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Hydro Multi-B
Installation and operating instructions
GRUNDFOS INSTRUCTIONS
Page 2
English (US)
Caution
Note
Note
English (US) Installation and operating instructions
Original installation and operating instructions.
CONTENTS
1. Symbols used in this document
2. Limited warranty
3. Product introduction
3.1 Introduction
3.2 Delivery and handling
3.3 Applications
3.4 Features and benefits
4. Delivery and handling
4.1 Delivery
4.2 Handling
5. Identification
5.1 Nameplate
5.2 Type key
6. Installation
6.1 Mechanical installation
6.2 Electrical installation
7. Operation
7.1 User interface
8. Startup
8.1 Positive inlet pressure startup procedure
8.2 Flooded suction and suction lift startup procedures
9. Operating modes
9.1 Local mode, external stop not activated
9.2 Local mode, external stop activated
9.3 Remote-controlled, external stop not activated
9.4 Remote-controlled, external stop activated
10. Functions
10.1 General functions
10.2 Functions for constant-pressure systems
11. Data communication
12. Maintenance and service
12.1 Maintenance
12.2 Frost protection
12.3 Service
12.4 Overview of inputs and outputs
13. Fault finding
14. Maintenance
14.1 Pumps
14.2 CU 323
15. Frost protection
16. Taking out of operation
17. Technical data
17.1 Pressure
17.2 Temperature
17.3 Relative humidity
17.4 Sound pressure level
18. Electrical data
18.1 Disposal
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Warnin g
Prior to installation, read these installation and
operating instructions. Installation and operation
must comply with local regulations and accepted
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1. Symbols used in this document
6
6
7
7
8
9
9
codes of good practice.
Warnin g
The use of this product requires experience with
and knowledge of the product.
Persons with reduced physical, sensory or
mental capabilities must not use this product,
unless they are under supervision or have been
instructed in the use of the product by a person
responsible for their safety.
Children must not use or play with this product.
Warnin g
If these safety instructions are not observed,
it may result in personal injury.
Warnin g
The surface of the product may be so hot that
it may cause burns or 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.
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2. Limited warranty
Products manufactured by GRUNDFOS PUMPS CORPORATION
(Grundfos) are warranted to the original user only to be free of
defects in material and workmanship for a period of 24 months
from date of installation, but not more than 30 months from date
of manufacture. Grundfos' liability under this warranty shall be
limited to repairing or replacing at Grundfos' option, without
charge, F.O.B. Grundfos' factory or authorized service station,
any product of Grundfos' manufacture. Grundfos will not be liable
for any costs of removal, installation, transportation, or any other
charges which may arise in connection with a warranty claim.
Products which are sold but not manufactured by Grundfos are
subject to the warranty provided by the manufacturer of said
products and not by Grundfos' warranty. Grundfos will not be
liable for damage or wear to products caused by abnormal
operating conditions, accident, abuse, misuse, unauthorized
alteration or repair, or if the product was not installed in
accordance with Grundfos' printed installation and operating
instructions.
To obtain service under this warranty, the defective product must
be returned to the distributor or deale r of Grund fos' p roducts from
which it was purchased together with proof of purchase and
installation date, failure date, and supporting installation data.
Unless otherwise provided, the distributor or dealer will contact
Grundfos or an authorized service station for instructions. Any
defective product to be returned to Grundfos or a service station
must be sent freight prepaid; documentation supporting the
warranty claim and/or a Return Material Authorization must be
included if so instructed.
GRUNDFOS WILL NOT BE LIABLE FOR ANY INCIDENTAL OR
CONSEQUENTIAL DAMAGES, LOSSES, OR EXPENSES
ARISING FROM INSTALLATION, USE, OR ANY OTHER
CAUSES. THERE ARE NO EXPRESS OR IMPLIED
WARRANTIES, INCLUDING MERCHANTABILITY OR FITNESS
FOR A PARTICULAR PURPOSE, WHICH EXTEND BEYOND
THOSE WARRANTIES DESCRIBED OR REFERRED TO
ABOVE.
Some jurisdictions do not allow the exclusion or limitation of
incidental or consequential damages and some jurisdictions do
not allow limit actions on how long implied warranties may last.
Therefore, the above limitations or exclusions may not apply to
you. This warranty gives you specific legal rights and you may
also have other rights which vary from jurisdiction to jurisdiction.
3. Product introduction
3.1 Introduction
As standard, Hydro Multi-B booster systems consist of two to
three CM(E) pumps coupled in parallel and mounted on a
common base frame with all the necessary fittings and a control
cabinet.
Fig. 1 Front view of Hydro Multi-B booster system
Fig. 2 Back view of Hydro Multi-B booster system
English (US)
TM05 8632 2513TM05 8633 2513
Pos. Description Quantity
1 Control cabinet 1
2 Suction manifold (316 SS) 1
3 Discharge manifold (316 SS) 1
4 Isolating valve (Nickel Plated Brass) 2 per pump
5 Non-return valve (Polyacetal (POM)) 1 per pump
6 Pump (CME A-version CI/304 SS) 2-3
7 Base frame (304 SS) 1
8 Pressure transmitter and pressure gauge 1
9 Inlet pressure switch and pressure gauge 1
Oval flange connection (CME 3 - CME 10) 2 per pump
10
Intermediate adapter connection (CME 15) 1 per pump
11 Screw cap or blanking flange 2
Optional diaphragm tank
12
(available as an accessory)
n/a
3
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English (US)
PT
H
set
Q
H
H
set
3.2 Delivery and handling
3.2.1 Delivery
The Hydro Multi-B booster system is delivered in packaging
specially designed for transport by fork-lift truck or a similar
vehicle.
