Grundfos CUE Series Installation And Operating Instructions Manual

GRUNDFOS INSTRUCTIONS

CUE, 110-250 kW

Installation and operating instructions

Declaration of Conformity

We Grundfos declare under our sole responsibility that the products CUE, to which this declaration relates, are in conformity with these Council Directives on the approximation of the laws of the EC Member States:

— Low Voltage Directive (2006/95/EC).

Standard used: EN 61800-5-1: 2003.

— EMC Directive (2004/108/EC).

Standard used: EN 61800-3: 2005.

Bjerringbro, 1st February 2008

Jan Strandgaard

Technical Director

CONTENTS

Caution

Note

Page

1. Symbols used in this document 3

2. Introduction 3

2.1 General description 3

2.2 Applications 3

2.3 References 3

3. Safety and warnings 4

3.1 Warning 4

3.2 Safety regulations 4

3.3 Installation requirements 4

3.4 Reduced performance under certain conditions 4

4. Identification 4

4.1 Nameplate 4

4.2 Packaging label 4

5. Mechanical installation 5

5.1 Reception and storage 5

5.2 Transportation and unpacking 5

5.3 Space requirements and air circulation 5

5.4 Mounting 6

6. Electrical connection 7

6.1 Electrical protection 7

6.2 Mains and motor connection 7

6.3 Connecting the signal terminals 9

6.4 Connecting the signal relays 10

6.5 Connecting the MCB 114 sensor input module 11

6.6 EMC-correct installation 11

6.7 RFI filters 12

6.8 Output filters 12

7. Operating modes 13

8. Control modes 13

9. Menu overview 14

10. Setting by means of the control panel 16

10.1 Control panel 16

10.3 Start-up guide 16

10.4 Menu GENERAL 20

10.5 Menu OPERATION 21

10.6 Menu STATUS 22

10.7 Menu INSTALLATION 23

11. Setting by means of PC Tool E-products 30

12. Priority of settings 30

13. External control signals 30

13.1 Digital inputs 30

13.2 External setpoint 31

13.3 GENIbus signal 31

13.4 Other bus standards 31

14. Maintenance and service 31

14.1 Cleaning the CUE 31

14.2 Service parts and service kits 31

15. Fault finding 32

15.1 Warning and alarm list 32

15.2 Resetting of alarms 32

15.3 Indicator lights 32

15.4 Signal relays 32

16. Technical data 33

16.1 Enclosure 33

16.2 Main dimensions and weight 33

16.3 Surroundings 34

16.4 Terminal tightening torques 34

16.5 Cable length 34

16.6 Fuses and cable cross-section 34

16.7 Inputs and outputs 36

16.8 Sound pressure level 36

17. Disposal 36

1. Symbols used in this document

Warnin g If these safety instructions are not observed, it

may result in personal injury!

If these safety instructions are not observed, it may result in malfunction or damage to the equipment!

Notes or instructions that make the job easier and ensure safe operation.

2. Introduction

This manual introduces all aspects of your Grundfos CUE frequency converter in the power range of 110-250 kW.

Always keep this manual close to the CUE.

2.1 General description

CUE is a series of external frequency converters especially designed for pumps.

Thanks to the start-up guide in the CUE, the installer can quickly set central parameters and put the CUE into operation.

Connected to a sensor or an external control signal, the CUE will quickly adapt the pump speed to the actual demand.

2.2 Applications

The CUE series and Grundfos standard pumps are a supplement to the Grundfos E-pumps range with integrated frequency converter.

A CUE solution offers the same E-pump functionality

• in the mains voltage or power ranges not covered by the Epump range.

• in applications where an integrated frequency converter is not desirable or permissible.

2.3 References

Technical documentation for Grundfos CUE:

• The manual contains all information required for putting the CUE into operation.

• The data booklet contains all technical information about the construction and applications of the CUE.

• Service instructions contain all required instructions for dismantling and repairing the frequency converter.

Technical documentation is available on www.grundfos.com > International website > WebCAPS.

If you have any questions, please contact the nearest Grundfos company or service workshop.

Warnin g Prior to installation, read these installation and

operating instructions. Installation and operation must comply with local regulations and accepted codes of good practice.

3. Safety and warnings

Caution

T/C: CUE202P1M2T5E20H1BXCXXXSXXXXAXBXCXXXXDX Prod. no: 12345678

S/N: 123456G234

IN: 3x380-500 V 50/60Hz 3.7A OUT: 3x0-Vin 0-100Hz 4.1 A 2.8 kVA CHASSIS/IP20 Tamb. 45C/122F

IIIIIIIIIIIBAR CODEIIIIIIIIIII

MADE IN DENMARK

Listed 76X1 E134261 Ind. Contr. Eq. See manual for prefuse

CAUTION:

SEE MANUAL / VOIR MANUEL

WARNING:

STORED CHARGE DO NOT TOUCH UNTIL 4 MIN AFTER DISCONNECTION

CHARGE RESIDUELLE, ATTENDRE 4 MIN APRES DECONNEXION

1.5 kW (400V) / 2 Hp (460V)

T/C: CUE202P1M2T5E20H1BXCXXXSXXXXAXBXCXXXXDX

/N:123456

OUT: 3x0-Vin 0-100Hz 4.1 A 2.8 kVA

CHASSIS/IP20 Tamb. 45C/122F

IIIIIIIIIIIBAR CODEIIIIIIIIIII

SEE MANUAL

VOIR MANUEL

WARNING:

STORED CHARGE DO NOT TOUCH UNTIL

MIN AFTER DISCONNECTION

MIN APRES DECONNEXION

1.5 kW (400V)

3.4.1 Reduction at low air pressure

3.1 Warning

Warnin g Any installation, maintenance and inspection

must be carried out by trained personnel.

Warnin g Touching the electrical parts may be fatal, even

after the CUE has been switched off. Before making any work on the CUE, the mains

supply and other input voltages must be switched off at least for as long as stated below.

Voltage Min. waiting time

15 minutes 20 minutes 380-500 V 110-250 kW 525-690 V 110-250 kW

Wait only for shorter time if stated so on the nameplate of the CUE in question.

3.2 Safety regulations

• The on/off button of the control panel does not disconnect the CUE from the mains voltage and must therefore not be used as a safety switch.

• The CUE must be earthed correctly and protected against indirect contact according to national regulations.

• The leakage current to earth exceeds 3.5 mA.

• Enclosure class IP20/21 must not be installed freely accessible, but only in a panel.

• Enclosure class IP54/55 must not be installed outdoors without additional protection against water and the sun.

• Always observe national and local regulations as to cable cross-section, short-circuit protection and overcurrent protection.

Warnin g At altitudes above 2000 m, PELV cannot be met.

PELV = Protective Extra Low Voltage. At low air pressure, the cooling capacity of air is reduced, and the

CUE automatically reduces the performance to prevent overload. It may be necessary to select a CUE with a higher performance.

3.4.2 Reduction in connection with long motor cables

The maximum cable length for the CUE is 300 m for unscreened and 150 m for screened cables. In case of longer cables, contact Grundfos.

The CUE is designed for a motor cable with a maximum crosssection as stated in section 16.6 Fuses and cable cross-section.

4. Identification

4.1 Nameplate

The CUE can be identified by means of the nameplate. An example is shown below.

Prod. no: 12345678 S

IN: 3x380-500 V 50/60Hz 3.7A

Listed 76X1 E134261 Ind. Contr. Eq. See manual for prefuse

G234

MADE IN DENMARK

CAUTION:

3.3 Installation requirements

The general safety necessitates special considerations as to these aspects:

• fuses and switches for overcurrent and short-circuit protection

• selection of cables (mains current, motor, load distribut ion and relay)

• net configuration (IT, TN, earthing)

• safety on connecting inputs and outputs (PELV).

3.3.1 IT mains

Warnin g Do not connect 380-500 V CUE frequency

converters to mains supplies with a voltage between phase and earth of more than 440 V.

In connection with IT mains and earthed delta mains, the mains voltage may exceed 440 V between phase and earth.

3.3.2 Aggressive environment

The CUE should not be installed in an

The CUE contains a large number of mechanical and electronic components. They are all vulnerable to environmental effects.

3.4 Reduced performance under c ertain conditions

The CUE will reduce its performance under these conditions:

• low air pressure (at high altitude)

• long motor cables.

The required measures are described in the next two sections.

environment where the air contains liquids, particles or gases which may affect and damage the electronic components.

CHARGE RESIDUELLE,ATTENDRE 4

Fig. 1 Example of nameplate

Text Description

T/C:

CUE (product name) 202P1M2... (internal code)

Prod.no: Product number: 12345678

Serial number: 123456G234

S/N:

The last three digits indicate the production date: 23 is the week, and 4 is the year 2004

1.5 kW Typical shaft power on the motor IN:

Supply voltage, frequency and maximum input current

Motor voltage, frequency and maximum output

OUT:

current. The maximum output frequency usually depends on the pump type.

CHASSIS/ IP20

Enclosure class

Tamb. Maximum ambient temperature

4.2 Packaging label

The CUE can also be identified by means of the label on the packaging.

TM04 3272 4808

5. Mechanical installation

Note

Min. 225

399

526

The individual CUE cabinet sizes are characterised by their enclosures. The table in section 16.1 shows the relationship of enclosure class and enclosure type.

5.1 Reception and storage

Check on receipt that the packaging is intact, and the unit is complete. In case of damage during transport, contact the transport company to complain.

Note that the CUE is delivered in a packaging which is not suitable for outdoor storage.

5.2 Transportation and unpacking

The CUE must only be unpacked at the installation sit e to preven t damage during the transport to the site.

Remove the cardboard box, and keep the CUE on the pallet as long as possible.

The packaging contains accessory bag(s), documentation and the unit itself.

The cardboard box has a drilling template for the mounting holes. See fig. 2.

5.3 Space requirements and air circulation

CUE units can be mounted si de by side, but as a sufficient air circulation is required for c ooling these requirements must be met:

• Sufficient free space above and below the C UE to allow airflow and cable connection. See fig. 4.

• Ambient temperature up to 45 °C.

Fig. 2 CUE packaging with drilling template

5.2.1 Lifting the CUE

Always lift the CUE using the lifting holes. Use a bar to avoid bending the lifting holes. See fig. 3.

Fig. 3 Recommended lifting method

TM03 9898 4607TM03 9897 4607

Fig. 4 Airflow direction and required space for cooling [mm]

TM03 9893 4607TM03 9896 4607

Furthermore, there must be sufficient space in front of the CUE for opening the door of the CUE. See fig. 5.

Fig. 5 Free space in front of the CUE [mm]

5.4 Mounting

Caution

Note

Caution

Note

Back

Front

5.4.1 Mounting the drip shield

To comply with the IP21 rating, a separate drip shield is to be fitted:

1. Remove the two screws. See fig. 6.

2. Fit the drip shield.

3. Fit and tighten the screws to 5.6 Nm.

Fig. 6 Fitting the drip shield

5.4.3 Mounting on the floor

Warnin g The CUE is top-heavy and may fall over if the

pedestal is not anchored to the floor.

The user is responsible for mounting the CUE securely on a firm surface.

See the pedestal kit instructions for further information.

By means of a pedestal (option), the CUE can also be mounted on the floor.

1. Mark the mounting holes on the floor. See fig. 8.

2. Drill the holes.

3. Mount the pedestal on the floor.

4. Mount the CUE on the pedestal using the enclosed screws. See fig. 9.

TM03 9901 4607

5.4.2 Mounting on the wall

The user is responsible for mounting the CUE securely on a firm surface.

See the main dimensions and weights in section

16.2.

1. Mark the mounting holes on the wall using the drilling template. See fig. 2.

2. Drill the holes. See fig. 7.

3. Fit the screws at the bottom, but leave loose. Lift the CUE up on the screws. Move the CUE against the wall, and fit the screws at the top. Tighten all four screws. See fig. 3.

