Grundfos MAGNA3 25-80 (N) Bedienungsanleitung

MAGNA3

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 MAGNA3

model D.

Sections 1-5 give the information necessary to be able to unpack,

install and start up the product in a safe way.

Sections 6-13 give important information about the product, as

well as information on service, fault finding and disposal of the

product.

CONTENTS

Page

1. General information 3

1.1 Hazard statements 3

1.2 Notes 3

1.3 Safety symbols on the pump 3

2. Receiving the product 3

2.1 Inspecting the product 3

2.2 Scope of delivery 3

2.3 Lifting the pump 4

3. Installing the product 5

3.1 Location 5

3.2 Tools 5

3.3 Mechanical installation 5

3.4 Positioning the pump 6

3.5 Control box positions 6

3.6 Pump head position 7

3.7 Changing the control box position 7

3.8 Electrical installation 9

3.9 Wiring diagrams 10

3.10 Connecting the power supply, plug-connected versions 12

3.11 Connecting the power supply, terminal-connected

versions 13

3.12 Connecting the external control 14

4. Starting up the product 15

4.1 Single-head pump 15

4.2 Twin-head pump 16

5. Handling and storing the product 16

5.1 Frost protection 16

6. Product introduction 17

6.1 Applications 17

6.2 Pumped liquids 17

6.3 Pump heads in twin-head pumps 17

6.4 Identification 18

6.5 Model type 18

6.6 Radio communication 18

6.7 Closed valve operation 18

6.8 Insulating shells 19

6.9 Non-return valve 19

7. Control functions 20

7.1 Quick overview of control modes 20

7.2 Operating modes 22

7.3 Control modes 22

7.4 Additional control mode features 26

7.5 Multipump modes 27

7.6 Flow estimation accuracy 28

7.7 External connections 29

7.8 Priority of settings 29

7.9 Input and output communication 30

8. Setting the product 34

8.1 Operating panel 34

8.2 Menu structure 34

8.3 Startup guide 34

8.4 Menu overview 36

8.5 "Home" menu 38

8.6 "Status" menu 38

8.7 "Settings" menu 39

8.8 "Assist" menu 48

8.9 "Description of control mode" 49

8.10 "Assisted fault advice" 49

9. Servicing the product 50

9.1 Differential-pressure and temperature sensor 50

9.2 External sensor condition 50

9.3 Disassembling the plug 50

10. Fault finding the product 51

10.1 Grundfos Eye operating indications 51

10.2 Fault finding table 52

10.3 Fault finding 53

11. Accessories 54

11.1 Grundfos GO 54

11.2 Communication interface module, CIM 54

11.3 Counterflanges 59

11.4 External sensors 60

11.5 Cable for sensors 60

11.6 Blanking flange 61

11.7 Insulating kits for air-conditioning and cooling systems 61

12. Technical data 61

12.1 Sensor specifications 62

13. Disposing of the product 63

Read this document and the quick guide before

installing the product. Installation and operation must

comply with local regulations and accepted codes of

good practice.

This appliance can be used by children aged from 8

years and above and persons with reduced physical,

sensory or mental capabilities or lack of experience

and knowledge if they have been given supervision

or instruction concerning use of the appliance in a

safe way and understand the hazards involved.

Children shall not play with the appliance. Cleaning

and user maintenance shall not be made by children

without supervision.

English (GB)

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.

1.3 Safety symbols on the pump

2. Receiving the product

2.1 Inspecting the product

Check that the product received is in accordance with the order.

Check that the voltage and frequency of the product match the

voltage and frequency of the installation site. See section

6.4.1 Nameplate.

2.2 Scope of delivery

2.2.1 Plug-connected single-head pump

The box contains the following items:

• MAGNA3 pump

• insulating shells

•gaskets

•quickguide

• safety instructions

• one ALPHA plug.

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.

Check the position of the clamp before you tighten it.

Incorrect position of the clamp will cause leakage

from the pump and damage the hydraulic parts in the

pump head.

Fit and tighten the screw that holds the clamp to 8

Nm ± 1 Nm.

Do not apply more torque than specified even though

water is dripping from the clamp. The condensed

water is most likely coming from the drain hole under

the clamp.

Pumps tested with water containing anticorrosive

additives are taped on the inlet and outlet ports to

prevent residual test water from leaking into the

packaging. Remove the tape before installing the

pump.

TM06 7224 3216

8Nm!

English (GB)

2.2.2 Plug-connected twin-head pump

The box contains the following items:

• MAGNA3 pump

•gaskets

• quick guide

• safety instructions

• two ALPHA plugs.

2.2.3 Terminal-connected single-head pump

The box contains the following items:

• MAGNA3 pump

• insulating shells

•gaskets

• quick guide

• safety instructions

• box with terminal and M20 cable gland.

2.2.4 Terminal-connected twin-head pump

The box contains the following items:

• MAGNA3 pump

•gaskets

• quick guide

• safety instructions

• two boxes with terminals and M 20 cable glands.