The forks of the fork-lift truck must be at least 6 ft (2 m) long.
3.2.2 Handling
The Hydro Multi-B booster system is delivered attached to a
wood pallet. It is recommended to move the system on wood
pallet to installation location. Detach from wood pallet and slide
off wood pallet at final location of installation.
Warnin g
When lifting the booster system, never use the
eyebolts of the motors.
Do not lift the booster system by the manifolds.
Do not stand on the manifolds.
When lifting the booster system, only use suitable lifting
equipment that is in good condition and approved for the weight.
The weight is stated on the nameplate of the booster system.
3.3 Applications
Grundfos Hydro Multi-B booster systems are for constant
pressure boosting applications.
The Hydro Multi-B system is designed to maintain a constant
pressure on the discharge side of the pumps. Hydro Multi-B
systems for constant-pressure applications adjust the
performance according to the demand and keep a constant
pressure in the following ways:
• by cutting the required number of pumps in and out
• through continuous adjustment of the speed of the running
CME pumps.
3.3.1 Operating principle
The user enters the required pressure of the system (setpoint) via
the user interface of the CU 323 control unit. The CU 323 adjusts
the system performance according to the feedback received from
the pressure transmitter installed on the discharge manifold.
3.3.2 Control variants
Hydro Multi-B systems for constant-pressure applications are
available as control variant E. The systems works as described
below.
Control variant E
Two to three electronically speed-controlled CME pumps.
One CME pump in operation.
H
Q
Three CME pumps in operation.
• Control variant E for constant-pressure applications
maintains a constant pressure through continuous adjustment
of the speed of the pumps.
• The system performance is adjusted to the demand by cutting
the required number of pumps in and out and through parallel
control of the pumps in operation.
TM03 0993 0905
TM00 7995 2296
TM00 7996 2296
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3.4 Features and benefits
The Hydro Multi-B is developed with focus on user-friendliness
and ease of operation.
The pumps are controlled via the CU 323 controller which
features a simple interface that makes it easy to control and
monitor the system.
When the system has been set up, the controller takes care of the
daily operation.
Fig. 3 CU 323 controller
The components and design of the Hydro Multi-B have been
chosen with focus on robustness and compactness. Every
system is thoroughly tested before is leaves the factory.
4. Delivery and handling
4.1 Delivery
The Hydro Multi-B booster system is delivered in a recyclable
packaging, specially designed for transport by fork-lift truck or a
similar vehicle.
The forks of the fork-lift truck must be at least 6 feet long.
4.2 Handling
Hydro Multi-B booster systems must be lifted as shown in fig. 4.
During handling, the lifting point should always be above the
centre of gravity of the booster system.
English (US)
TM05 0444 1211
TM05 0221 0911
Fig. 4 Correct lifting of Hydro Multi-B
Warnin g
When lifting the booster system, never use the
eyebolts of the motors.
Do not lift the booster system by the manifolds.
Do not stand on the manifolds.
When lifting the booster system, only use suitable lifting
equipment that is in good condition and approved for the weight.
The weight is stated on the nameplate of the booster system.
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English (US)
Note
Note
5. Identification
This section shows the nameplate, the type key and the codes
that can appear in the variant code.
As codes can be combined, a code position may
contain more than one code (letter).
5.1 Nameplate
The nameplate is fitted on the base frame.
Fig. 5 Nameplate
Pos. Descripti on
1 Type designation
2 Model
3 Supply voltage
4 Maximum head [ft]
5 Nominal head [ft]
6 Nominal flow rate [gpm]
7 Weight [lb]
Motor power [Hp] of pumps with variable frequency
8
drive
9 Code for pump versions
10 Number of E-pumps
11 E-pump type
12 System serial number
13 Control panel part number
14 Options
15 Country of origin
16 cULus Packaged Pumping Listing (Category QCZJ)
TM05 9777 4413
5.2 Type key
Code Example Hydro Multi-B E 2 CME 10-3 A 3 x 460 V, 60 Hz
Type range
System variants
E
Two to three pumps with integrated variable frequency drive
Number of pumps with integrated variable frequency drive, (CME) pump type and pump material
A
Cast iron (EN-GJL-200)
Supply voltage, frequency
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6. Installation
Caution
Note
Note
Note
Note
Note
Note
Note
Note
Warnin g
Installation and operation must comply with local
regulations and accepted codes of good practice.
Before installation, check the following:
• Does the booster system correspond to order?
• Are all visible parts intact?
6.1 Mechanical installation
6.1.1 Location
The booster system must be installed in a well ventilated room to
ensure sufficient cooling of the pumps and the control cabinet.
The booster system is not designed for outdoor
installation and must not be exposed to direct
sunlight.
