Grundfos LC 108, LCD 108 Installation And Operating Instructions Manual

LCD 108

Installation and operating instructions

GRUNDFOS INSTRUCTIONS

Declaration of Conformity

We, Grundfos, declare under our sole responsibility that the product LC/LCD 108, to which this declaration relates, is in conformity with these Council directives on the approximation of the laws of the EC member states:

— Machinery Directive (98/37/EC).

Standard used: EN 809: 2000.

— Low Voltage Directive (2006/95/EC).

Standards used: EN 60335-1: 2002 and EN 60335-2-51: 2003.

— EMC Directive (2004/108/EC).

Standards used: EN 61000-6-2 and EN 61000-6-3.

Bjerringbro, 15th December 2008

Niels Vinther

Technical Manager

2

CONTENTS

Page

1. General 3

1.1 Applications 3

1.2 Variants 3

2. Location and mounting 3

2.1 Location 4

2.2 Mounting of LCD 108 for direct-on-line starting 4

3. Systems for parallel operation with 3 float switches 4

3.1 Electrical connection 4

3.2 Setting 5

3.3 Control panel 7

3.4 Battery back-up functions 7

3.5 Reset button and ON-OFF-AUTO selector switch 8

4. Systems for parallel operation with 4 float switches 8

4.1 Electrical connection 8

4.2 Setting 9

4.3 Control panel 10

4.4 Battery back-up functions 11

4.5 Reset button and ON-OFF-AUTO selector switch 12

5. Systems for 100 % standby operation 13

5.1 Electrical connection 13

5.2 Setting 13

5.3 Control panel 15

5.4 Battery back-up functions 15

5.5 Reset button and ON-OFF-AUTO selector switch 16

6. System for full-control operation 17

6.1 Electrical connection 17

6.2 Setting 17

6.3 Control panel 19

6.4 Battery back-up functions 19

6.5 Reset button and ON-OFF-AUTO selector switch 20

7. Start-up 21

8. Maintenance 21

9. Technical data 21

10. Fault finding chart 22

11. Disposal 22

Before beginning installation procedures, these installation and operating instructions should be studied carefully. The installation and operation should also be in accordance with local regulations and accepted codes of good practice.

1. General

The LCD 108 controller is designed for the control of pumps in wastewater systems.

Type key:

1.1 Applications

The LCD 108 enables:

• control of two pumps based on signals from float switches,

• automatic pump changeover (even distribution of operating hours on both pumps),

• selection of automatic test run during long periods of inactivity (every 24 hours),

• battery back-up in case of mains supply failure (accessory for certain variants),

• starting delay within the range from 0 to 255 sec. (random) after returning from battery operation to mains operation (resulting in an even mains load when several pumping stations are started up at the same time),

• selection of automatic alarm resetting,

• selection of automatic restarting,

• setting of stop delays matching the actual operating conditions,

• indication of liquid level,

• alarm indication of:

- inadmissibly high liquid level,

- overload (via motor protection relay),

- overtemperature (via PTC resistance or thermal switch in

motor),

- wrong phase sequence (only certain variants),

- mains supply failure (only certain variants),

- defective float switch.

As standard, the LCD 108 has one alarm output for common alarm. Certain variants have an additional alarm output for separate high-level alarm.

Furthermore, the controller incorporates a buzzer (only certain variants).

1.2 Variants

The actual controller type, voltage variant, etc. are stated in the type key on the nameplate situated on the side of the controller cabinet.

The LCD 108 is available for direct-on-line starting. The LCD 108 can be connected and set to operation/control in 4

different ways, see sections 3. to 6.:

• Section 3. Systems for parallel operation with 3 float switches. (Electrodes can also be used.)

• Section 4. Systems for parallel operation with 4 float switches. (Electrodes can also be used.)

• Section 5. Systems for 100 % standby operation.

• Section 6. System for full-control operation.

