Grundfos Hydro Multi-B Series Bedienungsanleitung

Hydro Multi-B

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. Scope of these instructions

These installation and operating instructions apply to Grundfos

Hydro Multi-B booster systems. Hydro Multi-B is a range of

factory-assembled booster systems, ready for installation and

operation.

1. Symbols used in this document 2

2. Scope of these instructions 2

3. Product description 3

4. Application types 4

4.1 Booster system for constant-pressure applications 4

4.2 Booster systems for tank-filling applications 5

5. Delivery and handling 6

5.1 Delivery 6

5.2 Handling 6

6. Identification 6

6.1 Nameplate 6

6.2 Type key 7

7. Installation 8

7.1 Mechanical installation 8

7.2 Electrical installation 9

8. User interface 10

9. Startup 12

10. Operating modes 13

10.1 Local mode, external stop not activated 13

10.2 Local mode, external stop activated 13

10.3 Remote-controlled, external stop not activated 14

10.4 Remote-controlled, external stop activated 14

11. Functions 15

11.1 General functions 15

11.2 Functions for constant-pressure systems 16

11.3 Functions for tank-filling systems 17

12. Data communication 17

13. Fault finding 18

14. Maintenance 19

14.1 Pumps 19

14.2 CU 323 19

15. Frost protection 19

16. Taking out of operation 19

17. Technical data 19

17.1 Pressure 19

17.2 Temperature 19

17.3 Relative humidity 19

17.4 Sound pressure level 19

18. Electrical data 20

19. Related documents 20

20. Service 20

20.1 Service documentation 20

21. Disposal 20

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

The use of this product requires experience with

and knowledge of the product.

Persons with reduced physical, sensory or

mental capabilities must not use this product,

unless they are under supervision or have been

instructed in the use of the product by a person

responsible for their safety.

Children must not use or play with this product.

Warning

If these safety instructions are not observed,

it may result in personal injury.

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.

English (GB)

3. Product description

As standard, the booster systems consist of two to four pumps

coupled in parallel and mounted on a common base frame with all

the necessary fittings and a control cabinet.

Fig. 1 Front view of Hydro Multi-B CM, CME booster system

Fig. 2 Back view of Hydro Multi-B CM, CME booster system

Fig. 3 Front view of Hydro Multi-B CR booster system

Fig. 4 Back view of Hydro Multi-B CR booster system

TM04 9898 0211TM04 9899 0211

Pos. Description Quantity

1 Control cabinet 1

2 Suction manifold 1

3 Discharge manifold 1

4 Diaphragm tank 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 Flexible connection 1 per pump

12 Screw cap or blanking flange 2

TM06 867 4814TM06 2868 4814

Pos. Description Quantity

1 Control cabinet 1

2 Suction manifold 1

3 Discharge manifold 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

12 Screw cap or blanking flange 2

English (GB)

4. Application types

The booster systems are available for the following application

types:

• constant-pressure boosting

• tank filling.

Furthermore, two control variants of the booster systems are

available. The control variants are described below.

4.1 Booster system for constant-pressure applications

The booster system for constant-pressure applications is

designed to maintain a constant pressure on the discharge 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.

4.1.1 Operating principle

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

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

the system performance according to the feedback received from

the pressure transmitter installed in the discharge manifold.

4.1.2 Control variants

The booster systems for constant-pressure applications are available as control variants E and ES.

Both systems work as described below.

Control variant E Control variant ES

Two to four electronically speed-controlled pumps One to three mains-operated pumps and one speed-controlled

pump

TM03 0993 0905

TM03 0996 0905

One speed-controlled pump in operation. One speed-controlled pump in operation.

TM00 7995 2296

Three speed-controlled pumps in operation. One speed-controlled pump and two mains-operated pumps in

operation.

TM00 7996 2296

TM00 7998 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.

• Control variant ES for constant-pressure applications

maintains a constant pressure through continuous adjustment

of the speed of the speed-controlled pump. The other pumps

are cut in/out according to demand and to achieve a

performance corresponding to the consumption.

• The speed-controlled pump always starts first and will be the

last to stop. If the pressure cannot be maintained by the

pump, one or both mains-operated pumps will be cut in.

• Changeover among the mains-operated pumps is automatic

and depends on load, time and fault.

Hset

English (GB)

4.2 Booster systems 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 or

a level sensor.

4.2.1 Operating principle

The system has two methods of operation, one based on level

switches and the other on a level sensor.

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.

Factory setting

Start level: 15 % of setpoint

Stop level: 85 % of setpoint

High-level alarm: 95 % of setpoint.

4.2.2 Control variants

The booster systems for tank-filling applications are available as control variants E and ES. Both systems work as described below.