The booster system must have a 3 ft (1 m)
clearance on all sides for inspection and
dismantling.
6.1.2 Pipework
The pipework connected to the booster system
must be of adequate size.
Fig. 6 Example showing the position of expansion joint s, pipe
supports and mounting bolts
Connect the pipes to the manifolds of the booster system. Either
end can be used. Apply sealing compound to the unused end of
the manifold, and fit the screw cap. For manifolds with flanges,
fit a blanking flange with gasket.
It is advisable to install pipe supports for the suction and
discharge pipes. See fig. 6.
To achieve optimum operation and minimize noise and vibration,
it may be necessary to consider vibration dampening of the
booster system.
Noise and vibration are generated by the rotations in the motor
and pump and by the flow in pipework and fittings. The effect on
the environment is subjective and depends on correct installation
and the state of the other parts of the system.
If booster systems are installed in a building where the first user
on the line is close to the booster system, it is advisable to fit
expansion joints on the suction and discharge pipes to prevent
vibration being transmitted through the pipework. All nuts should
be re-tightened prior to start-up.
The pipes must be fastened to parts of the building to ensure that
they cannot move or be twisted.
6.1.3 Foundation
The booster system should be positioned on an even and solid
surface, for instance a concrete floor or foundation. The booster
system must be bolted to the floor or foundation.
As a rule of thumb, the weight of a concrete
foundation should be 1.5 x the weight of the
booster system.
6.1.4 Vibration dampers
To prevent the transmission o f vibrations to buildings, it may be
necessary to isolate the booster system foundation from building
parts by means of vibration dampers.
Which is the right damper varies from installation to installation,
and a wrong damper may increase the vibration level. Vibration
dampers should therefore be sized by the supplier of vibration
dampers. If the booster system is installed on a base frame with
vibration dampers, expansion joints should always be fitted on
the manifolds. This is important to prevent the booster system
TM04 9900 0211
from "hanging" in the pipework.
English (US)
Pos. Description
1 Expansion joint
2 Pipe support (and good location for isolating valve)
3 Mounting bolts
Expansion joints, pipe supports and mounting
bolts shown in fig. 6 above are not supplied with
a standard booster system.
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English (US)
Note
Note
6.1.5 Expansion joints
Expansion joints are installed with the following purposes:
• to absorb expansions/contractions in the pipework caused by
changing liquid temperature
• to reduce mechanical strains in connection with pressure
surges in the pipework
• to isolate mechanical structure-borne noise in the pipework
(only rubber bellows expansion joints).
Expansion joints must not be installed to
compensate for inaccuracies in the pipework
such as center displacement of flanges.
Fit expansion joints at a distance of minimum 1 to 1 - 1/2 times
the nominal flange diameter from the manifold on the suction as
well as on the discharge side. This prevents the development of
turbulence in the expansion joints, resulting in better suction
conditions and a minimum pressure loss on the discharge side.
Fig. 7 Examples of rubber bellows expansion joints without
and with limit rods
Expansion joints with limit rods can be used to minimize the
forces caused by the expansion joints. Expansion joints with limit
rods are always recommended for flanges larger than 6 inch.
The pipework should be anchored so that it does not stress the
expansion joints and the pump. Follow the supplier’s instructions
and pass them on to advisers or pipe installers.
6.2 Electrical installation
Warnin g
The electrical installation must be carried out by
an authorized person in accordance with local
regulations and the relevant wiring diagram.
• The electrical installation of the booster system must comply
with enclosure class UL Type 3R.
• Make sure that the booster system is suitable for the power
supply to which it is to be connected.
• Make sure that the wire cross-section corresponds to the
specifications in the wiring diagram.
TM02 4981 1902 - TM02 4979 1902
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7. Operation
7.1 User interface
The Hydro Multi-B incorporates a CU 323 control unit which
enables manual setting and monitoring of the booster system.
Figure 8 shows the user interface for a system with three pumps.
Fig. 8 User interface of cabinet and CU 323
English (US)
TM05 9283 4413
Pos. Buttons Description
1 Changes the system operating mode between "Normal" and "Stop".
On
Off
2 Increases the setpoint value.
3 Decreases the setpoint value.
4 Resets all alarms.
5
RESET
Changes the operating mode of the individual pumps between "AUTO" and "OFF". Each pump in the
system has an Auto/Off button.
Enables "Emergency/Manual" operation.
6
Note: If a pump is set to "Emergency" operation, it will run at 100 % speed, and the power supply to
the CU 323 will be switched off.
7 Switches the power supply to the control cabinet on or off.
Table continued on next page
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English (US)
E.St
OFF
On
0-
N
RESET
RESET
bUS
LOC
Err
H.L
WS
PT
Table continued from previous page
Pos. Displays Description
Setpoint Shows the setpoint.
External stop: Indicates that the system has been stopped externally via a digital input.
Indicates that the system has been set to "OFF".
8
Measured value Shows the actual, measured value on the discharge side.
9
/ measured
value
Pos.
10
11
12
13 AUTO Yellow The pump is controlled by the CU 323.
14 OFF Yellow The pump has been stopped by pressing or via remote control.
Indicator
lights
(pump LED)
Indicates that the system has been set from OFF to ON. "On" is only shown for 3 seconds after which
the setpoint will be shown.