TM03 9923 4607TM03 9895 4607

Fig. 8 Drilling template for pedestal [mm]

Fig. 7 Drilling of holes in the wall

TM03 8860 2607

Fig. 9 CUE on a pedestal

6. Electrical connection

Caution

ELCB

Mains

Motor

Warnin g The owner or installer is responsible for ensuring

correct earthing and protection according to national and local standards.

Warnin g Before making any work on the CUE, the mains

supply and other voltage inputs must be switched off for at least as long as stated in section 3. Safety and warnings.

Fig. 10 Example of three-phase mains connection of the CUE

with mains switch, back-up fuses and additional protection

6.1 Electrical protection

6.1.1 Protection against electric shock, indirect contact

6.1.5 Protection against overcurrent

The CUE has an internal overcurrent protection for overload protection on the motor output.

6.1.6 Protection against mains voltage transients

The CUE is protected against mains voltage transients according to EN 61800-3, second environment.

6.2 Mains and motor connection

The supply voltage and frequency are marked on the CUE nameplate. Make sure that the CUE is suitable for the power supply of the installation site.

6.2.1 Mains switch

A mains switch can be installed before the CUE according to local regulations. See fig. 10.

6.2.2 Wiring diagram

The wires in the terminal box must be as short as possible. Excepted from this is the earth conductor which must be so long that it is the last one to be disconnected in case the cable is

TM03 8525 1807

inadvertently pulled out of the cable entry.

Warnin g The CUE must be earthed correctly and protected

against indirect contact according to national regulations.

The leakage current to earth exceeds 3.5 mA, and a reinforced earth connection is required.

Protective conductors must always have a yellow/green (PE) or yellow/green/blue (PEN) colour marking.

Instructions according to EN IEC 61800-5-1:

• The CUE must be stationary, installed permanently and connected permanently to the mains supply.

• The earth connection must be carried out with duplicate protective conductors.

6.1.2 Protection against short-circuit, fuses

The CUE and the supply system must be protected against shortcircuit.

Grundfos demands that the back-up fuses mentioned in section

16.6 are used for protection against short-circuit.

The CUE offers complete short-circuit protection in case of a short-circuit on the motor output.

6.1.3 Additional protection

The leakage current to earth exceeds 3.5 mA.

If the CUE is connected to an electrical installation where an earth leakage circuit breaker (ELCB) is used as additional protection, the circuit breaker must be of a type marked with the following symbols:

Fig. 11 Wiring diagram, three-phase mains connection

Terminal Function

91 (L1)

Three-phase supply92 (L2) 93 (L3) 95/99 (PE) Earth connection 96 (U) 97 (V) 98 (W)

Three-phase motor connection, 0-100 % of

mains voltage

6.2.3 Gland plate

Cables are connected through the gland plate from the bottom. The gland plate must be fitted to the CUE to ensure the specified protection degree as well as to ensure sufficient cooling.

Drill holes in the marked areas. See fig. 12.

TM03 8799 2507

The circuit breaker is type B. The total leakage current of all the electrical equipment in the

installation must be taken into account. The leakage current from the CUE in normal operation can be

seen in section 16.7.1 Mains supply (L1, L2, L3). During start and in asymmetrical supply systems, the leakage

current can be higher than normal and may cause the ELCB to trip.

6.1.4 Motor protection

The motor requires no external motor protection. The CUE protects the motor against thermal overloading and blocking.

TM03 9900 4607

Fig. 12 CUE viewed from the bottom

6.2.4 Motor connection

Caution

Mains:

95 (PE)

Motor:

99 (PE)

Mains:

91 (L1) 92 (L2) 93 (L3)

Motor:

96 (U) 97 (V) 98 (W)

Mains Motor

For information about enclosure, see table in section 16.1.

The motor cable must be screened for the CUE to meet EMC requirements.

1. Connect the earth conductor to terminal 99 (PE). See fig. 14.

2. Connect the motor conductors to the terminals 96 (U), 97 (V), 98 (W), see fig. 15.

3. Fix the screened cable with a cable clamp.

4. Fit the EMC metal cover to ensure best EMC performance before connecting the mains cable. See fig. 13.

TM03 9967 4707TM03 9899 4607

Fig. 15 Mains and motor connection

Fig. 13 Fitting the EMC metal cover

6.2.5 Mains connection

Check that mains voltage and frequency correspond to the values on the nameplate of the CUE and the motor.

1. Connect the earth conductor to terminal 95 (PE). See fig. 14.

2. Connect the mains conductors to the terminals 91 (L1), 92 (L2), 93 (L3), see fig. 15.

3. Fix the mains cable with a cable clamp.

6.2.6 Terminal location

Take the following terminal positions into consideration when you design the cable connection. See figs 14 to 16.

TM03 9894 4607

Fig. 16 Position of mains and motor terminals, side view

Fig. 14 Earth connection

TM03 9905 4607

6.3 Connecting the signal terminals

Caution

Note

+24 V out

DI 2

DI 3

DI 4

GND

AO 1

+10 V out

Ext. setpoint

Sensor 1

GND

RS-485 GND Y

RS-485 A

RS-485 B

0/4-20 mA

1 K

0-20 mA

0/4-20 mA

0-10 V0-10 V

Start/stop

Terminals 53 and 54:

See section

6.3.5

Start/stop

GND

Signal terminals

Signal relays

As a precaution, signal cables must be separated from other groups by reinforced insulation in their entire lengths.

If no external on/off switch is connected, shortcircuit terminals 18 and 20 using a short wire.

Connect the signal cables according to the guidelines for good practice to ensure EMC-correct installation. See section

6.6 EMC-correct installation.

• Use screened signal cables with a conductor cross-section of min. 0.5 mm

• Use a 3-conductor screened bus cable in new systems.

6.3.1 Wiring diagram, signal terminals

and max. 1.5 mm2.

6.3.2 Minimum connection, signal terminals

Operation is only possible when the terminals 18 and 20 are connected, for instance by means of an external o n/off switch or a short wire.

TM03 9057 3207TM03 9902 4607TM03 9026 2807

Fig. 18 Required minimum connection, signal terminals

6.3.3 Access to signal terminals

All terminals for signal cables are located beneath the control panel and can be accessed by opening the door of the CUE. See fig. 19.

Terminal Type Function

12 +24 V out Supply to sensor 13 +24 V out Additional supply 18 DI 1 Digital input, start/stop 19 DI 2 Digital input, programmable 20 GND Common frame for digital inputs 32 DI 3 Digital input, programmable 33 DI 4 Digital input, programmable 39 GND Frame for analog output 42 AO 1 Analog output, 0-20 mA 50 +10 V out Supply to pote ntio me ter 53 AI 1 External setpoint, 0-10 V/4-20 mA 54 AI 2 Sensor input, sensor 1, 0/4-20 mA 55 GND Common frame for analog inputs 61 RS-485 GND Y GENIbus, GND 68 RS-485 A GENIbus, signal A (+) 69 RS-485 B GENIbus, signal B (-)

Terminals 27, 29 and 37 are not used.

Fig. 17 Wiring diagram, signal terminals

The RS-485 screen must be connected to frame.

TM03 8800 2507

Fig. 19 Signal cable routing

6.3.4 Fitting the conductor

1. Remove the insulation at a length of 9-10 mm.

2. Insert a screwdriver with a tip of maximum 0.4 x 2.5 mm into the square hole.

3. Insert the conductor into the corresponding round hole. Remove the screwdriver. The conductor is now fixed in the terminal.

Fig. 20 Fitting the conductor into the signal terminal

6.3.5 Setting the analog inputs, terminals 53 and 54

Note

A53

A54

Bus Ter = ON

Caution

OFF ON

BUS TER

C 1

NC 1

NO 1

NC 2

NO 2

The contacts A53 and A54 are positioned behind the control panel and used for setting the signal type of the two analog inputs.

The factory setting of the inputs is voltage signal "U".

If a 0/4-20 mA sensor is connected to terminal 54, the input must be set to current signal "I".

Switch off the power supply before setting the A54.

Remove the control panel to set the contact. See fig. 21.

Fig. 21 Setting contact A54 to current signal "I"

Remove the control panel to set the contact. See fig. 23.

Fig. 23 Setting the termination contact to "ON"

6.4 Connecting the signal relays

As a precaution, signal cables must be separated from other groups by reinforced insulation in

TM03 9104 3407TM03 9005 2807

their entire lengths.

TM03 9006 2807

6.3.6 RS-485 GENIbus network connection

One or more CUE units can be connected to a control unit via GENIbus. See the example in fig. 22.

Fig. 22 Example of an RS-485 GENIbus network

The reference potential, GND, for RS-485 (Y) communication must be connected to terminal 61.

If more than one CUE unit is connected to a GENIbus network, the termination contact of the last CUE must be set to "ON" (termination of the RS-485 port).

The factory setting of the termination contact is "OFF" (not terminated).

TM03 8801 2507

Fig. 24 Terminals for signal relays in normal state

(not activated)

Terminal Function

C 1 C 2 Common NO 1 NO 2 Normally open contact NC 1 NC 2 Normally closed contact

6.5 Connecting the MCB 114 sensor input module

CUEController

The MCB 1 14 is a n option o f fering a dditional analog input s f or the CUE.

6.5.1 Configuration of the MCB 114

The MCB 114 is equipped with three analog inputs for these sensors:

• One additional sensor 0/4-20 mA. See section 10.7.13 Sensor 2 (3.16).

• Two Pt100/Pt1000 temperature sensors for measurement of motor bearing temperature or an alternative temperature, such as liquid temperature. See sections 10.7.18 Temperature sensor 1 (3.21) and 10.7.19 Temperature sensor 2 (3.22).

When the MCB 114 has been in stalle d, the CUE will automatically detect if the sensor is Pt100 or Pt1000 when it is switched on.

6.5.2 Wiring diagram, MCB 114

GND

WIRE

TEMP

GND

TEMP

WIRE

GND

12111

VDO

1 98765432

I IN

6.6 EMC-correct installation

This section gives guidelines for good practice when installing the CUE. Follow these guidelines to meet EN 61800-3, first environment.

• Use only motor and signal cables with a braided metal screen in applications without output filter.

• There are no special requirements to supply cables, apart from local requirements.

• Leave the screen as close to the connecting terminals as possible. See fig. 26.

• Avoid terminating the screen by twisting the ends. See fig. 27. Use cable clamps or EMC screwed cable entries instead.

• Connect the screen to frame at both ends for both motor and signal cables. See fig. 28. If the controller has no cable clamps, connect only the screen to the CUE. See fig. 29.

• Avoid unscreened motor and signal cables in electrical cabinets with frequency converters.

• Make the motor cable as short as possible in applications without output filter to limit the noise level and minimise leakage currents.

• Screws for frame connections must always be tightened whether a cable is connected or not.

• Keep main cables, motor cables and signal cables separated in the installation, if possibl e.

Other installation methods may give similar EMC results if the above guidelines for good practice are followed.

Fig. 25 Wiring di agra m, MCB 114

Terminal Type Function

1 (VDO) +24 V out Supply to sensor 2 (I IN) AI 3 Sensor 2, 0/4-20 mA 3 (GND) GND Common frame for analog input 4 (TEMP)

5 (WIRE) 6 (GND) GND Common frame for temperature sensor 1 7 (TEMP)

8 (WIRE) 9 (GND) GND Common frame for temperature sensor 2

Terminals 10, 11 and 12 are not used.