Control variants E and ES

E: Two to four electronically speed-controlled pumps

ES: One to three mains-operated pumps and one speed-controlled pump

TM05 0222 0911

Fig. 5 Example of control variant ES

• 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 in order

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.

E-pump starts fixed-speed pump

starts

fixed-speed pump

stops E-pump stops

Time

Pump speed

100 %

70 %

English (GB)

5. Delivery and handling

5.1 Delivery

The booster system is delivered in a recyclable packaging,

specially designed for transport by fork-lift truck or a similar

vehicle.

The forks of the fork-lift truck must be at least 2 metres long.

5.2 Handling

The booster systems with CM and CME pumps must be lifted as

shown in fig. 6.

During handling, the lifting point should always be above the

centre of gravity of the booster system.

Fig. 6 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.

6. Identification

6.1 Nameplate

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

Fig. 7 Nameplate

TM05 0221 0911

Warning

When lifting the booster system, never use the

eyebolts of the motors.

Do not lift the booster system by the manifolds.

Do not stand on the manifolds.

TM04 9897 0211

Pos. Description

1 Product type

2 Code for model

3 Serial number

4 Main supply

5 Max. operating pressure

6 Liquid temperature, medium

7 Maximum flow rate [m3/h]

8 Nominal head [m]

9 Technical documents

10 Insulation class

11 Weight

12 Approval marks

13 QR code

14 Country of origin

English (GB)

6.2 Type key

* With ES systems, the first pump is equal to an E-pump. The remaining pumps are fixed-speed pump. Except from cases where the

E-pump is controlled by a CUE or VFD. In these cases, all pumps are fixed-speed pumps.

** Hydro Multi-B ES systems will only be shown with the E-pump description which means that the fixed-speed pump is identical in size,

number of stages, material combination and kW. Except from cases where the E-pump is controlled by a CUE or VFD. In these cases,

all pumps are fixed-speed pumps.

Example Hydro Multi-B ES 4 CME 0-8 U1 G- E-z U- G-

Type range

System variants

E: All pumps E-motor or all fixed-speed pumps with CUE/VFD

ES: Fixed-speed pumps, one E-motor or fixed-speed pump with CUE/VFD

Number of pumps*

Pump type**

Voltage code

U1: 3 x 380-415, N, PE, 50/60 Hz

U2: 3 x 380-415, PE, 50/60 Hz

U3: 3 x 380-415, N, PE, 50 Hz

U4: 3 x 380-415, PE, 50 Hz

U5: 3 x 380-415, N, PE, 60 Hz

U6: 3 x 380-415, PE, 60 Hz

U7: 1 x 200-240, PE, 50/60 Hz

U8: 1 x 200-240, N, PE, 50/60 Hz

U9: 3 x 220-240, PE, 60 Hz

UA: 3 x 440-480, PE, 60 Hz

UB: 1 x 220-240, N, PE, 50/60 Hz

UC: 1 x 220-240, N, PE, 50 Hz

Pump material

A: Cast iron (EN-GJL-200)

I: Stainless steel (EN 1.4301/AISI 304)

G: Stainless steel (EN 1.4401/AISI 316)

Design

E: ASEAN design and systems with the control cabinet mounted on the same base frame as the pumps.

F: ASEAN design and systems with the control cabinet centred on the base frame.

G: ASEAN design and systems with the control cabinet mounted on its own base for floor mounting. The control

cabinet can be placed up to 2 metres from the pumps.

H: ASEAN design and systems with the control cabinet mounted on its own base for floor mounting. The control

cabinet can be placed up to 2 metres from the pumps.

I: ASEAN design and systems with the control cabinet prepared for wall mounting. The control cabinet can be placed

up to 2 metres from the pumps.

Application mode

[-]: Constant pressure boosting

U: Tank filling

Manifold/base fame material

[-]: Stainless steel (EN 1.4301, AISI 304) / Black Painted Mild steel (Q235)

G: Galvanised steel / black painted mild steel (Q235)

X: Other materials

English (GB)

7. Installation

Before installation, check the following:

• Does the booster system correspond to order?

• Are all visible parts intact?

7.1 Mechanical installation

7.1.1 Location

The booster system must be installed in a well ventilated room to

ensure sufficient cooling of the pumps and the control cabinet.

The booster system must have a 1-metre clearance on all sides

for inspection and dismantling.

7.1.2 Pipework

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 suction and

discharge pipes. See fig. 8and fig. 9.

To achieve optimum operation and minimise noise and vibration,

it may be necessary to consider vibration dampening of the

booster system.

Noise and vibration are generated by the rotations in the motor

and pump and by the flow in pipework 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 suction and

discharge pipes to prevent vibration being transmitted through

the pipework.