Indicates that buttons on the CU 323 have been locked automatically. Unlock the buttons by pressing
(Reset) and or (Reset) and for 2 seconds.
Indicates that the system is remote-controlled.
Local: Appears if attempts to change local settings are made while the system is remote-controlled.
Appears in case of a primary sensor fault.
Alternates between the actual, measured value on the discharge side and "H.L" when a maximum
discharge pressure or a level limit has been exceeded.
Status Description
Off Normal state.
Red Water shortage fault.
Off Normal state.
Red
Off
Red A pump fault has occurred.
Green The pump is running.
Flashing green The pump is in standby mode or has been stopped by pressing or via remote control.
Primary and/or redundant sensor fault.
Maximum discharge pressure or level limit has been exceeded.
The pump has stopped due to cascade operation.
The system is in "OFF" state.
The power supply has been switched off.
Status
Pos.
15 and 16
* The last pump in operation might have been stopped temporarily by the low-flow stop function.
Indicator
lights
(system LEDs)
Pos. 13:
system run
(green)
Off Off The power supply has been switched off.
On Off The system is in normal operation.*
Flashing Off The system has been set to stop.
Off On The system has been stopped due to an alarm.
On On The system is in normal operation, but there is a warning.*
Flashing On The system has been set to stop, and there is a warning.
Pos. 14:
alarm
(red)
Description
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8. Startup
Caution
Note
Note
A positive inlet pressure is required before startup and during operation.
Do not start the pumps until they have been fully
primed.
Warnin g
When pumping hot liquids, ensure that persons
cannot accidentally come into contact with hot
surfaces of the product.
After having carried out the mechanical, electrical and hydraulic
installation described in sections 6.1 Mechanical installation and
6.2 Electrical installation, proceed as follows:
8.1 Positive inlet pressure startup procedure
1. Check that the precharge pressure in the diaphragm tank is
0.7 times the required discharge pressure (setpoint).
Note, precharge must be set with zero pressure on the tank.
2. Close all pump discharge isolation valves on Multi B system.
3. Open discharge valve on one pump and turn tap on discharge
side of system allowing water to pass through pump. Once
complete, close discharge i solatio n valve.
4. Repeat step 3 for all remaining pumps on system. Once
complete, open discharge isolation valve on all pumps after all
pumps have been vented.
5. Switch on the main disconnect switch.
6. Turn system on by pressing on off button and adjust setpoint
to desired setpoint value by pressing up or down button
on the controller.
8.2 Flooded suction and suction lift startup procedures
1. Check that the precharge pressure in the diaphragm tank is
0.7 times the required discharge pressure (setpoint).
Note, precharge must be set with zero pressure on the tank.
2. Switch off the main disconnect switch on the cabinet front.
3. Switch off the circuit breakers (located inside the cabinet) of
all pumps.
4. Set the "Normal/Emergency" switch (located on the front of
the control cabinet) for all pumps to "Emergency".
5. Close all pump discharge valves and prime all pumps. The
pumps are primed by opening cap on port of check valve
positioned closest to pump and filling water into port. The
pump is primed when water no longer is able to fill into pump.
Reinstall cap on check valve port and repeat for all pumps.
6. Switch on the relevant circuit breaker of pump to be started.
7. Switch on the main disconnect switch; this will start the pump
with relevant circuit breaker ON.
8. Vent the pump by slowly opening its discharge valve. This will
also allow gradual filling of discharge piping.
9. Set the "Normal/Emergency" switch for the relevant pump to
"Normal".
10.Switch off the main disconnect switch.
11.Repeat steps 6, 7, 8, 9 and 10 for the other pumps in the
system.
12.Switch on the main disconnect switch.
13.Adjust the required setpoint via the CU 323 by
pressing or .
14.Set the system to "On" by pressing .
15.Increase setpoint to desired setpoint value.
Hydro Multi-B is now in automatic mode and ready for operation.
Initial setpoint pressure value for system is 0 psi
and maximum pressure exceeded is 22 psi above
setpoint value.
This may cause "Maximum pressure exceeded"
alarm condition after startup is complete.
Increase setpoint pressure value to desired
pressure and possibly bleed off pressure on
discharge to clear "Maximum pressure
exceeded" fault.
On
Off
English (US)
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English (US)
Starting the system
Stopping the system
On
Off
On
Off
Changing the setpoint
Changing the setpoint
or
E.st
OFF
OFF
ON
ON
On
Off
On
Off
On
Off
Starting the system
Stopping the system
Note
Note
Changing the setpoint
or
Note
Note
9. Operating modes
User operation depends on the system mode. The system modes are described in the following sections.
9.1 Local mode, external stop not activated
In this mode, the system is locally controlled, and the external stop via digital input is not activated.
The flow charts below show examples of how settings can be made.
Starting and stopping the system
TM05 9701 4313TM05 9284 3613
Changing the setpoint while the system is running
Changing the setpoint while the system is in "OFF" mode
9.2 Local mode, external stop activated
In this mode, the system is locally controlled, and the external stop via digital input is activated.
External stop via digital input has higher priority than local control. This means that settings can be changed locally, but they will not be
effective until external stop has been deactivated. The flow charts below show examples of how settings can be made.