AI 4 Temperature sensor 1, Pt100/Pt1000

AI 5 Temperature sensor 2, Pt100/Pt1000

TM04 3273 3908

Fig. 26 Example of stripped cable with screen

Fig. 27 Do not twist the screen ends

Fig. 28 Example of connection of a 3-conductor bus cable with

screen connected at both ends

TM02 1325 0901TM03 8812 2507TM03 8732 2407TM03 8731 2407

Fig. 29 Example of connection of a 3-conductor bus cable with

screen connected at the CUE (controller with no cable clamps)

6.7 RFI filters

Unscreened cable

screened motor cable

CUE

Unscreened cable

screened motor

cable

CUE Filter

CUE and filter close to well

CUE

Screened

cable

Unscreened drop cable

Unscreened

cable

Filter

CUE

Screened

cable

* Both ends of the screened cable between filter and connection box must be connected to earth

Connection box *

Screened

cable

Unscreened drop cable

Unscreened

cable

Filter

To meet the EMC requirements, the CUE comes with the following types of built-in radio frequency interference filter (RFI).

Voltage Typical shaft power P2 RFI filter type

Figures 30 and 31 show installations with and without filter and where to use screened and unscreened cable.

3 x 380-500 V 110-250 kW C2 3 x 525-690 V 110-250 kW C3

Description of RFI filter types

For use in domestic and industrial areas, connected permanently to the mains supply. In domestic areas,

C2:

special care should be taken regarding EMC-correct installation.

For use in industrial areas with own low-voltage

C3:

transformer.

RFI filter types are according to EN 61800-3.

6.7.1 Equipment of category C2

• In a domestic environment this product may cause radio interference in which case supplementary mitigation measures may be required.

6.7.2 Equipment of category C3

• This type of power drive system (PDS) is not intended to be used on a low-voltage public network which supplies domestic premises.

• Radio frequency interference is expected if used on such a network.

6.8 Output filters

Output filters are used for reducing the voltage stress on the motor windings and the stress on the motor insulation system as well as for decreasing acoustic noise from the frequency converter-driven motor.

Two types of output filter are available as accessories for the CUE:

• dU/dt filters

• sine-wave filters.

Use of output filters

TM03 8802 2507TM03 8803 2507TM04 3579 4608TM04 3580 4608

Fig. 30 Example of installation without filter

Fig. 31 Example of installation with filter. The cable between

the CUE and filter must be short.

Fig. 32 Submersible pump without connection box

Fig. 33 Submersible pump with connection box and screened

cable

Pump type

SP, BM, BMB with 380 V motor and up

Other pumps, noise reduction

Other pumps, higher noise reduction

Pumps with 690 V motor

Typical shaft

power P2

110 kW and up 0-150 m 150-300 m

110 kW and up

All – 0-300 m

The lengths stated apply to the motor cable.

dU/dt

filter

– 0-300 m

Sine-wave

filter

7. Operating modes

Min.

Max.

CUE

Δp

CUE

Δp

CUE

Δp

CUE

The following operating modes are set on the control panel in menu OPERATION, display 1.2. See section 10.5.2.

Operating mode Description

Normal

Stop Min. The pump is running at minimum speed

Max. The pump is running at maximum speed

Example: Max. curve operation can for instance be used in connection with venting the pump during installation.

Example: Min. curve operation can for instance be used in periods with a very small flow requirement.

The pump is running in the control mode selected

The pump has been stopped (green indicator light is flashing)

Min. and max. curves. The pump speed is kept at a given set value for minimum and maximu m speed, respectively.

TM03 8813 2507

8.0.2 Controlled operation (closed loop)

TM03 8475 1607

TM03 8476 1607

Proportional differential pressure. The differential pressure is reduced at falling flow rate and increased at rising flow rate.

TM03 8804 2507

Constant differential pressure, pump. The differential pressure is kept constant, independently of the flow rate.

TM03 8804 2507

Constant differential pressure, system. The differential pressure is kept constant, independently of the flow rate.

TM03 8806 2507

8. Control modes

The control mode is set on the control panel in menu INSTALLATION, display 3.1. See section 10. 7.1 .

There are two basic control modes:

• Uncontrolled operation (open loop).

• Controlled operation (closed loop) with a sensor connected. See sections 8.0.1 and 8.0.2.

8.0.1 Uncontrolled operation (open loop)

Constant curve. The speed is kept at a set value in the range between the min. and max. curve. The setpoint is set in % corresponding to the required speed.

TM03 8479 1607

Example: Operation on constant curve can for instance be used for pumps with no sensor connected.

Example: Typically used in connection with an overall control system such as the MPC or another external controller.

Constant pressure. The pressure is kept constant, independently of the flow rate.

TM03 8476 1607

TM03 8805 2507

Constant pressure with stop function. The outlet pressure is kept constant at high flow rate. On/ off operation at low

TM03 8477 1607

flow rate.

TM03 8807 2507

Constant level. The liquid level is kept constant, independently of the flow rate.

TM03 8482 1607

TM03 8808 2607

Constant level with stop function. The liquid level is kept constant at high flow rate. On/off operation at

TM03 8482 1607

low flow rate.

TM03 8809 2607

Constant flow rate. The flow rate is kept constant, independently of the head.

TM03 8478 1607

TM03 8810 2507

Constant temperature. The liquid temperature is kept constant, independently of

TM03 8482 1607

the flow rate.

TM03 8811 2507

9. Menu overview

Automatic or manual setting of the direction of rotation

START-UP GUIDE 0. GENERAL 1. OPERATION

0.1 1.1

1/16 0.2 1.2

2/16 0.24 1.3

3/16 8/16 1.4

4/16 9/16 1.5-1.9

5/16 10/16-14/16

6/16 15/16 1.10-1.14

7/16 16/16

Fig. 34 Menu overview

Menu structure

The CUE has a start-up guide, which is started at the first startup. After the start-up guide, the CUE has a menu structure divided into four main menus:

1. GENERAL gives access to the start-up guide for the general setting of the CUE.

2. OPERATION enables the setting of setpoint, selection of operating mode and resetting of alarms. It is also possible to see the latest five warnings and alarms.

3. STATUS shows the status of the CUE and the pump. It is not possible to change or set values.

4. INSTALLATION gives access to all parameters. Here a detailed setting of the CUE can be made.

2. STATUS 3. INSTALLATION

2.1 2.10 3.1 3.12

2.2 2.11 3.2 3.13

2.3 2.12 3.3 3.15

2.4 2.13 3.3A 3.16

2.5 2.14 3.4 3.17

2.6 2.15 3.5 3.18

2.7 2.16 3.6 3.19

2.8 2.17 3.7 3.20

2.9 3.8 3.21

3.9 3.22

3.10 3.23

3.11 3.24

10. Setting by means of the control panel

On/

Off

CUE

On/

Off

Alarm

On/

Off

Note

Display name

Current display / total number

Value field

Display name

Display number, menu name

Value field

10.1 Control panel

Warnin g The on/off button on the control panel does not

disconnect the CUE from the mains voltage and must therefore not be used as a safety switch.

On/

The control panel is used for local setting of the CUE. The functions available depend on the pump family connected to the CUE.

The on/off button has the highest priority. In "of f" condition, pump operation is not possible.

On/

Adjusting the display contrast

Press OK and + for darker display. Press OK and – for brighter display.

Indicator lights

The operating condition of the pump is indicated by the indicator lights on the front of the control panel. See fig. 35.

The table show the function of the indicator lights.

Indicator light

On (green)

Off (orange) Alarm (red) Indicates an alarm or a warning.

Displays, general terms

Figures 36 and 37 shows the general terms of the display.

Function

The pump is running or has been stopped by a stop function.

If flashing, the pump has been stopped by the user (CUE menu), external start/stop or bus.

The pump has been stopped with the on/off button.

Alarm

Fig. 35 Control panel of the CUE

Editing buttons

Button Function

On/

Navigating buttons

Button Function

The editing buttons of the control panel can be set to these values:

•Active

• Not active

When set to Not active (locked), the editing buttons do not function. It is only possible to navigate in the menus and read values.

Activate or deactivate the buttons by pressing the arrow up and arrow down buttons simultaneously for 3 seconds.

Makes the pump ready for operation/starts and stops the pump.

Saves changed values, resets alarms and expands the value field.

Changes values in the value field.

Navigates from one menu to another. When the menu is changed, the display shown will always be the top display of the new menu.

Navigates up and down in the individual menu.

Fig. 36 Example of display in the start-up guide

TM03 8719 2507

Fig. 37 Example of display in the user menu

10.2 Back to factory setting

Follow this procedure to get back to the factory setting:

1. Switch off the power supply to the CUE.

2. Press On/Off, OK and + while switching on the power supply. The CUE will reset all parameters to factory settings. The display

will turn on when the reset is com pleted .

10.3 Start-up guide

Check that equipm ent co nnec ted is read y for start-up, and that the CUE has been connected to supply voltage.

Have nameplate data for motor, pump and CUE at hand.

Use the start-up guide for the general setting of the CUE including the setting of the correct direction of rotation.

The start-up guide is started the first time when the CUE is connected to supply voltage. It can be restarted in menu GENERAL. Please note that in this case all previous settings will be erased.

Bulleted lists show possible settings. Factory settings are shown in bold.

10.3.1 Welcoming display

10.3.6 Supply voltage (5/16)

• Press OK. You will now be guided through the start-up guide.

10.3.2 Language (1/16)

Select the language to be used in the display:

•English UK

• English US

•German

• French

•Italian

• Spanish

• Portuguese

• Greek

•Dutch

• Swedish

• Finnish

•Danish

•Polish

•Russian

• Hungarian

• Czech

• Chinese

• Japanese

• Korean.

10.3.3 Units (2/16)

Select the units to be used in the display:

• SI: m, kW, bar...

• US: ft, HP, psi...

10.3.4 Pump family (3/16)

Select supply voltage according to the rated supply voltage of the installation site.

Unit 1 x 200-240 V: *

• 1 x 200 V

• 1 x 208 V

• 1 x 220 V

• 1 x 230 V

• 1 x 240 V.

Unit 3 x 200-240 V:

• 3 x 200 V

• 3 x 208 V

• 3 x 220 V

• 3 x 230 V

• 3 x 240 V.

Unit 3 x 380-500 V:

• 3 x 380 V

• 3 x 400 V

• 3 x 415 V

• 3 x 440 V

• 3 x 460 V

• 3 x 500 V.

Unit 3 x 525-600 V:

• 3 x 575 V.

Unit 3 x 525-690 V:

• 3 x 575 V

• 3 x 690 V.

* Single-phase input - three-phase output. The setting range depends on the CUE type, and the factory

setting corresponds to the rated supply voltage of the CUE.

10.3.7 Max. motor current (6/16)

Set the maximum motor current according to the motor nameplate:

• 0-999 A The setting range depends on the CUE type, and the factory

setting corresponds to a typical motor current at the motor power selected.

10.3.8 Speed (7/16)

Select pump family according to the pump nameplate:

• CR, CRI, CRN, CRT

• SP, SP-G, SP-NE

•...

Select "Other" if the pump family is not on the list.

10.3.5 Rated motor power (4/16)

Set the rated motor power, P2, according to the motor nameplate:

• 0.55-90 kW The setting range is size-related, and the factory setting

corresponds to the rated power of the CUE.

Set the rated speed according to the pump nameplate:

• 0-9999 min

-1

The factory setting depends on previous selections. Based on the set rated speed, the CUE will automatically set the motor frequency to 50 or 60 Hz.

10.3.9 Frequency (7A/16)

This display appears only if manual entering of the frequency is required.

Set the frequency according to the motor nameplate:

• 40-200 Hz The factory setting depends on previous selections.

10.3.10 Control mode (8/16)

Note

Select the desired control mode. See section 10.7.1.

• Open loop

• Constant pressure

• Constant differential pressure

• Proportional differential pressure

• Constant flow rate

• Constant temperature

• Constant level

• Constant other value.

The possible settings and the factory setting depend on the pump family.

The CUE will give an alarm if the control mode selected requires a sensor and no sensor has been installed. To continue the setting without a sensor, select "Open loop", and proceed. When a sensor has been connected, set the sensor and co ntrol mode in menu INSTALLATION.