2.3 Lifting the pump

Always lift directly on the pump head or the cooling fins when

handling the pump. See fig. 1.

For large pumps, it may be necessary to use lifting equipment.

Position the lifting straps as illustrated in fig. 1.

Fig. 1 Correct lifting of pump

Fig. 2 Incorrect lifting of pump

TM06 7225 3216TM05 8159 2013TM06 6791 2316

Observe local regulations concerning limits for

manual lifting or handling.

TM05 5820 3216

Do not lift the pump head by the control box, i.e. the

red area of the pump. See fig. 2.

TM05 5821 3216

English (GB)

3. Installing the product

3.1 Location

The pump is designed for indoor installation.

Always install the pump in an dry environment where it will not be

exposed to drops or splashes, for example water, from

surrounding equipment or structures.

As the pump contains stainless-steel parts, it is important that it is

not installed directly in environments, such as:

• Indoor swimming pools where the pump would be exposed to

the ambient environment of the pool.

• Locations with direct and continuous exposure to a marine

atmosphere.

• In rooms where hydrochloric acid (HCl) can form acidic

aerosols escaping from, for example, open tanks or frequently

opened or vented containers.

The above applications do not disqualify for installation of

MAGNA3. However, it is important that the pump is not installed

directly in these environments.

Stainless steel variants of MAGNA3 can be used to pump pool

water. See section 6.2 Pumped liquids.

To ensure sufficient cooling of motor and electronics, observe the

following requirements:

• Position the pump in such a way that sufficient cooling is

ensured.

• The ambient temperature must not exceed 40 °C.

3.2 Tools

Fig. 3 Recommended tools

3.3 Mechanical installation

The pump range includes both flanged and threaded versions.

These installation and operating instructions apply to both

versions, but give a general description of flanged versions. If the

versions differ, the threaded version will be described separately.

Install the pump so that it is not stressed by the pipes. For

maximum permissible forces and moments for pipe connections

acting on the pump flanges or threaded connections, see page

64.

You can suspend the pump directly in the pipes, provided that the

pipes support the pump.

Twin-head pumps are prepared for installation on a mounting

bracket or base plate. The pump housing has a M12 thread.

TM05 6472 4712

Pos. Tool Size

1 Screwdriver, straight slot 0.6 x 3.5 mm

2 Screwdriver, straight slot 1.2 x 8.0 mm

3 Screwdriver, torx bit TX10

4 Screwdriver, torx bit TX20

5 Hexagon key 5.0 mm

6 Side cutter

7 Open-end spanner Depending on DN size

8 Pipe wrench Only used for pumps

with unions

0.6 x 3.5

5.0

1.2 x 8.0

TX20

TX10

Step Action Illustration

Arrows on the pump housing

indicate the flow direction

through the pump. The flow

direction can be horizontal or

vertical, depending on the

control box position.

TM05 2862 3216 - TM05 8456 3216

Close the isolating valves

and make sure that the

system is not pressurised

during the installation of the

pump.

TM05 2863 3216

3Mount the pump with gaskets

in the pipes.

TM05 2864 3216

English (GB)

3.4 Positioning the pump

Always install the pump with horizontal motor shaft.

• Pump installed correctly in a vertical pipe. See fig. 4(A).

• Pump installed correctly in a horizontal pipe. See fig. 4(B).

• Do not install the pump with vertical motor shaft. See fig. 4(C

and D).

Fig. 4 Pump installed with horizontal motor shaft

3.5 Control box positions

To ensure adequate cooling, make sure that the control box is in

horizontal position with the Grundfos logo in vertical position. See

fig. 5.

Fig. 5 Pump with control box in horizontal position

Fig. 6 Automatic vent

Flanged version:

Fit bolts and nuts. Use the

right size of bolts according

to system pressure.

For further information about

torques, see page 64.

Threaded version:

Tighten the union nuts.

TM05 2865 3216 - TM05 8455 3216

TM05 2866 3216

Step Action Illustration

Make sure that the isolating valves are closed

before rotating the control box.

TM05 2915 3216

Twin-head pumps installed in horizontal pipes can

be fitted with an automatic vent, Rp 1/4, in the

upper part of the pump housing if no venting valve

is installed in the system. See fig. 6.

TM05 6061 3216

English (GB)

3.6 Pump head position

If you remove the pump head before installing the pump in the

pipes, pay special attention when fitting the pump head to the

pump housing:

1. Visually check that the floating ring in the sealing system is

centred. See figs 7and 8.

2. Gently lower the pump head with rotor shaft and impeller into

the pump housing.

3. Make sure that the contact face of the pump housing and that

of the pump head are in contact before you tighten the clamp.

See fig. 9.

Fig. 7 Correctly centred sealing system

Fig. 8 Incorrectly centred sealing system

Fig. 9 Fitting the pump head to the pump housing

3.7 Changing the control box position

TM05 6650 3216TM05 665132162

Observe the position of the clamp before you tighten

it. Incorrect position of the clamp will cause leakage

from the pump and damage the hydraulic parts in

the pump head. See fig. 9.