Starting and stopping the system
If the buttons are not touched for 3 seconds, the CU 323 will revert to the initial display.
Changing the setpoint
TM05 9285 3613TM04 9580 4610
TM05 9286 3613
If the buttons are not touched for 3 seconds, the CU 323 will revert to the initial display.
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9.3 Remote-controlled, external stop not activated
Keep pressed for 3 seconds
See section 9.1 Local mode,
external stop not activated for
changing settings in local mode.
or
or or
or
or
Note
Note
BUS
LOC
E.st
On
Off
On
Off
Keep pressed for 3 seconds
See section 9.2 Local mode, external
stop activated for changing settings
in local mode.
or
or
or
or
Note
Note
In this mode, the system is remote-controlled, and the external stop via digital input is not activated.
If local settings are to be changed, follow the flow chart examples below.
If the buttons are not touched for 3 seconds, the CU 323 will revert to the initial display.
9.4 Remote-controlled, external stop activated
In this mode, the system is remote-controlled, and the external stop via digital input is activated.
If local settings are to be changed, follow the flow chart examples below.
English (US)
TM05 9287 3613
TM04 9583 4610
If the buttons are not touched for 3 seconds, the CU 323 will revert to the initial display.
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English (US)
Caution
WS
Note
Note
10. Functions
Hydro Multi-B booster systems include application-optimized
software.
10.1 General functions
10.1.1 Dry-running protection (pressure switch on suction standard)
When a pump is running in "Emergency" mode, it
is not protected against dry running.
To protect the pumps again st damage fro m dry running, the Hydro
Multi-B incorporates a water shortage function. This function is
based on the monitoring of the inlet pressure or the level in a t ank
on the suction side.
The pressure or level can be monitored by one of the following:
• pressure switch (standard)
• float switch
• level switch
• external electrode relay
• analog sensor.
Dry-running protection with pressure switch, float switch,
level switch or external electrode relay
Set the monitoring device to the desired limit.
If water shortage is detected for more than 5 seconds, the system
will stop, and the indicator light illuminates.
RESET
Press when the water supply has been re-established.
Dry-running protection with analog sensor
The limit for the minimum inlet pressure in the suction manifold is
a factory-set value which can only be changed by a Grundfos
service engineer using PC tools.
If the sensor output is below the limit for minimum inlet pressure
for more than 5 seconds, the system will stop, and the
indicator light illuminates.
RESET
Press when the water supply has been re-established.
10.1.2 Automatic pump changeover
The automatic pump changeover function ensures an equal
number of operating hours of the pumps, but it also ensures that,
in case of an alarm on one pump, another pump is automatically
started.
There are three types of automatic pump changeover:
• operation-dependent pump change
• alarm-dependent pump change
• time-dependent pump change.
Operation-dependent pump change
At increasing demand, the pump with the lowest number of
operating hours will be started first.
At decreasing demand, the pump with the highest number of
operating hours will be stopped first.
Alarm-dependent pump change
If a pump stops due to an alarm, the CU 323 will send a stop
command to the pump to prevent auto-restarting and start
another pump which is ready to start and which has the lowest
number of operating hours.
WS
Time-dependent pump change
In certain applications, the demand remains constant for long
periods and does not require all pumps to run. In such situations,
pump changeover does not take place naturally, and forced pump
changeover may thus be required.
Once every 24 hours, the CU 323 checks if any of the running
pumps has a higher number of operating hours than the pumps
that are stopped. If this is the case, the pump will be stopped, and
a pump with a lower number of operating hours will start.
10.1.3 Minimum time between start and stop
This function ensures a delay between the start/stop of o ne pump
and the start/stop of another pump. The purpose is to prevent
hunting when pumps start and stop continuously.
If the system is stopped due to an alarm, the
minimum time between start and stop will be
ignored, and the pumps will be stopped
immediately.
10.2 Functions for constant-pressure systems
10.2.1 Pump cascade control
The cascade function ensures that only the required number of
pumps is running. This means that the number of running pumps
always corresponds to the required flow at the entered setpoint.
The first pump is started if the pressure at the discharge manifo ld
is below the setpoint.
If the first pump is not able to keep the discharge pressure at the
setpoint, and the minimum time between start/stop has passed,
another pump is started.
During the start and stop of a pump, the speed of the speedcontrolled pump is controlled in such way that the pressure
disturbance is kept as low as possible.
At decreasing demand, pumps will be stopped if the pressure
rises above the setpoint. Pumps will not be stopped until the
minimum time between start/stop has passed.
The last pump in operation
If only one pump is operating, this pump can be operated in
energy-saving on/off mode.
See section 10.2.4 Low-flow operation.
The number of possible starts/stops per hour for all pumps is
limited by the maximum number of starts per hour.
10.2.2 Standby pumps
This function is optional and available on request. The function
makes it possible to limit the maximum performance of the Hydro
Multi-B by selecting one or more pumps as standby pumps.
If a three-pump system has one standby pump, maximum two
pumps are allowed to operate at a time.
If one of the two pumps in operation has a fault and is stopped,
the standby pump will be started. The performance o f th e bo ost er
system is thus not reduced.
The status as standby pump alternates between all pumps.