10.3.11 Rated flow rate (8A/16)

Constant pressure:

• 0-2.5 bar

•0-4 bar

•0-6 bar

• 0-10 bar

• 0-16 bar

Constant flow rate:

•1-5 m

• 2-10 m

• 6-30 m

• 15-75 m

•Other.

• 0-25 bar

• Other.

Constant temperature:

• –25 to 25 °C

• 0 to 25 °C

• 50 to 100 °C

• 0 to 150 °C

• Other.

Constant level:

• 0-0.1 bar

•0-1 bar

• 0-2.5 bar

•0-6 bar

• 0-10 bar

•Other.

If the control mode selected is "Constant other value", or if the measuring range selected is "Other", the sensor must be set according to the next section, display 9A/16.

10.3.14 Another sensor connected to terminal 54 (9A/16)

This display appears only if the control mode selected is proportional differential pressure.

Set the rated flow rate according to the pump nameplate:

• 1-6550 m

10.3.12 Rated head (8B/16)

This display only appears if the control mode selected is proportional differential pressure.

Set the rated head according to the pump nameplate:

• 1-999 m

10.3.13 Sensor connected to terminal 54 (9/16)

This display only appears when the control mode "Constant other value" or the measuring range "Other" has been selected in display 9/16.

• Sensor output signal:

0-20 mA

4-20 mA.

• Unit of measurement of sensor:

bar, mbar, m, kPa, psi, ft, m gal/h, gal/m, gal/s, ft

/h, m3/min, m3/s, l/h, l/min, l/s,

/min, ft3/s,°C, °F, %.

• Sensor measuring range. The measuring range depends on the sensor connected and the

measuring unit selected.

10.3.15 Priming and venting (10/16)

See the installation and operating instructions of the pump. The general setting of the CUE is now completed, and the start-

up guide is ready for setting the direction of rotation:

• Press OK to go on to automatic or manual setting of the direction of rotation.

10.3.16 Automatic setting of the direction of rotation (11/16)

Set the measuring range of the connected sensor with a signal range of 4-20 mA. The measuring range depends on the control mode selected:

Proportional differential pressure:

• 0-0.6 bar

•0-1 bar

• 0-1.6 bar

• 0-2.5 bar

•0-4 bar

•0-6 bar

• 0-10 bar

Constant differential pressure:

• 0-0.6 bar

• 0-1.6 bar

• 0-2.5 bar

•0-4 bar

•0-6 bar

• 0-10 bar

•Other.

Warnin g During the test, the pump will run for a short

time. Ensure no personnel or equipment is in danger!

Before setting the direction of rotation, the CUE will make an automatic motor adaptation of certain pump types. This will take a few minutes. The adaptation is carried out during standstill.

The CUE automatically tests and sets the correct direction of rotation without changing the cable connections.

This test is not suitable for certain pump types and will in certain cases not be able to determine for certainty the correct direction of rotation. In these cases, the CUE changes over to manual setting where the direction of rotation is determined on the basis of the installer’s observations.

Information displays.

• Press OK to continue.

10.3.18 General settings are completed (16/16)

• Press OK to make the pump ready for operation or start the pump in the operating mode Normal. Then display 1.1 of menu OPERATION will appear.

10.3.19 Manual setting when the direction of rotation is

visible (13/16)

It must be possible to observe the motor fan or shaft.

Information displays.

• Press OK to continue.

The pump starts after 10 seconds. It is possible to interrupt the test and return to the previous

display.

The pump runs with both directions of rotation and stops automatically.

It is possible to interrupt the test, stop the pump and go to manual setting of the direction of rotation.

The correct direction of rotation has now been set.

• Press OK to set the setpoint. See Setpoint (15/

16) on page 19.

10.3.17 Setpoint (15/16)

The automatic setting of the direction of rotation has failed.

• Press OK to go to manual setting of the direction of rotation.

The pump starts after 10 seconds. It is possible to interrupt the test and return to the previous

display.

The pressure will be shown during the test if a pressure sensor is connected. The motor current is always shown during the test.

State if the direction of rotation is correct.

•Yes •No

Set the setpoint according to the control mode and sensor selected.

The correct direction of rotation has now been set.

• Press OK to set the setpoint. See Setpoint (15/

16) on page 19.

The direction of rotation is not correct.

• Press OK to repeat the test with the opposite direction of rotation.

10.3.20 Manual setting when the direction of rotation is not

Note

visible (13/16)

It must be possible to observe the head or flow rate.

Information displays.

• Press OK to continue.

The pump starts after 10 seconds. It is possible to interrupt the test and return to the previous

display.

The second test is completed. Write down the pressure and/or flow rate, and state which test

gave the highest pump performance:

• First test

• Second test

• Make new test.

The correct direction of rotation has now been set.

• Press OK to set the setpoint. See Setpoint (15/16) on page 19.

10.4 Menu GENERAL

If the start-up guide is started, all previous settings will be erased!

The start-up guide must be carried out on a cold motor!

Repeating the start-up guide may lead to a heating of the motor.

The menu makes it possible to return to the start-up guide, which is usually only used dur ing t he firs t start-u p of th e CUE.

10.4.1 Return to start-up guide (0.1)

The pressure will be shown during the test if a pressure sensor is connected. The motor current is always shown during the test.

The first test is completed.

• Write down the pressure and/or flow rate, and press OK to continue the manual test with the opposite direction of rotation.

The pump starts after 10 seconds. It is possible to interrupt the test and return to the previous

display.

State your choice:

•Yes

•No.

If Yes is selected, all settings will be erased, and the entire startup guide must be completed.

10.4.2 Type code change (0.2)

This display is for service use only.

The pressure will be shown during the test if a pressure sensor is connected. The motor current is always shown during the test.

10.4.3 Copy of settings

Alarm (1.3)

It is possible to copy the settings of a CUE and reuse them in another one. Options:

• No copy.

• to CUE (copies the settings of the CUE).

• to control panel (copies the settings to another CUE). The CUE units must have the same firmware version. See section

10.6.16 Firmware version (2.16).

10.5 Menu OPERATION

10.5.1 Setpoint (1.1)

Setpoint set Actual setpoint

Actual value Set the setpoint in units of the feedback sensor. In control mode Open loop, the setpoint is set in % of the

maximum performance. The setting range will lie between the min. and max. curves. See fig. 44.

In all other control modes except proportional differential pressure, the setting range is equal to the sensor measuring range. See fig. 45.

In control mode Proportional differential pressure, the setting range is equal to 25 % to 90 % of max. head. See fig. 46.

If the pump is connected to an external setpoint signal, the value in this display will be the maximum value of the external setpoint signal. See section 13.2 External setpoint.

10.5.2 Operating mode (1.2)

In case of an alarm, the cause will appear in the display. See section 15.1 Warning and alarm list.

Warning (1.4)

In case of warning, the cause will appear in the display. See section 15.1 Warning and alarm list.

10.5.4 Fault log

For both fault types, alarm and warning, the CUE has a log function.

Alarm log (1.5-1.9)

In case of an "alarm", the last five alarm indications will appear in the alarm log. "Alarm log 1" shows the latest alarm, "Alarm log 2" shows the latest alarm but one, etc.

The display shows three pieces of information:

• the alarm indication

• the alarm code

• the number of minutes the pump has been connected to the power supply after the alarm occurred.

Warning log (1.10-1.14)

Set one of the following operating modes:

• Normal (duty)

• Stop

• Min.

• Max. The operating modes can be set without changing the setpoint

setting.

10.5.3 Fault indications

Faults may result in two types of indication: Alarm or warning. An "alarm" will activate an alarm indication in CUE and cause

the pump to change operating mode, typically to stop. However, for some faults resulting in alarm, the pump is set to continue operating even if there is an alarm.

A "warning" will activate a warning indication in CUE, but the pump will not change operating or control mode.

In case of a "warning", the last five warning indications will appear in the warning log. "Warning log 1" shows the latest fault, "Warning log 2" shows the latest fault but one, etc.

The display shows three pieces of information:

• the warning indication

• the warning code

• the number of minutes the pump has been connected to the power supply after the warning occurred.

10.6 Menu STATUS

The displays appearing in this menu are status displays only. It is not possible to change or set values.

The tolerance of the displayed value is stated unde r each disp lay. The tolerances are stated as a guide in % of the maximum values of the parameters.

10.6.1 Actual setpoint (2.1)

This display shows the actual setpoint and the external setpoint. The actual setpoint is shown in units of feedback sensor. The external setpoint is shown in a range of 0-100 %. If the

external setpoint influence is disactivated, the value 100 % is shown. See section 13.2 External setpoint.

10.6.2 Operating mode (2.2)

10.6.6 Speed (2.6)

Tolerance: ± 5 % This display shows the actual pump speed.

10.6.7 Input power and motor current (2.7)

Tolerance: ± 10 % This display shows the actual pump input power in W or kW and

the actual motor current in Ampere [A].

10.6.8 Operating hours and power consumption (2.8)

This display shows the actual operating mode (Normal, Stop, Min. or Max.). Furthermore, it shows where this operating mode was selected (CUE menu, Bus, External or On/off button).

10.6.3 Actual value (2.3)

This display shows the actual value controlled. If no sensor is connected to the CUE, "–" will appear in the

display.

10.6.4 Measured value, sensor 1 (2.4)

This display shows the actual value measured by sensor 1 connected to terminal 54.

If no sensor is connected to the CUE, "–" will appear in the display.

10.6.5 Measured value, sensor 2 (2.5)

Tolerance: ± 2 % This display shows the number of operating hours and the power

consumption. The value of operating hours is an accumulated value and cannot be reset. The value of power consumption is an accumulated value calculated from the unit’s birth, and it cannot be reset.

10.6.9 Lubrication status of motor bearings (2.9)

This display shows how many times the user has given the lubricated information and when to replace the motor bearings.

When the motor bearings have been relubricated, confirm this action in the INSTALLATION menu. See section

10.7.17 Confirming relubrication/replacement of motor bearings (3.20). When relubrication is confirmed, the figure in the above

display will be increased by one.

10.6.10 Time until relubrication of motor bearings (2.10)

This display is only shown if an MCB 114 sensor input module has been installed.

This display shows the actual value measured by sensor 2 connected to an MCB 114.

If no sensor is connected to the CUE, "–" will appear in the display.

This display is only shown if display 2.11 is not shown. This display shows when to relubricate the motor bearings. The

controller monitors the operating pattern of the pump and calculates the period between bearing relubrications. If the operating pattern changes, the calculated time till relubrication may change as well.

The estimated time until relubrication takes into account if the pump has been running with reduced speed.

See section 10.7.17 Confirming relubrication/replacement of motor bearings (3.20).

10.6.11 Time until replacement of motor bearings (2.11)

Note

10.6.15 Accumulated flow (2.15)

This display is only shown if display 2.10 is not shown. This display shows when to replace the motor bearings. The

controller monitors the operating pattern of the pump and calculates the period between bearing replacements.

The estimated time until replacement of motor bearings takes into account if the pump has been running with reduced speed.

See section 10.7.17 Confirming relubrication/replacement of motor bearings (3.20).

10.6.12 Temperature sensor 1 (2.12)

This display is only shown if an MCB 114 sensor input module has been installed.

This display shows the measuring point and the actual value measured by Pt100/Pt1000 temperature sensor 1 connected to the MCB 114. The measuring point is selected in display 3.21.

If no sensor is connected to the CUE, "–" will appear in the display.

10.6.13 Temperature sensor 2 (2.13)

This display is only shown if a flowmeter has been configured. This display shows the value of the accumulated flow and the

specific energy for the transfer of the pumped liquid. The flow measurement can be connected to the digital p ulse input

(terminal 33) or the analog input (terminal 54).

10.6.16 Firmware version (2.16)

This display shows the version of the software.

10.6.17 Configuration file (2.17)

This display shows the configuration file.