Fig. 8 Example showing the position of expansion joints, pipe

supports and machine shoes

Fig. 9 Example showing the position of expansion joints, pipe

supports and mounting bolts

All nuts should be re-tightened prior to startup.

The pipes must be fastened to parts of the building to ensure that

they cannot move or be twisted.

7.1.3 Foundation

The booster system should be positioned on an even and solid

surface, for instance a concrete floor or foundation. The booster

system must be bolted to the floor or foundation.

7.1.4 Vibration dampers

To prevent the transmission of vibrations to buildings, we

recommend that you isolate the booster system foundation from

building parts by means of vibration dampers.

Which is the right damper varies from installation to installation,

and a wrong damper may increase the vibration level.

Vibration dampers should therefore be sized by the supplier of

vibration dampers. If the booster system is installed on a base

frame with vibration dampers, expansion joints should always be

fitted on the manifolds. This is important to prevent the booster

system from "hanging" in the pipework.

Warning

Installation and operation must comply with local

regulations and accepted codes of good practice.

Caution

The booster system is not designed for outdoor

installation and must not be exposed to direct

sunlight.

Note

The pipework connected to the booster system

must be of adequate size.

TM03 2154 3805

TM04 9900 0211

Pos. Description

1 Expansion joint

2 Pipe support

3 Mounting bolts

Note

Expansion joints, pipe supports and mounting

bolts shown in fig. 8and fig. 9above are not

supplied with a standard booster system.

Note

As a rule of thumb, the weight of a concrete

foundation should be 1.5 x the weight of the

booster system.

English (GB)

7.1.5 Expansion joints

Expansion joints are installed with the following purposes:

• to absorb expansions/contractions in the pipework caused by

changing liquid temperature

• to reduce mechanical strains in connection with pressure

surges in the pipework

• to isolate mechanical structure-borne noise in the pipework

(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 suction as well

as on the discharge side. This prevents the development of

turbulence in the expansion joints, resulting in better suction

conditions and a minimum pressure loss on the discharge side.

Fig. 10 Examples of rubber bellows expansion joints without

and with limit rods

Expansion joints with limit rods can be used to minimise the

forces caused by the expansion joints. Expansion joints with limit

rods are always recommended for flanges larger than DN 100.

The pipework should be anchored so that it does not stress the

expansion joints and the pump. Follow the supplier’s instructions

and pass them on to advisers or pipe installers.

7.1.6 Pre-filling 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 x setpoint.

7.2 Electrical installation

• The electrical installation of the booster system must comply

with enclosure class IP54.

• Make sure that the booster system is suitable for the power

supply to which it is to be connected.

• Make sure that the wire cross-section corresponds to the

specifications in the wiring diagram.

• If the system cannot be installed with the supply disconnecting

device located minimum 0.6 m above service level (ground

level), 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. Furthermore, this device

must be installed in a position in accordance with EN 60204-1,

paragraph 5.3.4. Based on a risk assessment performed by

the installer/end-user, the system must, if required, be

connected to an external emergency stop device or an

emergency switching off device in accordance with the

requirements of EN ISO 13850.

Note

Expansion joints must not be installed to

compensate for inaccuracies in the pipework

such as centre displacement of flanges.

TM02 4981 1902 - TM02 4979 1902

Note

Use nitrogen to avoid corrosion.

Warning

The electrical installation must be carried out by

an authorised person in accordance with local

regulations and the relevant wiring diagram.

English (GB)

8. User interface

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

Figure 11 shows the user interface for a system with four pumps.

Fig. 11 User interface of cabinet and CU 323

TM05 0479 1111

Pos. Buttons Description

1 Changes the system operating mode between "Normal" and "Stop".

2 Increases the setpoint value.

3 Decreases the setpoint value.

4 Resets all alarms.

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

system has an Auto/Off button.

Enables manual operation.

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

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

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

Off

RESET

OFF AUTO

CU 323

system run

alarm

10 11

Off

RESET

OFF AUTO

CU 323

system run

alarm

Off

RESET

Pos. Displays Description

Setpoint Shows the setpoint. After unlocking, the setpoint will flash.

Proportional pressure control. PPP will be flashing one second followed by the current setpoint for

4 seconds. Only available for E-systems.

Tank symbol appearing in tank-filling mode with float switches.

/ setpoint Alternates between tank symbol and 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 will be shown.

Indicates that buttons on the CU 323 have been locked automatically. Unlock the buttons by

pressing (Reset) and or (Reset) and .

Indicates that the system is remote-controlled.

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

1___!

E.St

OFF

0-N

RESET

bUS

LOC

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