Contact Grundfos for further information.
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10.2.3 Maximum pressure exceeded
PT
H.L
Sto p = H
set
+ 0.5 x on/off band
Sta rt = H
set
- 0.5 x on/off band
Stop
Start
H [ft]
Time [sec.]
AB C B C
A: Normal operation
B: Pressure boosting
C: Stop
This function protects th e piping on the discharge side of the
booster system against damaging high pressures. The pressure
is monitored, and if the pressure is higher than 22 psi (1.5 bar)
above the setpoint for more than 5 seconds, the pumps are
stopped, the indicator light illuminates, and the display
indicates high limit .
When the pressure falls below the setpoint, the system will
automatically restart.
10.2.4 Low-flow operation
When only one pump is operating due to cascade, the Hydro
Multi-B will regularly check for low flow by decreasing the pump
speed.
When low flow is detected, the Hydro Multi-B will change its mode
of operation to "low-flow operation" and run in on/off mode as
described below.
In on/off mode, the system has two phases:
• Off phase
Water is drawn from the diaphragm tank until the pressure of
the system reaches the lower limit of the on/off band
(P
- 0.5 x on/off band).
set
• Boosting phase
The pump runs at 100 % speed until the pressure reaches the
upper limit of the on/off band (P
+ 0.5 x on/off band).
set
Fig. 9 On/off operation
11. Data communication
The CU 323 must have a CIM module (Communication Interface
Module) fitted to be able to transfer data to the SCADA system.
12. Maintenance and service
12.1 Maintenance
Warnin g
Before starting work on the pumps, make sure
that the power supply has been switched off.
Lock the main switch with a padlock to ensure
that it cannot be accidentally switched on.
12.1.1 Pumps
The internal pump parts are maintenance-free. It is important to
keep the motor clean in order to ensure adequate cooling of the
motor. If the pump is installed in dusty environments, it must be
cleaned and checked regularly. Take the enclosure class of the
motor into account when cleaning.
The motor has maintenance-free, greased-for-life bearings.
12.1.2 CU 323
The CU 323 is maintenance-free. It must be kept clean and dry.
Protect it against direct sunlight. Furthermore, the CU 323 must
not be outside the ambient temperature range.
12.2 Frost protection
Pumps which are not being used during periods of frost should be
drained to avoid damage. Follow the instructions below:
1. Close the isolating valves before and after the pump.
2. Remove the filling and drain plugs.
3. Remember to open the isolating valves and refit the plugs
before the pump is put into operation again.
Warnin g
Ensure that the escaping water does not cause
injury to persons or damage to the motor or other
components.
In hot-water installations, special attention
should be paid to the risk of injury caused by
scalding hot water.
Do not fit the filling and drain plugs until the pump is to be used
again.
12.2.1 Taking out of operation
Switch off the main disconnect switch to take the booster system
TM03 9292 4807
out of operation.
Warnin g
The conductors in front of the main switch are
still energized. Lock the main switch with a
padlock to ensure that it cannot be accidentally
switched on.
Individual pumps are taken out of operation by switching off the
corresponding motor-protective circuit breaker, automatic circuit
breaker or fuse.
English (US)
15
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English (US)
12.3 Service
12.3.1 Service tools
Designation Further information
PC Tool Link USB 96705378
Anti-static service kit 96884939
Product
number
12.4 Overview of inputs and outputs
12.4.1 Layout of the back of the CU 323
Fig. 10 Back of the CU 323
Group Description
1 Connection of power supply
2 Internal GENIbus connection
3 Fieldbus connection (CIM module) (optional)
4 Input for PTC sensor or thermal switch
5 Analog inputs
6 Digital output
7 Relay outputs
8 Digital inputs
9 Service connection
12.4.2 Terminal groups
TM04 9282 3810
Abbreviation Meaning
DI Digital input
DO Digital output
RO Relay output
AI Analog input
NC Normally closed contact
NO Normally open contact
CCommon
PTC Positive temperature coefficient
16
Page 17
Pos. Terminal Description Data Diagram
L
N
CU
L
N
P
A
Y
B
CU E-pump
A1
Y1
B1
34
33
32
31
30
PTC 1
CU 323
PTC 3
PTC 2
54
53
50
51
55
1
2
CU 323
CU 323
81
77
79
80
80
74
73
72
70
71
75
CU 323
12
11
10
CU 323
L Connection to phase conductor
N Connection to neutral conductor
1 x 100-240 VAC ± 10 %, 50/60 Hz
1
PE Connection to protective earth
English (US)
A1 RS-485 A
Y1 RS-485 GND
2
B1 RS-485 B
GENIbus (internal)
Fix the screen with a cable clamp.
Functional earth
3 Connection to external fieldbus, see installation and operating instructions for the CIM module.
30 PTC 1
31 GND, PTC
4
32 PTC 2
Input for PTC sensor or thermal switch.
33 GND, PTC
34 PTC 3
50 + 24 V
51 AI1
5
53 + 24 V
54 AI2
Supply to sensor.
Short-circuit-protected 30 mA.
Input for analog signal.
0-20 / 4-20 mA or 0-10 V.
Supply to sensor.
Short-circuit-protected 30 mA.