10.7 Menu INSTALLATION

10.7.1 Control mode (3.1)

This display is only shown if an MCB 114 sensor input module has been installed.

This display shows the measuring point and the actual value measured by Pt100/Pt1000 temperature sensor 2 connected to the MCB 114. The measuring point is selected in display 3.22.

If no sensor is connected to the CUE, "–" will appear in the display.

10.6.14 Flow rate (2.14)

This display is only shown if a flowmeter has been configured. This display shows the actual value measured by a flowmeter

connected to the digital pulse input (terminal 33) or the analog input (terminal 54).

Select one of the following control modes:

• Open loop

• Constant pressure

• Constant differential pressure

• Proportional differential pressure

• Constant flow rate

• Constant temperature

• Constant level

• Constant other value.

If the pump is connected to a bus, the control mode cannot be selected via the CUE. See section 13.3 GENIbus signal.

10.7.2 Controller (3.2)

CUE

Δt

CUE

Δp

CUE

System/application

Heating

system

Cooling

system

0.2 0.5

The CUE has a factory setting of gain (K

) and integral time (Ti).

However, if the factory setting is n ot the opt imum set ting, the ga in and the integral time can be changed in the display.

•The gain (K

• The integral time (T

) can be set within the range from 0.1 to 20.

) can be set within the range from 0.1 to

3600 s. If 3600 s is selected, the controller will function as a P controller.

• Furthermore, it is possible to set the controller to inverse control, meaning that if the setpoint is increased, the speed will be reduced. In the case of inverse control, the gain (K

)

must be set within the range from –0.1 to –20.

The table below shows the suggested controller settings:

SP, SP-G, SP-NE: 0.5 0.5

0.2 0.5

SP, SP-G, SP-NE: 0.5 0.5

0.2 0.5

–2.5 100

0.5 –0.5 10 + 5L

0.5 10 + 5L

0.5 –0.5 30 + 5L2 *

0.5 0.5 *

< 5 m: 0.5 *

0.5

> 5 m: 3 *

> 10 m: 5 *

* Ti = 100 seconds (factory setting).

1. Heating systems are systems in which an increase in pump performance will result in a rise in temperature at the sensor.

2. Cooling systems are systems in which an increase in pump performance will result in a drop in temperature at the sensor.

= Distance in [m] between pump and sensor.

= Distance in [m] between heat exchanger and sensor.

How to set the PI controller

Note

For most applications, the factory setting of the controller constants K

and Ti will ensure optimum pump operation.

However, in some applications an adjustment of the controller may be needed.

Proceed as follows:

1. Increase the gain (K

) until the motor becomes unstable.

Instability can be seen by observing if the measured value starts to fluctuate. Furthermore, instability is audible as the motor starts hunting up and down. As some systems, such as temperature controls, are slowreacting, it may be difficult to observe that the motor is unstable.

2. Set the gain (K

) to half the value of the value which made the

motor unstable. This is the correct setting of the gain.

3. Reduce the integral time (T

) until the motor becomes

unstable.

4. Set the integral time (T

) to twice the value which made the

motor unstable. This is the correct setting of the integral time.

General rules of thumb:

• If the controller is too slow-reacting, increase K

• If the controller is hunting or unstable, dampen the system by reducing K

or increasing Ti.

10.7.3 External setpoint (3.3)

10.7.4 Signal relays 1 and 2 (3.4 and 3.5)

The CUE has two signal relays. In the display below, select in which operating situations the signal relay should be activated.

Signal relay 1 Signal relay 2

• Ready

• Alarm

• Operation

• Pump running

• Not active

• Warning

• Relubricate.

• Ready

• Alarm

• Operation

• Pump running

• Not active

• Warning

• Relubricate.

For distinction between alarm and warning, see section 10.5.3 Fault indications.

10.7.5 Buttons on the CUE (3.6)

The input for external setpoint signal (terminal 53) can be set to the following types:

• Active

• Not active.

If Active is selected, the actual se tpoint is inf luenced by the signal connected to the external setpoint input. See section

13.2 External setpoint.

The editing buttons (+, –, On/Off, OK) on the control panel can be set to these values:

•Active

• Not active.

When set to Not active (locked), the editing buttons do not function. Set the buttons to Not active if the pump should be controlled via an external control system.

Activate the buttons by pressing the arrow up and arrow down buttons simultaneously for 3 seconds.

10.7.6 Protocol (3.7)

This display shows the protocol selection for the RS-485 port of the CUE. The protocol can be set to these values:

• GENIbus

•FC

•FC MC.

If GENIbus is selected, the com municat io n is set accord ing to the Grundfos GENIbus standard. FC and FC MC is for service purpose only.

10.7.7 Pump number (3.8)

This display shows the GENIbus number. A number between 1 and 199 can be allocated to the pump. In the case of bus communication, a number must be allocated to each pump.

The factory setting is "–".

10.7.8 Digital inputs 2, 3 and 4 (3.9 to 3.11)

Stop pressure

ΔH

Start pressure

Continuous operation

On/off operation

The digital inputs of the CUE (terminal 19, 32 and 33) can individually be set to different functions.

Select one of the following functions:

• Min. (min. curve)

• Max. (max. curve)

• Ext. fault (external fault)

• Flow switch

• Alarm reset

• Dry running (from external sensor)

• Accumulated flow (pulse flow, only terminal 33)

• Not active.

The selected function is active when the digital input is activated (closed contact). See also section 13.1 Digital inputs.

Min.

When the input is activated, the pump will operate according to the min. curve.

Max.

When the input is activated, the pump will operate according to the max. curve.

Ext. fault

When the input is activated, a timer will be started. If the input is activated for more than 5 seconds, an external fault will be indicated. If the input is deactivated, the fault condition will cease and the pump can only be restarted manually by resetting the fault indication.

Flow switch

When this function is selected, the pump will be stopped when a connected flow switch detects low flow.

It is only possible to use this function if the pump is connected to a pressure sensor or a level sensor, and the stop function is activated. See sections 10.7.10 and 10.7.11.

Alarm reset

When the input has been activated, the alarm is reset if the cause of the alarm no longer exists.

Dry running

When this function is selected, lack of inlet pressure or water shortage can be detected. This requires the use of an accessory, such as:

• a Grundfos Liqtec

dry-running switch

• a pressure switch installed on the suction side of a pump

• a float switch installed on the suction side of a pump. When lack of inlet pressure or water shortage (Dry running) is

detected, the pump will be stopped. The pump cannot restart as long as the input is activated.

Restarts may be delayed by up to 30 minutes, depending of the pump family.

Accumulated flow

When this function is set for digital input 4 and a pulse sensor is connected to terminal 33, the accumulated flow can be measured.

10.7.9 Digital flow input (3.12)

This display appears only if a flowmeter has been configured in display 3.11.

The display is used for setting the volume for every pulse for the function Accumulated flow with a pulse sensor connected to terminal 33.

Setting range:

• 0-1000 litre/pulse. The volume can be set in the unit selected in the start-up guide.

10.7.10 Constant pressure with stop function (3.13)

Settings

The stop function can be set to these values:

• Active

• Not active. The on/off band can be set to these values:

• ΔH is factory-set to 10 % of actual setpoint.

• ΔH can be set within the range from 5 % to 30 % of the actual setpoint.

Descriptions

The stop function is used for changing between on/off operation at low flow and continuous operation at high flow.

TM03 8477 1607

Fig. 38 Constant pressure with stop function. Difference

between start and stop pressures (ΔH)

Low flow can be detected in two different ways:

1. A built-in "low-flow detection function" which functions if the digital input is not set up for flow switch.

2. A flow switch connected to the digital input.

1. Low-flow detection function

The pump will check the flow regularly by reducing the speed for a short time. If there is no or only a small change in pressure, this means that there is low flow.

The speed will be increased until the stop pressure (actual setpoint + 0.5 x ΔH) is reached and the pump will stop after a few seconds. The pump will restart at the latest when the pressure has fallen to the start pressure (actual setpoint – 0.5 x ΔH).

If the flow in the off period is higher than the low-flow limit, the pump will restart before the pressure has fallen to the start pressure.

When restarting, the pump will react in the following way:

Caution

Pressure sensor

Diaphragm tank

Non-return valve

Pump

Diaphragm tank

Pressure sensor

Pump Non-return valve

Sta rt leve l

ΔH

Stop level

1. If the flow is higher than the low-flow limit, the pump will return to continuous operation at constant pressure.

2. If the flow is lower than the low-flow limit, the pump will continue in start/stop operation. It will continue in start/stop operation until the flow is higher than the low-flow limit. When the flow is higher than the low-flow limit, the pump will return to continuous operation.

2. Low-flow detection with flow switch

When the digital input is activated because there is low-flow, the speed will be increased until the stop pressure (actual setpoint +

0.5 x ΔH) is reached, and the pump will stop. When the pressure

has fallen to start pressure, the pump will start again. If there is still no flow, the pump will reach the stop pressure and stop. If there is flow, the pump will continue operating according to the setpoint.

Operating conditions for the stop function

It is only possible to use the stop function if the system incorporates a pressure sensor, a non-return valve and a diaphragm tank.

The non-return valve must always be installed before the pressure sensor. See figs 39 and 40.

If a flow switch is used to detect low flow, the switch must be installed on the system side after the diaphragm tank.

10.7.11 Constant level with stop function (3.13)

Settings

The stop function can be set to these values:

• Active

• Not active. The on/off band can be set to these values:

• ΔH is factory-set to 10 % of actual setpoint.

• ΔH can be set within the range from 5 % to 30 % of actual setpoint.

A built-in low-flow detection function will automatically measure and store the power consumption at approx. 50 % and 85 % of the rated speed.

If Active is selected, proceed as follows:

1. Close the isolating valve to create a no-flow condition.

2. Press OK to start the auto-tuning.

Description

The stop function is used for changing between on/off operation at low flow and continuous operation at high flow.

Fig. 39 Position of the non-return valve and pressure sensor in

system with suction lift operation

Fig. 40 Position of the non-return valve and pressure sensor in

system with positive inlet pressure

Diaphragm tank

The stop function requires a diaphragm tank of a certain minimum size. The tank must be installed as close as possible after the pump and the precharge pressure must be 0.7 x actual setpoint.

Recommended diaphragm tank size:

Rated flow rate of pump

[m³/h]

Typical diaphragm tank size

[litres]

0-6 8

7-24 18 25-40 50 41-70 120

71-100 180

If a diaphragm tank of the above size is installed in the system, the factory setting of ΔH is the correct setting. If the tank installed is too small, the pump will start and stop too often. This can be remedied by increasing ΔH.

TM03 8582 1907TM03 8583 1907

Fig. 41 Constant level with stop function. Difference between

start and stop levels (ΔH)

Low flow can be detected in two different ways:

1. With the built-in low-flow detection function.

2. With a flow switch connected to a digital input.

1. Low-flow detection function

The built-in low-flow detection is based on the measurement of speed and power.

When low flow is detected, the pump will stop. When the level has reached the start level, the pump will st art a gain. If there is still no flow, the pump will reach the stop level and stop. If there is flow, the pump will continue operating according to the setpoint.

2. Low-flow detection with flow switch

When the digital input is activated because of low flow, the speed will be increased until the stop level (actual setpoint – 0.5 x ΔH) is reached, and the pump will stop. When the level has reached the start level, the pump will start again. If there is still no flow, the pump will reach the stop level and stop. If there is flow, the pump will continue operating according to the setpoint.

Operating conditions for the stop function

It is only possible to use the constant level stop function if the system incorporates a level sensor, and all valves can be closed.

TM03 9099 3307

10.7.12 Sensor 1 (3.15)

Note

Nominal speed Max. speed

Actual speed range

Min. speed

Pump-dependent speed range

Min. speed, adjusted

Max. speed, adjusted

Speed [%]

Min.

Max.

100 %

Setting of sensor 1 connected to terminal 54. This is the feedback sensor.