2. Location and mounting

Example LCD 108 400 3 23 SMS

LCD = two-pump controller 108 = type designation Phase voltage [V] 1 = single-phase

3 = three-phase Maximum operating current per pump [A] SMS = with SMS unit

Before starting any work on pumps used to pump liquids which could be constituted as being hazardous to health, thorough cleaning/venting of pumps, pits, etc. must be carried out according to local regulations.

Before making any connections in the LCD 108 or work on pumps, pits, etc., it must be ensured that the electricity supply has been switched off and that it cannot be accidentally switched on.

The installation must be carried out by authorized personnel in accordance with local regulations.

3

2.1 Location

22

12

T21

T11

T22

T12

H-NOH-COM

H-NC

G-NO

G-COM

G-NC

21

11

32

42

31

41

The LCD 108 controller and an EEx barrier, if required, must not be installed in explosion hazard areas.

Only float switches approved for use in explosion hazard areas may be used. The float switches must be connected via an EEx barrier, e.g. Grundfos number 96440300.

The LCD 108 can be mounted at ambient temperatures ranging from –30 °C to +50 °C.

Enclosure class: IP 65. When installed outdoors, the LCD 108 must be placed in a

protective shed or cupboard. The LCD 108 must not be exposed to direct sunlight.

2.2 Mounting of LCD 108 for direct-on-line starting

Before mounting, remove the transport protectors, if any, from inside the cabinet.

Mount the LCD 108:

• on a plane wall surface,

• with the Pg cable entries pointing downwards (additional Pg cable entries, if required, must be fitted in the bottom plate of the cabinet),

• with four screws through the mounting holes in the back plate of the cabinet. The mounting holes must be bored with a 4 mm bore. Fit the screws into the mounting holes and tighten securely. Fit the plastic caps supplied with the controller on the screws (IP 65).

Figure 1 shows the terminals listed under positions 2 and 3.

3. Systems for parallel operation with 3 float switches

Description (see also page 23 or 24):

The pumps are controlled by the liquid level in the pit.

• When the float switch, pos. 1, registers liquid, the first pump is started.

• When the float switch, pos. 2, registers liquid, the next pump is started.

• When the float switch, pos. 1, does not register any liquid, the "stop delay" is initiated (can be set). After expiration of the stop delay, both pumps are stopped.

• The pumps operate alternately.

The top float switch, pos. 3, activates the high-level alarm.

Before starting any work on pumps used to pump liquids which could be constituted as being hazardous to health, thorough cleaning/venting of pumps, pits, etc. must be carried out according to local regulations.

Before making any connections in the LCD 108 or work on pumps, pits, etc., it must be ensured that the electricity supply has been switched off and that it cannot be accidentally switched on.

3.1 Electrical connection

Parallel operation with 3 float switches, pages 23 or 24.

Before starting work on the system, switch off the supply voltage and lock the mains switch in position 0. Any external voltage connected to the system must be switched off before work is started.

Fig. A1 on page 23.

The figures show all electrical connections required to connect the LCD 108 for direct-on-line starting, parallel operation with 3 float switches.

Fig. A2 on page 24.

The figure shows all electrical connections required to connect the LCD 108 for star-delta starting, parallel operation with 3 float switches.

Fig. 1

Key to the symbols in figs. 1 and 1:

Pos. Description

Terminal block for level inputs

1

(11-12, 21-22, 31-32, 41-42). Terminal block with:

• input for the PTC resistance/thermal switch of the motor (T11-T21, T12-T22),

2

• output for external alarm device for high-level alarm (H-NC, H-COM, H-NO) (only certain variants),

• output for external alarm device for common alarm (G-NC, G-COM, G-NO).

Note: If the distance between the controller and pit exceeds 20 metres, it is not advisable to use electrodes as problems with the signal values sent back to the controller may arise.

In such cases, it is recommended to use float switches. Note: Cables of up to 100 metres can be connected between the

controller and the float switches.

4

TM01 4833 2308

The LCD 108 must be connected in accordance with the rules and standards in force for the application in question.

The operating voltage and frequency are marked on the controller nameplate. Make sure that the controller is suitable for the electricity supply on which it will be used.