Input for analog signal.
0-20 / 4-20 mA or 0-10 V.
55 GND
All terminals (except mains terminals) must only be connected to voltages not exceeding 16 V
77 Relay 1
and 22.6 V
rms
or 35 VDC.
peak
79 Relay 2
6
80 Common
Relay contact for starting and stopping
mains-operated pumps.
80 Common
81 Relay 3
70 Relay 1 C
71 Relay 1 NO
72 Relay 1 NC
7
73 Relay 2 C
74 Relay 2 NO
75 Relay 2 NC
10 DI1
Digital input11 GND
8
12 DI2
All terminals (except mains terminals) must only be connected to voltages not exceeding 16 V
and 22.6 V
or 35 VDC.
peak
9 GENIbus Service connection
rms
17
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English (US)
13. Fault finding
Warnin g
Before making any connections in pumps, terminal boxes or control cabinet, make sure that the power supply has
been switched off for at least five minutes and that it cannot be accidentally switched on.
Fault Possible cause Remedy
Current pressure is higher than or equal to
the setpoint.
Power supply disconnected. Connect the power supply.
Main disconnect switch turned off. Turn on the main disconnect switch.
Main switch is defective. Replace the main switch.
The pumps are not running.
The pumps start, but stop
immediately.
The operating pressure is not
reached.
The Hydro Multi-B has stopped
and cannot restart.
Unstable water supply from the
Hydro Multi-B.
Pumps are running, but deliver
no water.
The Hydro Multi-B is unable to
reach the setpoint.
Leakage from the shaft seal. Shaft seal is defective. Replace the shaft seal.
Noise. The pumps are cavitating.
Very frequent starts and stops. Wrong diaphragm tank precharge pressure. Set correct precharge pressure.
Motor protection is activated. Contact Grundfos.
Motor is defective. Repair or replace the motor.
The pressure transmitter is defective.
Cable is broken or short-circuited.
Incorrect GSC file.
Water shortage or no inlet pressure.
The pressure transmitter is defective.
Cable is broken or short-circuited.
CU 323 fault:
• Power supply disconnected.
The CU 323 is defective.
Inlet pressure too low. Check the suction pipe and the suction strainer, if any.
Suction pipe or pumps partly blocked by
impurities.
Pumps suck air. Check the suction pipe for leakages.
Pressure transmitter is defective. Replace the transmitter.
Incorrect GSC file. Check if the GSC file is correct by means of a PC Tool.
The valves are closed. Open the valves.
Suction pipe or pumps blocked by impurities. Clean the suction pipe or pumps.
Non-return valve blocked in closed position.
Suction pipe leaky. Check the suction pipe for leakages.
Air in suction pipe or pumps.
Too high consumption.
Too many standby pumps selected. Reduce the number of standby pumps.
Pipe fracture or leakage in the system. Check the system and repair any damage.
Incorrect GSC file. Check if the GSC file is correct by means of a PC Tool.
Wait until the pressure has dropped, or lower the
pressure on the discharge side of the Hydro Multi-B,
and check that the pumps start.
Replace the pressure transmitter.
0-145 psi (0-10 bar) transmitters with 0-10 V,
0-20 mA or 4-20 mA output signals are monitored by
the Hydro Multi-B.
Repair or replace the cable.
Check if the GSC file is correct by means of a PC Tool.
Re-establish the supply of water to the Hydro Multi-B.
When the inlet pressure has been re-established,
press [Reset] to restart the system.
Replace the pressure transmitter.
0-145 psi (0-10 bar) transmitters with 0-10 V, 0-20 mA
or 4-20 mA output signals are monitored by the Hydro
Multi-B.
Repair or replace the cable.
Connect the power supply.
Contact Grundfos.
Clean the suction pipes, strainer or pumps.
Clean the non-return valve. The non-return valve must
move freely.
Vent and prime the pumps. Check the suction pipe for
leakages.
• Reduce consumption, if possible.
• Install a bigger Hydro Multi-B booster system.
Clean the suction pipe/pumps and possibly the suction
strainer.
18
Page 19
14. Maintenance
Caution
Note
Note
Note
Note
17. Technical data
Warnin g
Before starting work on the pumps, make sure
that the power supply has been switched off.
Lock the main switch with a padlock to ensure
that it cannot be accidentally switched on.
14.1 Pumps
The internal pump parts are maintenance-free. It is important to
keep the motor clean in order to ensure adequate cooling of the
motor. If the pump is installed in dusty environments, it must be
cleaned and checked regularly. Take the enclosure class of the
motor into account when cleaning.
The motor has maintenance-free, greased-for-life bearings.
14.2 CU 323
The CU 323 is maintenance-free. It must be kept clean and dry.
Protect it against direct sunlight. Furthermore, the CU 323 must
not be outside the ambient temperature range. See section
17. Technical data.
15. Frost protection
Pumps which are not being used during periods of frost should be
drained to avoid damage. Follow the instructions below:
1. Close the isolating valves before and after the pump.
2. Remove the filling and drain plugs.
3. Remember to open the isolating valves and refit the plugs
before the pump is put into operation again.
Warnin g
Ensure that the escaping water does not cause
injury to persons or damage to the motor or other
components.