Select among the following values:

• Sensor output signal:

0-20 mA 4-20 mA.

• Unit of measurement of sensor: bar, mbar, m, kPa, psi, ft, m3/h, m3/s, l/s, gpm, °C, °F, %.

• Sensor measuring range.

10.7.13 Sensor 2 (3.16)

Setting of sensor 2 connected to an MCB 114 sensor input module.

Select among the following values:

• Sensor output signal:

0-20 mA 4-20 mA.

• Unit of measurement of sensor: bar, mbar, m, kPa, psi, ft, m3/h, m3/s, l/s, gpm, °C, °F, %.

• Sensor measuring range: 0-100 %.

10.7.14 Duty/standby (3.17)

Settings

The duty/standby function can be set to these values:

• Active

• Not active.

Activate the duty/standby function as follows:

1. Connect one of the pumps to the mains supply. Set the duty/standby function to Not active. Make the necessary settings in menu OPERATION and INSTALLATION.

2. Set the operating mode to Stop in menu OPERATION.

3. Connect the other pump to the mains supply. Make the necessary settings in menu OPERATION and INSTALLATION. Set the duty/standby function to Active.

The running pump will search for the other pump and automatically set the duty/standby function of this pump to Active. If it cannot find the other pump, a fault will be indicated.

The two pumps must be connected electrically via the GENIbus, and nothing else must be connected on the GENIbus.

The duty/standby function applies to two pumps connected in parallel and controlled via GENIbus. Each pump must be connected to its own CUE and sensor.

The primary targets of the function is the following:

• To start the standby pump if the duty pump is stopped due to an alarm.

• To alternate the pumps at least every 24 hours.

10.7.15 Operating range (3.18)

How to set the operating range:

• Set the min. speed within the range from a pump-dependent min. speed to the adjusted max. speed. The factory setting depends on the pump family.

• Set the max. speed within the range from adjusted min. speed to the pump-dependent maximum speed. The factory setting will be equal to 100 %, i.e. the speed stated on the pump nameplate.

The area between the min. and max. speed is the actual operating range of the pump.

The operating range can be changed by the user within the pump-dependent speed range.

For some pump families, oversynchronous operation (max. speed above 100 %) will be possible. This requires an oversize motor to deliver the shaft power required by the pump during oversynchronous operation.

Fig. 42 Setting of the min. and max. curves in % of maximum performance

TM04 3581 4608

10.7.16 Motor bearing monitoring (3.19)

Note

10.7.18 Temperature sensor 1 (3.21)

The motor bearing monitoring function can be set to these values:

• Active

• Not active. When the function is set to Active, the CUE will give a warning

when the motor bearings are due to be relubricated or replaced.

Description

The motor bearing monitoring function is used to give an indication when it is time to relubricate or replace the motor bearings. See display 2.10 and 2.11.

The warning indication and the estimated time t ake into account if the pump has been running with reduced speed. The bearing temperature is included in the calculation if temperature sensors are installed and connected to an MCB 114 sensor input module.

The counter will continue counting even if the function is switched to Not active, but a warning will not be given when it is time for relubrication.

10.7.17 Confirming relubrication/replacement of motor bearings (3.20)

This function can be set to these values:

• Relubricated

• Replaced

• Nothing done.

When the motor bearings have been relubricated or replaced, confirm this action in the above display by pressing "OK".

Relubricated cannot be selected for a period of time after confirming relubrication.

Relubricated

When the warning Relubricate motor bearings has been confirmed,

• the counter is set to 0.

• the number of relubrications is increased by 1.

When the number of relubrications has reached the permissible number, the warning Replace motor bearings appears in the display.

Replaced

When the warning Replace motor bearings has been confirmed,

• the counter is set to 0.

• the number of relubrications is set to 0.

• the number of bearing changes is increased by 1.

This display is only shown if an MCB 114 sensor input module has been installed.

Select the function of a Pt100/Pt1000 temperature sensor 1 connected to an MCB 114:

• D-end bearing

• ND-end bearing

• Other liq. temp. 1

• Other liq. temp. 2

• Motor winding

• Pumped liq. temp.

• Ambient temp.

• Not active.

10.7.19 Temperature sensor 2 (3.22)

This display is only shown if an MCB 114 sensor input module has been installed.

Select the function of a Pt100/Pt1000 temperature sensor 2 connected to an MCB 114:

• D-end bearing

• ND-end bearing

• Other liq. temp. 1

• Other liq. temp. 2

• Motor winding

• Pumped liq. temp.

• Ambient temp.

• Not active.

10.7.20 Standstill heating (3.23)

The standstill heating function can be set to these values:

• Active

• Not active. When the function is set to Active and the pump is stopped by a

stop command, a current will be applied to the motor windings. The standstill heating function pre-heats the motor to avoid

condensation.

Rated

Ramp-up Ramp-down

Speed

Time

Minimum

Initial ramp Final ramp

On/

Off

10.7.21 Ramps (3.24)

Set the time for each of the two ramps, ramp-up and ramp-down:

• Factory setting: Depending on power size.

• The range of the ramp parameter: 1-3600 s.

-1

The ramp-up time is the acceleration time from 0 min

to the rated motor speed. Choose a ramp-up time such that the output current does not exceed the maximum current limit for the CUE.

The ramp-down time is the deceleration time from rated motor speed to 0 min

-1

. Choose a ramp-down time such that no overvoltage arises and such that the generated current does not exceed the maximum current limit for the CUE.

Fig. 43 Ramp-up and ramp-down, display 3.24

11. Setting by means of PC Tool E-products

Special setup requirements differing from the settings available via the CUE require the use of Grundfos PC Tool E-products. This again requires the assistance of a Grundfos service technician or engineer. Contact your local Grundfos company for more information.

12. Priority of settings

The on/off button has the highest priority. In "off"

On/

condition, pump operation is not possible.

The CUE can be controlled in various ways at the same time. If two or more operating modes are active at the same time, the operating mode with the highest priority will be in force.

12.0.1 Control without bus signal, local operating mode

Priority CUE menu External signal

1Stop 2Max. 3 Stop 4 5Min. Min. 6 Normal Normal

Example: If an external signal has activated the operating mode Max., it will only be possible to stop the pump.

12.0.2 Control with bus signal, remote-controlled operating mode

Priority CUE menu External signal Bus signal

1Stop 2Max. 3 Stop Stop 4 5 6

Example: If the bus signal has activated the operating mode Max., it will only be possible to stop the pump.

TM03 9439 4007

13. External control signals

13.1 Digital inputs

The overview shows functions in connection with closed contact.

Terminal Type Function

18 DI 1 • Start/stop of pump

•Min. (min. curve)

•Max. (max. curve)

• Ext. fault (external fault)

19 DI 2

32 DI 3

33 DI 4

The same function must not be selected for more than one input. See fig. 17.

• Flow switch

• Alarm reset

• Dry running (from external sensor)

• Not active.

•Min. (min. curve)

•Max. (max. curve)

• Ext. fault (external fault)

• Flow switch

• Alarm reset

• Dry running (from external sensor)

• Not active.

• Min. (min. curve)

• Max. (max. curve)

• Ext. fault (external fault)

• Flow switch

• Alarm reset

• Dry running (from external sensor)

• Accumulated flow (pulse flow)

• Not active.

Max.

Max. Min. Normal

13.2 External setpoint

Setpoint

Max. curve

Setpoint, CUE menu

Min. curve

Ext. setpoint signal

Actual setpoint

0 10 V

Actual setpoint range

Setpoint

Sensor max.

Setpoint, CUE menu

Sensor min.

Ext. setpoint signal

Actual setpoint

0 10 V

Actual setpoint range

Note

Setpoint

90 % of max. head

Setpoint, CUE menu

25 % of max. head

Ext. setpoint signal

Actual setpoint

010 V

Actual setpoint range

Terminal Type Function

53 AI 1 • External setpoint (0-10 V)

The setpoint can be remote-set by connecting an analog signal transmitter to the setpoint input (terminal 53).

Open loop

In control mode Open loop (constant curve), the actual setpoint can be set externally within the range from the min. curve to the setpoint set via the CUE menu. See fig. 44.

Fig. 44 Relation between the actual setpoint and the external

setpoint signal in control mode Open loop

Closed loop

In all other control modes, except proportional differential pressure, the actual setpoint can be set externally within the range from the lower value of the sensor measuring range (sensor min.) to the setpoint set via the CUE menu. See fig. 45.

Proportional differential pressure

In control mode Proportional differential pressure, the actual setpoint can be set externally within the range from 25 % of maximum head to the setpoint set via the CUE menu. See fig. 46.

Fig. 46 Relation between the actual setpoint and the external

setpoint signal in control mode Proportional differential pressure

Example: At a maximum head of 12 metres, a setpoint of 6 metres set via the CUE menu and an external setpoint of 40 %, the actual setpoint will be as follows:

TM03 8856 2607TM03 8856 2607

(setpoint, CUE menu – 25 % of maximum

Actual setpoint =

head) x % external setpoint signal + 25 % of

maximum head = (6 – 12 x 25 %) x 40 % + 12/4 =4.2 m

13.3 GENIbus signal

The CUE supports serial communication via an RS-485 input. The communication is carried out according to the Grundfos GENIbus protocol and enables connection to a building management system or another external control system.

Operating parameters, such as setpoint and operating mode can be remote-set via the bus signal. At the same time, the pump can provide status information about important parameters, such as actual value of control parameter, input power and fault indications.

Contact Grundfos for further details.

TM03 8856 2607

Fig. 45 Relation between the actual setpoint and the external

Example: At a sensor min. value of 0 bar, a setpoint set via the

CUE menu of 3 bar and an external setpoint of 80 %, the actual setpoint will be as follows:

Actual setpoint =

setpoint signal in control mode Controlled

(setpoint set via the CUE menu – sensor min.)

x % external setpoint signal + sensor min. = (3 – 0) x 80 % + 0 = 2.4 bar

If a bus signal is used, the number of settings available via the CUE will be reduced.

13.4 Other bus standards

Grundfos offers various bus solutions with communication according to other standards.

Contact Grundfos for further details.

14. Maintenance and service

14.1 Cleaning the CUE

Keep the cooling fins and fan blades clean to ensure sufficient cooling of the CUE.

14.2 Service parts and service kits

For further information on service parts and service kits, visit www.grundfos.com > International website > WebCAPS.

15. Fault finding

15.1 Warning and alarm list

Status

Code and display text

Warning

Alarm

Too high leakage

current 2 Mains phase failure 3 External fault

16 Other fault

z Stop Aut. z Stop Man. z Stop Aut.

30 Replace motor bearings z 32 Overvoltage

40 Undervoltage

48 Overload 49 Overload 55 Overload 57 Dry running

Too high CUE 64

temperature

Too high motor 70

temperature

Communication fault, 77

duty/standby 89 Sensor 1 outside range

Temperature sensor 1 91

outside range

z Stop Aut.

z Stop Aut. z Stop Aut.

z Stop Aut.

z Stop Aut. z Stop Aut.

z Stop Aut.

93 Sensor 2 outside range z

Setpoint signal outside 96

range

Too high bearing 148

temperature

Too high bearing 149

temperature 155 Inrus h faul t

Temperature sensor 2 175

outside range

Relubricate motor 240

bearings 241 Motor phase failure

242 AMA

In case of an alarm, the CUE will change the operating mode

did not succeed z –Man.

z Stop Aut.

z Stop Aut. z Stop Aut.

z Stop Aut.

depending on the pump type.

AMA, Automatic Motor Adaptation. Not active in the present

software.

Warning is reset in display 3.20.

Operat-

ing mode

Locked alarm

z Stop Man.

– Man. –Aut.

–Aut.

z Stop Man.

–Aut.

–Aut. –Aut.

–Aut.

– Man. –Aut.

Reset-

ting

Aut.