All cables/wires must be fitted through the Pg cable entries and gaskets (IP 65).

Maximum back-up fuse is stated on the controller nameplate. If required according to local regulations, an external mains

switch must be installed. Note: If the PTC resistance/thermal switch of the motor is

connected, the factory-fitted short-circuit jumper must be removed (terminals T11-T21, T12-T22). For correct installation of PTC resistor/thermal switch, see the installation and operating instructions of the pump. Single-phase motors must be connected to an external operating capacitor and in certain cases also to a starting capacitor. Further details can be found in the installation and operating instructions for the pump in question.

Float switches placed in an explosion hazard area must be connected via an EEx barrier, e.g. Grundfos number 96440300. The EEx barrier must not be installed in the explosion hazard area.

Equipment used in explosion hazard areas must in each individual case have been approved for this particular application. Furthermore, the cables into the explosion hazard area must be laid in accordance with local regulations.

Note: Float switches of the same type as Grundfos product number 96003332 or 96003695, i.e. float switches with gold-plated contacts suitable for low voltages and currents (40 V/ 100 mA), must be used. All EEx-approved float switches are also suitable.

The float switches must be connected as NO contacts, i.e. brown and black leads, when float switches, Grundfos product number 96003332 or 96003695, are used.

Key to the symbols in fig. A1 on page 23 and fig. A2 on page 24:

Pos. Description

Float switch for start of the first pump/

1

common stop. 2 Float switch for start of the next pump. 21-22 3 Float switch for high-level alarm. 31-32

Terminal

number

11- 12

3.2 Setting

Parallel operation with 3 float switches, pages 23 and 24.

The module CU 212 has a 10-pole DIP switch in the bottom right corner, see fig. 2.

Note: During the setting of the DIP switch, the controller must always be dead for at least 1 minute to achieve the correct configuration during start-up after change of the DIP switch setting.

The DIP switch setting offers the following possibilities:

• selection of starting delay and automatic test run (switch 4),

• setting of stop delay (switches 5, 6 and 7),

• selection of automatic alarm resetting (switch 9),

• selection of automatic restarting (switch 10).

At this setting, the start-up is delayed within the range from 0 to 255 sec. (random) after the electricity supply has been switched on when the liquid level is sufficiently high.

Automatic test run carried out every 24 hours.

After the electricity has been switched on, the pump will start immediately when the liquid level is sufficiently high.

No automatic test run.

• Switches 5, 6 and 7, stop delay:

When the DIP switch setting is changed, the controller must be switched off for at least 1 minute!

The stop delay is the time from the stop signal is given until the pump is stopped. It must be ensured that the pump is not running dry.

0 sec. 60 sec.

15 sec. 90 sec.

30 sec. 120 sec.

45 sec. 180 sec.

•Switch 8:

When the DIP switch setting is changed, the controller must be switched off for at least 1 minute!

Switch 8 has no function in connection with the actual application (parallel operation with 3 float switches, pages 23 and 24), but this setting must be maintained!

•Switch 9, automatic alarm resetting:

When the DIP switch setting is changed, the controller must be switched off for at least 1 minute!

Fig. 2

Set the DIP switch as shown in fig. 2. Each individual switch (1 to 10) of the DIP switch can be set to

position OFF or ON. During the setting of the DIP switch, the controller must always

be dead for at least 1 minute to achieve the correct configuration during start-up after change of the DIP switch setting.

Set the switches 1 to 10 as follows:

•Switches 1, 2 and 3, application type:

When the DIP switch setting is changed, the controller must be switched off for at least 1 minute!

This setting determines the actual application type (parallel operation with 3 float switches, pages 23 and 24).

•Switch 4, starting delay and automatic test run

(only in the case of battery back-up): When the DIP switch setting is changed, the controller must

be switched off for at least 1 minute!

This setting ensures automatic resetting of alarm signals to external alarm devices and the built-in buzzer. However, an alarm signal will only be reset if the cause of the fault no longer exists.