In hot-water installations, special attention
should be paid to the risk of injury caused by
scalding hot water.
Do not fit the filling and drain plugs until the pump is to be used
again.
16. Taking out of operation
Switch off the main switch to take the booster system out of
operation.
Warnin g
The conductors in front of the main switch are
still energized. Lock the main switch with a
padlock to ensure that it cannot be accidentally
switched on.
Individual pumps are taken out of operation by switching off the
corresponding motor-protective circuit breaker, automatic circuit
breaker or fuse.
17.1 Pressure
Inlet pressure
A positive inlet pressure is required before startup and during operation.
Flooded suction and suction lift applications are
possible on some, but not all, Multi-B systems.
Special attention must be applied to confirm inlet
conditions (NPSH
) is greater than NPSHR at the
A
maximum capacity at which the pump will run.
Calculation of the inlet pressure is recommended in these cases:
• Water is drawn through long pipes.
• Inlet conditions are poor.
In this manual, the term ‘inlet pressure’ is defined
as the pressure/vacuum which can be measured
immediately before the booster system.
To avoid cavitation, make sure that there is a minimum inlet
pressure on the suction side of the booster system. The minimum
inlet pressure in psi can be calculated as follows:
H=P
P
b
H
f
- NPSH - Hf - Hv - H
b
s
= Barometric pressure in feet (33.9 feet at sea level). In
closed systems, p
indicates system pressure in feet.
b
= Friction loss in suction piping in feet. (At the highest flow
the pump will be delivering.)
= Vapor pressure in feet.
H
v
NPSH = Net Positive Suction Head in feet.
NPSH can be read from the NPSH curve at the maximum capacity
at which the pump will run.
(See Grundfos CM, CME Data booklet 98435269 / L-CM-PG-001).
= Safety margin = minimum 2 feet.
H
s
If "H" is calculated as positive, the pump can operate at a suction
of maximum "H" feet. If "H" is calculated as negative, an inlet
pressure (psia) of minimum "H" feet is required.
Maximum inlet pressure
The actual inlet pressure plus the pressure when the pump is
operating against a closed valve should always be lower than the
maximum system pressure.
Operating pressure
As standard, the maximum operating pressure is 145 psi (10 bar).
17.2 Temperature
Liquid temperature: +32 °F to +140 °F (0 °C to +60 °C).
Ambient temperature: +32 °F to +104 °F (0 °C to +40 °C).
17.3 Relative humidity
Maximum 95 %.
English (US)
19
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English (US)
Note
Note
Note
Note
Note
Note
Note
Note
Note
Note
17.4 Sound pressure level
For sound pressure level, see installation and operating
instructions for the CM pumps.
The sound pressure level for a number of pumps can be
calculated as follows:
=L
L
max.
= Maximum sound pressure level
L
max.
= Sound pressure level for one pump
L
pump
+ (n - 1) x 3
pump
n = Number of pumps.
Considering the flow in pipes, vibrations, etc.,
the actual sound pressure level of the
Hydro Multi-B system will be lower than 90 dB(A).
18. Electrical data
Supply voltage
See Hydro Multi-B nameplate.
Digital inputs
Open-circuit voltage 24 VDC
Closed-circuit curren t 5 mA, DC
Frequency range 0-4 Hz
All digital inputs are supplied with PELV voltage
(Protective Extra-Low Voltage).
Analog inputs
0-20 mA
Input current and voltage
Tolerance ± 3.3 % of full scale
Repetitive accuracy ± 1 % of full scale
Input resistance, current < 250 Ω
Input resistance, voltage 10 kΩ ± 10 %
Supply to sensor
4-20 mA
0-10 V
24 V, maximum 50 mA per
sensor, short-circuit-protected
Inputs for PTC sensor/thermal switch
For PTC sensors to DIN 44082. Thermal switches can also be
connected.
Open-circuit voltage 8 VDC ± 15 %
Closed-circuit current 1.7 mA, DC
Inputs for PTC sensors are electrically separated
from the other inputs and outputs of the Hydro
Multi-B.
18.1 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.
Subject to alterations.
All analog inputs are supplied with PELV voltage
(Protective Extra-Low Voltage).
Digital outputs (relay outputs)
Normally open contacts
(DO1, DO2 and DO3)
Normally closed contacts
(DO4 and DO5)
C, NO
C, NC, NO
Maximum contact load 240 VAC, 2 A
Minimum contact load 5 VDC, 10 mA
All digital outputs are potential-free relay contacts.
Some outputs have a common C terminal. For
further information, see the wiring diagram
supplied with the Hydro Multi-B.
20
Page 21
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17100 West 118th Terrace
Olathe, Kansas 66061
Phone: +1-913-227-3400
Fax: +1-913-227-3500
www.grundfos.us
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2941 Brighton Road
Oakville, Ontario L6H 6C9 Canada
Phone: +1-905 829 9533
Fax: +1-905 829 9512
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Parque Industrial Stiva Aeropuerto
C.P. 66600 Apodaca, N.L. Mexico
Phone: +011-52-81-8144 4000
Fax: +011-52-81-8144 4010
www.grundfos.mx
Grundfos companies
Page 22
98504518 0117
ECM: 1201915
www.grundfos.com
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