15.2 Resetting of alarms

In case of fault or malfunction of the CUE, check the alarm list in menu OPERATION. The latest five alarms and latest five warnings can be found in the log menus.

Contact a Grundfos technician if an alarm occurs repeatedly.

15.2.1 Warning

The CUE will continue the operation as long as the warning is active. The warning remains active until the cause no longer exists. Some warnings may switch to alarm condition.

15.2.2 Alarm

In case of an alarm, the CUE will stop the pump or change the operating mode depending on the alarm typ e and pump type. See section 15.1 Warning and alarm list.

Pump operation will be resumed when the cause of the alarm has been remedied and the alarm has been reset.

Resetting an alarm manually

• Press OK in the alarm display.

• Press On/Off twice.

• Activate a digital input DI 2-DI 4 set to Alarm reset or the digital input DI 1 (Start/stop).

If it is not possible to reset an alarm, the reason may be that the fault has not been remedied, or that the alarm has been locked.

15.2.3 Locked alarm

In case of a locked alarm, the CUE will stop the pump and become locked. Pump operation cannot be resumed until the cause of the locked alarm has been remedied and the alarm has been reset.

Resetting a locked alarm

• Switch off the power supply to the CUE for approx. 30 seconds. Switch on the power supply, and press OK in the alarm display to reset the alarm.

15.3 Indicator lights

The table show the function of the indicator lights.

Indicator light

Function

The pump is running or has been stopped by a

On (green)

stop function. If flashing, the pump has been stopped by the

user (CUE menu), external start/stop or bus.

Off (orange)

The pump has been stopped with the on/off button.

Alarm (red) Indicates an alarm or a warning.

15.4 Signal relays

The table show the function of the signal relays.

Type Function

Relay 1

• Ready

•Alarm

• Operation

• Ready

Relay 2

•Alarm

• Operation

16. Technical data

16.1 Enclosure

The individual CUE cabinet sizes are characterised by their enclosures. The table shows the relationship of enclosure class and enclosure type.

Example:

Read from the namepl ate :

• Supply voltage = 3 x 380-500 V.

• Typical shaft power = 110 kW.

• Enclosure class = IP21. The table shows that the CUE enclosure is D1.

Typical shaft

power P2

[kW] [HP] IP21 IP54 IP21 IP54

110 150

160 250

250 350

3 x 380-500 V 3 x 525-690 V

D1 D1

D2 D2200 300

16.2 Main dimensions and weight

Enclosure

D1 D1132 200

D2 D2

Fig. 47 Enclosure s D1 an d D2

Enclosure

D1 1209 1154 420 304 380 20 11 11 25 104 D2 1589 1535 420 304 380 20 11 11 25 151 Shipping dimensions D1 650 – 1730 – 570 – – – – – D2 650 – 1730 – 570 – – – – –

The dimensions are maximum height, width and depth. Dimensions are without options

Height [mm] AaBb C c∅d ∅ef

Width [mm]

Depth [mm]

Screw holes [mm]

Weight [kg]

TM03 9922 4607

16.3 Surroundings

Relative humidity 5-95 % RH Ambient temperature Max. 45 °C Average ambient temperature over 24 hours Max. 40 °C Minimum ambient temperature at full

operation Minimum ambient temperature at reduced

operation Temperature during storage and

transportation

–25 to 65 °C

0 °C

–10 °C

Storage duration Max. 6 months Maximum altitude above sea level without

performance reduction Maximum altitude above sea level with

performance reduction

1000 m

3000 m

Note: The CUE comes in a packaging which is not suitable for outdoor storage.

16.4 Terminal tightening torques

Screws M10 19 Nm Screws M8 9.5 Nm

16.5 Cable length

Maximum length, screened motor cable 150 m Maximum length, unscreened motor cable 300 m Maximum length, signal cable 300 m

16.6 Fuses and cable cross-section

Warnin g Always comply with national and local

regulations as to cable cross-sections.

16.6.1 Cable cross-section to signal terminals

Maximum cable cross-section to signal terminals, rigid conductor

Maximum cable cross-section to signal terminals, flexible conductor

Minimum cable cross-section to signal terminals

16.6.2 Non-UL fuses and conductor cross-section to mains and motor

Typical shaft

power P2

[kW] [A]

3 x 380-500 V

110 300 gG 2 x 70 132 350 gG 2 x 70 160 400 gG 2 x 185 200 500 gG 2 x 185 250 600 gR 2 x 185

3 x 525-690 V

110 225 – 2 x 70 132 250 – 2 x 70 160 350 – 2 x 185 200 400 – 2 x 185 250 500 – 2 x 185

Screened motor cable, unscreened supply cable. AWG,

Maximum

fuse size

Fuse

type

Maximum conductor

cross-section

see section 16.6.3.

[mm

]

1.5 mm

1.0 mm

0.5 mm

16.6.3 UL fuses and conductor cross-section to mains and motor

Typical shaft

power P2

[kW]

3 x 380-500 V

110 FWH-300 JJS-300 NOS-300 170M3017 2028220-315 L50S-300 A50-P300 2 x 2/0 132 FWH-350 JJS-350 NOS-350 170M3018 2028220-315 L50S-350 A50-P350 2 x 2/0 160 FWH-400 JJS-400 NOS-400 170M4012 206xx32-400 L50S-400 A50-P400 2 x 350 MCM 200 FWH-500 JJS-500 NOS-500 170M4014 206xx32-500 L50S-500 A50-P500 2 x 350 MCM 250 FWH-600 JJS-600 NOS-600 170M4016 206xx32-600 L50S-600 A50-P600 2 x 350 MCM

– – – – Bussmann

3 x 525-690 V

110 – – – 170M3017 2061032.315 – 6.6URD30D08A0315 2 x 2/0 132 – – – 170M3018 2061032.350 – 6.6URD30D08A0350 2 x 2/0 160 – – – 170M4011 2061032.350 – 6.6URD30D08A0350 2 x 2/0 200 – – – 170M4012 2061032.400 – 6.6URD30D08A0400 2 x 350 MCM 250 – – – 170M4014 2061032.500 – 6.6URD30D08A0500 2 x 350 MCM

Screened motor cable, unscreened supply cable.

American Wire Gauge.

Bussmann

E1958 JFHR2

Bussmann

E4273

T/JDDZ

Bussmann

E4274

H/JDDZ

Fuse type Maximum conductor

Bussmann

E125085

JFHR2

E125085

JFHR2

SIBA

E180276

RKI/JDDZ

SIBA

E180276

JFHR2

Littel Fuse

E71611 JFHR2

– Ferraz-Shawmut

Ferraz-Shawmut

E60314

JFHR2

E76491

JFHR2

cross-section

[AWG]

–

16.7 Inputs and outputs

Note

Subject to alterations.

16.7.1 Mains supply (L1, L2, L3)

Supply voltage 380-500 V ± 10 % Supply voltage 525-690 V ± 10 % Supply frequency 50/60 Hz Maximum temporary imbalance between

phases Leakage current to earth >3.5 mA Number of cut-ins, enclosure D max. 1 time/2 min.

Do not use the supply voltage for switching the CUE on and off.

16.7.2 Motor output (U, V, W)

Output voltage 0-100 % Output frequency 0-100 Hz Switching on output not recommended

Output voltage in % of supply voltage.

Depending on the pump family selected.

16.7.3 RS-485 GENIbus connection

Terminal number 68 (A), 69 (B), 61 GND (Y)

The RS-485 circuit is functionally separated from other central circuits and galvanically separated from the supply voltage (PELV).

16.7.4 Digital inputs

Terminal number 18, 19, 32, 33 Voltage level 0-24 VDC Voltage level, open contact > 19 VDC Voltage level, closed contact < 14 VDC Maximum voltage on input 28 VDC Input resistance, R

All digital inputs are galvanically separated from the supply voltage (PELV) and other high-voltage terminals.

16.7.5 Signal relays

Relay 01, terminal number 1 (C), 2 (NO), 3 (NC) Relay 02, terminal number 4 (C), 5 (NO), 6 (NC)

Maximum terminal load (AC-1) Maximum terminal load (AC-15) Maximum terminal load (DC-1)

Minimum terminal load

IEC 60947, parts 4 and 5.

CCommon NO Normally open NC Normally closed

The relay contacts are galvanically separated from other circuits by reinforced insulation (PELV).

3 % of rated value

Approx. 4 kΩ

240 VAC, 2 A

240 VAC, 0.2 A

50 VDC, 1 A

24 V DC 10 mA 24 V AC 20 mA

16.7.6 Analog inputs

Analog input 1, terminal number 53

Voltage signal A53 = "U"

Voltage range 0-10 V Input resistance, R

Approx. 10 kΩ Maximum voltage ± 20 V Current signal A53 = "I"

Current range 0-20, 4-20 mA Input resistance, R

Approx. 200 Ω Maximum current 30 mA Maximum fault, terminals 53, 54 0.5 % of full scale Analog input 2, terminal number 54

Current range 0-20, 4-20 mA Input resistance, R

Approx. 200 Ω

Current signal A54 = "I"

Maximum current 30 mA Maximum fault, terminals 53, 54 0.5 % of full scale

1. The factory setting is voltage signal "U". All analog inputs are galvanically separated from the supply

voltage (PELV) and other high-voltage terminals.

16.7.7 Analog output

Analog output 1, terminal number 42

Current range 0-20 mA Maximum load to frame 500 Ω Maximum fault 0.8 % of full scale

The analog output is galvanically separated from the supply voltage (PELV) and other high-voltage terminals.

16.7.8 MCB 114 sensor input module

Analog input 3, terminal number 2

Current range 0/4-20 mA Input resistance < 200 Ω Analog inputs 4 and 5, terminal number 4, 5 and 7, 8 Signal type, 2- or 3-wire Pt100/Pt1000

Note: When using Pt100 with 3-wire cable, the resistance must not exceed 30 W.

16.8 Sound pressure level

Enclosure D1: maximum 76 dBA Enclosure D2: maximum 74 dBA

The sound pressure of the CUE is measured at a distance of 1 m from the unit.

The sound pressure level of a motor controlled by a frequency converter may be higher than that of a corresponding motor which is not controlled by a frequency converter. See section

6.7 RFI filters.

17. Disposal

This product or parts of it must be disposed of in an environmentally sound way:

1. Use the public or private waste collection service.

2. If this is not possible, contact the nearest Grundfos company or service workshop.

Argentina

Bombas GRUNDFOS de Argentina S.A. Ruta Panamericana km. 37.500 Lote 34A 1619 - Garin Pcia. de Buenos Aires Phone: +54-3327 414 444 Telefax: +54-3327 411 111

Australia

GRUNDFOS Pumps Pty. Ltd. P.O. Box 2040 Regency Park South Australia 5942 Phone: +61-8-8461-4611 Telefax: +61-8-8340 0155

Austria

GRUNDFOS Pumpen Vertrieb Ges.m.b.H. Grundfosstraße 2 A-5082 Grödig/Salzburg Tel.: +43-6246-883-0 Telefax: +43-6246-883-30

Belgium

N.V. GRUNDFOS Bellux S.A. Boomsesteenweg 81-83 B-2630 Aartselaar Tél.: +32-3-870 7300 Télécopie: +32-3-870 7301

Belorussia

Представительство ГРУНДФОС в Минске 220090 Минск ул.Олешева 14 Теле фо н: (8632) 62-40-49 Факс: (8632) 62-40-49

Bosnia/Herzegovina

GRUNDFOS Sarajevo Paromlinska br. 16, BiH-71000 Sarajevo Phone: +387 33 713290 Telefax: +387 33 231795

Brazil

Mark GRUNDFOS Ltda. Av. Humberto de Alencar Castelo Branco, 630 CEP 09850 - 300 São Bernardo do Campo - SP Phone: +55-11 4393 5533 Telefax: +55-11 4343 5015