At this setting, the alarm signal must be reset manually by means of the reset button (the reset button is described in section 3.5).

•Switch 10, automatic restarting:

When the DIP switch setting is changed, the controller must be switched off for at least 1 minute!

TM01 6870 2308

This setting enables automatic restarting after the PTC resistance/thermal switch of the motor has cut out the pump. Restarting will not be carried out until the motor has cooled to normal temperature.

When the pumps connected are used in explosion hazard areas, switch 10 must not be in this position!

At this setting, the pump must be restarted manually after the PTC resistance/thermal switch of the motor has cut out the pump. To restart the pump, push the ON-OFFAUTO selector switch into position OFF for a short period (the ON-OFF-AUTO selector switch is described in section 3.5).

When the pumps connected are used in explosion hazard areas, switch 10 must be in this position!

5

AC/DC selector:

AC 1 2

13-18 VAC

0 V

AC

DC

G3 4

AC 1 2

13-18 VAC

0 V

AC

DC

G3 4

AC 1 2

12 VDC

0 V

AC

DC

G3 4

The AC/DC selector switch for electrodes and/or float switches is placed as shown in fig. 3.

Fig. 3

Operation with electrodes and float switches:

Selector switch in position AC:

It is possible to connect 3 electrodes (1 as reference electrode) and 2 float switches. The controller transmits a 13 to 18 VAC signal.

Operation with float switches: Selector switch in position AC:

It is possible to connect 4 float switches. The controller transmits a 13 to 18 VAC signal.

TM02 5747 3902

Operation with float switches: Selector switch in position DC:

It is possible to connect 4 float switches. Cables of up to 100 metres can be connected between the controller and the float switches. The controller transmits a 12 VDC signal.

If the distance between the controller and pit exceeds 20 metres, it is not advisable to use electrodes as problems with the signal values sent back to the controller may arise. In such cases, it is recommended to use float switches.

6

3.3 Control panel

CU 212

21

1 2

1234756

12 11

9 8

10

1

CU 212

2

CU 212

2

1

Parallel operation with 3 float switches, pages 23 and 24.

Figure 4 shows the control panel of the CU 212 module.

Fig. 4

Key to the symbols in fig. 4:

Pos. Description

Green indicator light for pump 1 and 2, indicating 1

starting delay (flashing) and pump operation

(permanently on).

Red indicator light for pump 1 and 2. 2

Flashing: Fault in PTC resistor/thermal switch

On: Fault in motor-protective circuit breaker.

Red indicator light, indicating wrong phase sequence 3

(only certain variants and three-phase pumps only). 4 Red indicator light, indicating common alarm.

ON-OFF-AUTO selector switch for pump 1, three 5

positions, see section 3.5.

ON-OFF-AUTO selector switch for pump 2, three 6

positions, see section 3.5.

Reset button, push-button for manual resetting of alarm 7

signals to external alarm devices and the built-in buzzer

(only certain variants), see section 3.5.

Orange indicator light, which is activated by the float 8

switch for start of the first pump/common stop.

Orange indicator light, which is activated by the float 9

switch for start of the next pump.

Two orange indicator lights, which are activated by the

10

float switch for high-level alarm. In case of high-level

and

alarm, the top indicator light is flashing and the other is

11

permanently on.

Green indicator light, indicating that the electricity

12

supply has been switched on.

The table below shows the situations which may occur if the normal electricity supply to the LCD 108 fails and a back-up battery is connected:

= the indicator light is off. = the indicator light is on. = the indicator light is flashing.

Mains supply failure:

• The common alarm is active.

The red indicator light is on.

• The green indicator light (electricity

supply switched on) is off.

Mains supply failure and high-level alarm:

TM01 6397 3902

• The common alarm is active.

The red indicator light is on.

• The top orange indicator light is flashing.

• The second orange indicator light from the top is on.

• The green indicator light (electricity supply switched on) is off.

3.4 Battery back-up functions

Parallel operation with 3 float switches, pages 23 and 24.