TM05 5837 3216

The warning symbol on the clamp holding the pump

head and pump housing together indicates that there

is a risk of personal injury. See specific warnings

below.

CAUTION

Crushing of feet

Minor or moderate personal injury

- Do not drop the pump head when loosening the

clamp.

CAUTION

Pressurised system

Minor or moderate personal injury

- Pay special attention to any escaping vapour

when loosening the clamp.

Fit and tighten the screw that holds the clamp to 8

Nm ± 1 Nm. Do not apply more torque than specified

even though water is dripping from the clamp. The

condensed water is most likely coming from the drain

hole under the clamp.

Check the position of the clamp before you tighten

the clamp. Incorrect position of the clamp will cause

leakage from the pump and damage the hydraulic

parts in the pump head.

Make sure that the isolating valves are closed

before rotating the control box.

8Nm!

English (GB)

Step Action Illustration

Loosen the screw in

the clamp that holds

the pump head and

pump housing

together.

If you loosen the

screw too much, the

pump head will be

completely

disconnected from

the pump housing.

TM05 2867 3216

Carefully turn the

pump head to the

desired position.

If the pump head is

stuck, loosen it with

a light blow of a

rubber mallet.

TM05 2868 3216

Place the control

box in horizontal

position so that the

Grundfos logo is in

vertical position.

The motor shaft

must be in

horizontal position.

TM05 2869 3216

Due to the drain

hole in the stator

housing, position

the gap of the clamp

as shown in step 4a

or 4b.

TM05 2870 0612

Single-head pump.

Position the clamp

so that the gap

points towards the

arrow.

It can be in position

3, 6, 9 or 12 o'clock.

TM05 2918 3216

5.0

Twin-head pump.

Position the clamps

so that the gaps

point towards the

arrows.

They can be in

position 3, 6, 9 or 12

o'clock.

TM05 2917 3216

Fit and tighten the

screw that holds the

clamp to 8 Nm ± 1

Nm.

Do not retighten the

screw if condensed

water is dripping

from the clamp.

TM05 2872 0612

Fit the insulating

shells.

The insulating shells

for pumps in

air-conditioning and

cooling systems

must be ordered

separately.

TM05 2874 3216

Step Action Illustration

8 Nm5.0

English (GB)

As an alternative to insulating shells, you can insulate the pump

housing and pipes as illustrated in fig. 10.

Fig. 10 Insulating the pump housing and pipe in a heating

system

3.8 Electrical installation

Carry out the electrical connection and protection according to

local regulations.

Check that the supply voltage and frequency correspond to the

values stated on the nameplate.

• Make sure that the pump is connected to an external main

switch.

• The pump requires no external motor protection.

• The motor incorporates thermal protection against slow

overloading and blocking (IEC 34-11: TP 211).

• When switched on via the power supply, the pump starts after

approximately 5 seconds.

3.8.1 Supply voltage

1 x 230 V ± 10 %, 50/60 Hz, PE.

The voltage tolerances are intended for mains-voltage variations.

Do not use the voltage tolerances for running pumps at other

voltages than those stated on the nameplate.

In heating systems, do not insulate the control box or

cover the operating panel.

TM05 2889 3216

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.

Lock the main switch in position 0. Type and

requirements as specified in EN 60204-1, 5.3.2.

WARNING

Electric shock

Death or serious personal injury

- Connect the pump to an external main switch with

a minimum contact gap of 3 mm in all poles.

- Use earthing or neutralisation for protection

against indirect contact.

- If a plug-connected pump is connected to an

electric installation where an electrical circuit

breaker (voltage sensing ELCB, residual-current

device RCD or residual-current circuit device

RCCB) is used as an additional protection, this

circuit breaker must be marked with the first or

both of the symbols shown below.

If the pump is terminal-connected, the circuit

breaker must be marked with both of the symbols

below.

Make sure that the fuse is dimensioned according to

the nameplate and local legislation.

Connect all cables in accordance with local

regulations.

Make sure that all cables are heat-resistant up to 75

°C.

Install all cables in accordance with EN 60204-1 and

EN 50174-2:2000.

English (GB)

3.9 Wiring diagrams

3.9.1 Connection to power supply, plug-connected versions

Fig. 11 Example of plug-connected motor with main switch, backup fuse and additional protection

3.9.2 Connection to external controllers, plug-connected versions

Fig. 12 Example of connections in the control box of plug-connected versions

The connection terminals of plug-connected versions (fig. 12)

differ from those of terminal-connected versions (fig. 13), but they

have the same function and connection options.

TM05 5277 3712

External switch

Fuse

RCD/RCCB

TM07 0380 1518

NC NO C

S/S

24V IN

Relay 1 Relay 2Digital inputAnalog input

Sensor

Vcc Signal

Operation Alarm

Start/

stop On/off

timer

Use C and NC for fault signals as this enables serial

connections of more relays and detection of signal

cable defects.

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