Bulgaria

GRUNDFOS Pumpen Vertrieb Representative Office - Bulgaria Bulgaria, 1421 Sofia Lozenetz District 105-107 Arsenalski blvd. Phone: +359 2963 3820, 2963 5653 Telefax: +359 2963 1305

Canada

GRUNDFOS Canada Inc. 2941 Brighton Road Oakville, Ontario L6H 6C9 Phone: +1-905 829 9533 Telefax: +1-905 829 9512

China

GRUNDFOS Pumps (Shanghai) Co. Ltd. 51 Floor, Raffles City No. 268 Xi Zang Road. (M) Shanghai 200001 PRC Phone: +86-021-612 252 22 Telefax: +86-021-612 253 33

Croatia

GRUNDFOS predstavništvo Zagreb Cebini 37, Buzin HR-10000 Zagreb Phone: +385 1 6595 400 Telefax: +385 1 6595 499

Czech Republic

GRUNDFOS s.r.o. Čajkovského 21 779 00 Olomouc Phone: +420-585-716 111 Telefax: +420-585-716 299

Denmark

GRUNDFOS DK A/S Martin Bachs Vej 3 DK-8850 Bjerringbro Tlf.: +45-87 50 50 50 Telefax: +45-87 50 51 51 E-mail: info_GDK@grundfos.com www.grundfos.com/DK

Estonia

GRUNDFOS Pumps Eesti OÜ Peterburi tee 92G 11415 Tallinn Tel: + 372 606 1690 Fax: + 372 606 1691

Finland

OY GRUNDFOS Pumput AB Mestarintie 11 FIN-01730 Vantaa Phone: +358-3066 5650 Telefax: +358-3066 56550

France

Pompes GRUNDFOS Distribution S.A. Parc d’Activités de Chesnes 57, rue de Malacombe F-38290 St. Quentin Fallavier (Lyon) Tél.: +33-4 74 82 15 15 Télécopie: +33-4 74 94 10 51

Germany

GRUNDFOS GMBH Schlüterstr. 33 40699 Erkrath Tel.: +49-(0) 211 929 69-0 Telefax: +49-(0) 211 929 69-3799 e-mail: infoservice@grundfos.de Service in Deutschland: e-mail: kundendienst@grundfos.de

Greece

GRUNDFOS Hellas A.E.B.E. 20th km. Athinon-Markopoulou Av. P.O. Bo x 7 1 GR-19002 Peania Phone: +0030-210-66 83 400 Telefax: +0030-210-66 46 273

Hong Kong

GRUNDFOS Pumps (Hong Kong) Ltd. Unit 1, Ground floor Siu Wai Industrial Centre 29-33 Wing Hong Street & 68 King Lam Street, Cheung Sha Wan Kowloon Phone: +852-27861706 / 27861741 Telefax: +852-27858664

Hungary

GRUNDFOS Hungária Kft. Park u. 8 H-2045 Törökbálint, Phone: +36-23 511 110 Telefax: +36-23 511 111

India

GRUNDFOS Pumps India Private Limited 118 Old Mahabalipuram Road Thoraipakkam Chennai 600 096 Phone: +91-44 2496 6800

Indonesia

PT GRUNDFOS Pompa Jl. Rawa Sumur III, Blok III / CC-1 Kawasan Industri, Pulogadung Jakarta 13930 Phone: +62-21-460 6909 Telefax: +62-21-460 6910 / 460 6901

Ireland

GRUNDFOS (Ireland) Ltd. Unit A, Merrywell Business Park Ballymount Road Lower Dublin 12 Phone: +353-1-4089 800 Telefax: +353-1-4089 830

Italy

GRUNDFOS Pompe Italia S.r.l. Via Gran Sasso 4 I-20060 Truccazzano (Milano) Tel.: +39-02-95838112 Telefax: +39-02-95309290 / 95838461

Japan

GRUNDFOS Pumps K.K. Gotanda Metalion Bldg., 5F, 5-21-15, Higashi-gotanda Shiagawa-ku, Tokyo 141-0022 Japan Phone: +81 35 448 1391 Telefax: +81 35 448 9619

Korea

GRUNDFOS Pumps Korea Ltd. 6th Floor, Aju Building 679-5 Yeoksam-dong, Kangnam-ku, 135-916 Seoul, Korea Phone: +82-2-5317 600 Telefax: +82-2-5633 725

Latvia

SIA GRUNDFOS Pumps Latvia Deglava biznesa centrs Augusta Deglava ielā 60, LV-1035, Rīga, Tālr.: + 371 714 9640, 7 149 641 Fakss: + 371 914 9646

Lithuania

GRUNDFOS Pumps UAB Smolensko g. 6 LT-03201 Vilnius Tel: + 370 52 395 430 Fax: + 370 52 395 431

Malaysia

GRUNDFOS Pumps Sdn. Bhd. 7 Jalan Peguam U1/25 Glenmarie Industrial Park 40150 Shah Alam Selangor Phone: +60-3-5569 2922 Telefax: +60-3-5569 2866

México

Bombas GRUNDFOS de México S.A. de C.V. Boulevard TLC No. 15 Parque Industrial Stiva Aeropuerto Apodaca, N.L. 66600 Phone: +52-81-8144 4000 Telefax: +52-81-8144 4010

Netherlands

GRUNDFOS Netherlands Veluwezoom 35 1326 AE Almere Postbus 22015 1302 CA ALMERE Tel.: +31-88-478 6336 Telefax: +31-88-478 6332 e-mail: info_gnl@grundfos.com

New Zealand

GRUNDFOS Pumps NZ Ltd. 17 Beatrice Tinsley Crescent North Harbour Industrial Estate Albany, Auckland Phone: +64-9-415 3240 Telefax: +64-9-415 3250

Norway

GRUNDFOS Pumper A/S Strømsveien 344 Postboks 235, Leirdal N-1011 Oslo Tlf.: +47-22 90 47 00 Telefax: +47-22 32 21 50

Poland

GRUNDFOS Pompy Sp. z o.o. ul. Klonowa 23 Baranowo k. Poznania PL-62-081 Przeźmierowo Tel: (+48-61) 650 13 00 Fax: (+48-61) 650 13 50

Portugal

Bombas GRUNDFOS Portugal, S.A. Rua Calvet de Magalhães, 241 Apartado 1079 P-2770-153 Paço de Arcos Tel.: +351-21-440 76 00 Telefax: +351-21-440 76 90

România

GRUNDFOS Pompe România SRL Bd. Biruintei, nr 103 Pantelimon county Ilfov Phone: +40 21 200 4100 Telefax: +40 21 200 4101 E-mail: romania@grundfos.ro

Russia

ООО Гру ндфос Росс ия, 109544 Москва, ул. Школьная

Тел. (+7) 495 737 30 00, 564 88 00 Факс (+7) 495 737 75 36, 564 88 11

E-mail grundfos.moscow@grundfos.com

Serbia

GRUNDFOS Predstavništvo Beograd Dr. Milutina Ivkovića 2a/29 YU-11000 Beograd Phone: +381 11 26 47 877 / 11 26 47 496 Telefax: +381 11 26 48 340

Singapore

GRUNDFOS (Singapore) Pte. Ltd. 24 Tuas West Road Jurong Town Singapore 638381 Phone: +65-6865 1222 Telefax: +65-6861 8402

Slovenia

GRUNDFOS PUMPEN VERTRIEB Ges.m.b.H., Podružnica Ljubljana Blatnica 1, SI-1236 Trzin Phone: +386 1 563 5338 Telefax: +386 1 563 2098 E-mail: slovenia@grundfos.si

Spain

Bombas GRUNDFOS España S.A. Camino de la Fuentecilla, s/n E-28110 Algete (Madrid) Tel.: +34-91-848 8800 Telefax: +34-91-628 0465

Sweden

GRUNDFOS AB Lunnagårdsgatan 6 431 90 Mölndal Tel.: +46-0771-32 23 00 Telefax: +46-31 331 94 60

Switzerland

GRUNDFOS Pumpen AG Bruggacherstrasse 10 CH-8117 Fällanden/ZH Tel.: +41-1-806 8111 Telefax: +41-1-806 8115

Taiwan

GRUNDFOS Pumps (Taiwan) Ltd. 7 Floor, 219 Min-Chuan Road Tai ch ung, Tai wan, R. O.C. Phone: +886-4-2305 0868 Telefax: +886-4-2305 0878

Thailand

GRUNDFOS (Thailand) Ltd. 947/168 Moo 12, Bangna-Trad Rd., K.M. 3, Bangna, Phrakanong Bangkok 10260 Phone: +66-2-744 1785 ... 91 Telefax: +66-2-744 1775 ... 6

Turkey

GRUNDFOS POMPA San. ve Tic. Ltd. Sti. Gebze Organize Sanayi Bölgesi Ihsan dede Caddesi,

2. yol 200. Sokak No. 204 41490 Gebze/ Kocaeli Phone: +90 - 262-679 7979 Telefax: +90 - 262-679 7905 E-mail: satis@grundfos.com

Ukraine

ТОВ ГРУНДФОС УКРАЇНА 01010 Київ, Вул. Московська 8б,

Тел.:(+38 044) 390 40 50 Фах.: (+38 044) 390 40 59

E-mail: ukraine@grundfos.com

United Arab Emirates

GRUNDFOS Gulf Distribution P.O. Box 16768 Jebel Ali Free Zone Dubai Phone: +971-4- 8815 166 Telefax: +971-4-8815 136

United Kingdom

GRUNDFOS Pumps Ltd. Grovebury Road Leighton Buzzard/Beds. LU7 8TL Phone: +44-1525-850000 Telefax: +44-1525-850011

U.S.A.

GRUNDFOS Pumps Corporation 17100 West 118th Terrace Olathe, Kansas 66061 Phone: +1-913-227-3400 Telefax: +1-913-227-3500

Usbekistan

Представительство ГРУНДФОС в Ташкенте 700000 Ташкент ул.Усм ан а Носира 1-й тупик 5 Телеф он : (3712) 55-68-15 Факс: (3712) 53-36-35

Addresses revised 11.01.2008

Being responsible is our foundation

Thinking ahead makes it possible

Innovation is the essence

96783675 0208

www.grundfos.com

Grundfos CUE Series Installation And Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1. Symbols used in this document

2. Introduction

2.1 General description

2.2 Applications

2.3 References

3. Safety and warnings

3.1 Warning

3.2 Safety regulations

4. Identification

4.1 Nameplate

3.3 Installation requirements

3.4 Reduced performance under c ertain conditions

4.2 Packaging label

5. Mechanical installation

5.1 Reception and storage

5.2 Transportation and unpacking

5.3 Space requirements and air circulation

5.4 Mounting

6. Electrical connection

6.1 Electrical protection

6.2 Mains and motor connection

6.3 Connecting the signal terminals

6.4 Connecting the signal relays

6.5 Connecting the MCB 114 sensor input module

6.6 EMC-correct installation

6.7 RFI filters

6.8 Output filters

7. Operating modes

8. Control modes

9. Menu overview

10. Setting by means of the control panel

10.1 Control panel

10.2 Back to factory setting

10.3 Start-up guide

10.4 Menu GENERAL

10.5 Menu OPERATION

10.6 Menu STATUS

10.7 Menu INSTALLATION

11. Setting by means of PC Tool E-products

12. Priority of settings

13. External control signals

13.1 Digital inputs

13.2 External setpoint

13.3 GENIbus signal

13.4 Other bus standards

14. Maintenance and service

14.1 Cleaning the CUE

14.2 Service parts and service kits

15. Fault finding

15.1 Warning and alarm list

15.2 Resetting of alarms

15.3 Indicator lights

15.4 Signal relays

16. Technical data

16.1 Enclosure

16.2 Main dimensions and weight

16.3 Surroundings

16.4 Terminal tightening torques

16.5 Cable length

16.6 Fuses and cable cross-section

16.7 Inputs and outputs

16.8 Sound pressure level

17. Disposal