If a back-up battery for CU 212 (accessory for certain variants) is installed, the following functions will be carried out if the normal electricity supply to the LCD 108 fails (see also the illustrations below):

• The common alarm is active, the red indicator light is on –

cannot be reset!

• If the external alarm device for common alarm is supplied from an external power source, this device will be active – cannot be reset by means of the reset button!

• The built-in buzzer (only certain variants) is activated – can be reset by means of the reset button!

• If the liquid level in the pit rises above the level for high-level alarm, the top orange indicator light will be flashing and the second orange indicator light from the top will be permanently on.

• If the starting delay function and automatic test run were selected (switch 4 of the DIP switch), the start-up will be delayed after the electricity supply has been switched on when the liquid level is sufficiently high, see section 3.2.

7

3.5 Reset button and ON-OFF-AUTO selector switch

21

Parallel operation with 3 float switches, pages 23 and 24.

The reset button is a push-button for manual resetting of alarm signals to external alarm devices and the built-in buzzer (i.e. not for resetting of the alarm memory as this is reset by means of the ON-OFF-AUTO selector switch, see position OFF ( )). Even if the fault condition still exists, the external alarm devices and the built-in buzzer will be reset when the reset button is pressed.

The ON-OFF-AUTO selector switch for each pump has three different positions:

ON ( ), top position:

• The pump will start when the selector switch is pushed into this position (unless the motor protection relay has cut out the pump).

• If the PTC resistance/thermal switch of the motor registers overtemperature, the pump will not be switched off. Note: It is the user’s responsibility to decide how long the pump is to run with this fault indication. Over a long period, the pump will be damaged!

In explosion hazard areas, switch 10 of the DIP switch must be set as stated in section 3.2. Consequently,

the pump cannot be started when the PTC resistance/thermal switch of the motor registers overtemperature.

OFF ( ), middle position:

• The pump cannot start when the selector switch has been set to this position.

• The alarm memory is reset by pushing the selector switch into position OFF ( ). The alarm memory is the light indication of a fault condition which has disappeared. If a fault condition still exists when the selector switch is pushed into position ON ( ) or AUTO ( ), the alarm indication will be repeated immediately.

AUTO ( ), bottom position:

• The pump is controlled by the input signals from the float switches and the pump according to the selected DIP switch setting.

• Alarm signals will automatically be reset. Switch 9 of the DIP switch can, however, be set to manual resetting which is carried out by means of the reset button, see section 3.2.

• The pump will restart automatically when a given fault condition disappears. However, this is dependent on the setting of switch 10 of the DIP switch, see section 3.2.

• When the pump starts automatically after a fault condition which has disappeared, the indicator light will continue to show the fault condition (alarm memory) and the indication can only be removed by resetting the alarm memory, see position OFF ().

4. Systems for parallel operation with 4 float switches

Description (see also page 25 or 26):

The pumps are controlled by the liquid level in the pit.

• The float switch, pos. 2, starts the first pump.

• The float switch, pos. 3, starts the next pump.

• The float switch, pos. 1, stops both pumps after expiration of the "stop delay" (can be set).

• The pumps operate alternately.

• The top float switch, pos. 4, activates the high-level alarm.

Before starting any work on pumps used to pump liquids which could be constituted as being hazardous to health, thorough cleaning/venting of pumps, pits, etc. must be carried out according to local regulations.

Before making any connections in the LCD 108 or work on pumps, pits, etc., it must be ensured that the electricity supply has been switched off and that it cannot be accidentally switched on.

4.1 Electrical connection

Parallel operation with 4 float switches, pages 25 and 26.

Before starting work on the system, switch off the supply voltage and lock the mains switch in position 0. Any external voltage connected to the system must be switched off before work is started.

Fig. B1 on page 25.

The figures show all electrical connections required to connect the LCD 108 for direct-on-line starting, parallel operation with 4 float switches.

Fig. B2 on page 26.

The figure shows all electrical connections required to connect the LCD 108 for star-delta starting, parallel operation with 4 float switches.