See section 6.3.1 PFU 2000 DIP switch settings.

If the function selector in the PFU 2000 has been turned to posi-

tion MAX, the setpoint influences, “clock program” and “remote

on/off” are not effective.

Start/stop of pumps (display 301):

•“on”

The pump is ready for operation.

•“off”

The pump is switched off.

Operation with PFU 2000 EPROM settings:

The controller will operate according to the local control parame-

ter settings.

For further information, see section

6.3.1 PFU 2000 DIP switch settings.

Off

3.1.3 Closed-loop control

The closed-loop controller (a control system with a feed-back sig-

nal from a transmitter) is programmed for operation of centrifugal

pumps and takes their influence on the hydraulic system into ac-

count.

Fig. 8

The only control parameter to be set to adapt the controller to the

system conditions is “system time” (display 204), instead of PID

parameters as is the case with conventional closed-loop control-

lers.

• Operation with PFU 2000 RAM / PMU 2000 settings:

With the settings in the start/stop menu (displays 300 and 301)

and with the function selector in the PFU 2000 withinthe range

from 0% to 100%, the closed-loop controller is operating.

• Operation with PFU 2000 EPROM settings:

With the function selector in the PFU 2000 within the range

from 0% to 100%, the closed-loop controller is operating.

Fig. 9

For further information, see section

3.2.5 Setpoint influences.

PMU 2000

PFU 2000

GRUNDFOS BUS

TM00 8277 2596

100%0%

MAXSTOP

Setpoint

Function selector in the PFU 2000

TM00 5217 2796

3.1.6 Water shortage monitoring

The water shortage monitoring function switches off all

pumps.

Note: If the booster set has been delivered without a water short-

age monitor, it should not be started until a water shortage moni-

tor has been installed. Otherwise, there is a risk of damage to the

pumps.

If the function “fire fight” (display 222) is activated, the water

shortage monitoring function is suppressed.

Operation with PFU 2000 RAM / PMU 2000 settings:

Pre-pressure measuring can be set to “on” or “off” (display 216).

Via an analog signal:

Set “prepress.measuring” to “on” (display 216) if a pressure

transmitter is installed on the suction side of the booster set.

The PFU 2000 analog input 2 measures the pre-pressure. The

water shortage monitoring will be carried out according to the set

“min. prepressure” (display 231).

Via a digital signal:

Set “prepress.measuring” to “off” (display 216).

The signal on the PFU 2000 analog input 2 is evaluated as a dig-

ital signal for water shortage monitoring from a pressure switch,

level switch or an electrode relay.

Operation with PFU 2000 EPROM settings:

The pre-pressure can be measured via the PFU 2000 analog

input 2.

Via an analog signal:

If the signal is lower than 5% of the measuring range for more

than 5 secs., a fault is indicated.

Via a digital signal:

If the switch contact indicates water shortage for more than

5 secs., a fault is indicated.

For further information, see section

3.2.13 PFU 2000 analog input 2 configuration.

3.1.7 On/off mode at low flow

One of the advantages of variable-speed pump systems is the

possibility of maintaining a constant discharge pressure, irrespec-

tive of flow and pre-pressure. To avoid unnecessary energy con-

sumption at low flow, it is possible to operate the system with an

adjustable pressure hysteresis (on/off band).

If only one pump is operating at low speed, changeover to on/off

mode will be attempted by checking whether the flow is low

enough (approx. once per minute).

The boost frequency and the flow rate at which the controller

changes over to on/off mode and back to constant-pressure

mode is influenced by the following control parameters:

• On/off band

When the setting of the on/off band is increased, the change-

over will be carried out at higher flow rates (lower boost fre-

quency at the same flow). If the on/off band is set to zero,

there will be no changeover to on/off mode.

• Medium switching sequence

When this setting is reduced, the changeover will be carried

out at higher flow rates (higher boost frequency allowed).

• Buffer tank capacity

With increased tank capacity, the changeover will be carried

out at higher flow rates (lower boost frequency at the same

flow).

Fig. 11

1. Actual setpoint.

2. Pressure: actual setpoint + on/off band.

3. Operation at normal flow.

4. 3% boost (high flow is registered).

5. 3% boost (low flow is registered), increased test boost and

changeover to on/off mode.

6. Short period of pressure boosting.

7. Long period at zero speed.

8. Further decreased flow caused lower boost frequency in on/off

mode.

9. Increased flow; controller changes back to constant-pressure

mode.

For further information, see sections

3.2.6 On/off band,

3.2.10 Medium switching sequence and

3.2.17 Minimum pump speed limit.

1. 3.

Time

7. 8. 9.

HPressure in on/off mode

TM00 7785 1996

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