Grundfos MAGNA 2000 Series, MAGNA 32-120, MAGNA 65-120, MAGNA 50-60, MAGNA 65-60 Installation And Operating Instructions Manual

GRUNDFOS INSTRUCTIONS

GRUNDFOS MAGNA

Series 2000

MAGNA 32-120, 40-120, 50-120, 65-120, 50-60, 65-60

Installation and operating instructions

Declaration of Conformity

We Grundfos declare under our sole responsibility that the products
MAGNA Series 2000, to which this declaration relates, are in conformity

with the Council Directives on the approximation of the laws of the
EC Member States relating to

– Machinery (98/37/EC).
– Electrical equipment designed for use within certain voltage limits

(2006/95/EC).
Standards used: EN 60335-1: 2002 and EN 60335-2-51: 2003,
SAP96732176.

– Electromagnetic compatibility (2004/108/EC).

Standard used: EN 61800-3.

Déclaration de Conformité

Nous Grundfos déclarons sous notre seule responsabilité que les
produits MAGNA Série 2000 auxquels se réfère cette déclaration sont
conformes aux Directives du Conseil concernant le rapprochement des
législations des Etats membres CE relatives à

– Machines (98/37/CE).
– Matériel électrique destiné à employer dans certaines limites

de tension (2006/95/CE).
Standards utilisés: EN 60335-1: 2002 et EN 60335-2-51: 2003,
SAP96732176.

– Compatibilité électromagnétique (2004/108/CE).

Standard utilisé: EN 61800-3.

Declaración de Conformidad

Nosotros Grundfos declaramos bajo nuestra única responsabilidad que
los productos MAGNA Serie 2000 a los cuales se refiere esta declara-
ción son conformes con las Directivas del Consejo relativas a la
aproximación de las legislaciones de los Estados Miembros de la CE
sobre
– Máquinas (98/37/CE).
– Material eléctrico destinado a utilizarse con determinadas límites

de tensión (2006/95/CE).
Normas aplicadas: EN 60335-1: 2002 y EN 60335-2-51: 2003,
SAP96732176.

– Compatibilidad electromagnética (2004/108/CE).

Norma aplicada: EN 61800-3.

Δήλωση Συμμόρφωσης

Εμείς η Grundfos δηλώνουμε με αποκλειστικά δική μας ευθύνη ότι τα
προιόντα MAGNA Σειρά 2000 συμμορφώνονται με την Οδηγία το υ
Συμβουλίου επί της σύγκλισης των νόμων των Κρατών Mελών της
Ευρωπαικής Ενωσης σε σχέση με τα

– Μηχανήματα (98/37/EC).
– Ηλεκτρικές συσκευές σχεδιασμένες γιά χρήση εντός ορισμένων

ορίων ηλεκτρικής τάσης (2006/95/EC).
Πρότυπα που χρησιμοποιήθηκαν: EN 60335-1: 2002 και

EN 60335-2-51: 2003, SAP96732176.

– Ηλεκτρομαγνητική συμβατότητα (2004/108/EC).

Πρότυπο που χρησιμοποιήθηκε: EN 61800-3.

Försäkran om överensstämmelse

Vi Grundfos försäkrar under ansvar, att produkterna
MAGNA Serie 2000, som omfattas av denna försäkran, är i överens-

stämmelse med Rådets Direktiv om inbördes närmande till
EU-medlemsstaternas lagstiftning, avseende

– Maskinell utrustning (98/37/EC).
– Elektrisk material avsedd för användning inom vissa spännings-

gränser (2006/95/EC).
Använda standarder: EN 60335-1: 2002 och EN 60335-2-51: 2003,
SAP96732176.

– Elektromagnetisk kompatibilitet (2004/108/EC).

Använd standard: EN 61800-3.

Konformitätserklärung

Wir Grundfos erklären in alleiniger Verantwortung, dass die Produkte
MAGNA Serie 2000, auf die sich diese Erklärung bezieht, mit den fol-

genden Richtlinien des Rates zur Angleichung der Rechtsvorschriften
der EG-Mitgliedstaaten übereinstimmen

– Maschinen (98/37/EG).
– Elektrische Betriebsmittel zur Verwendung innerhalb bestimmter

Spannungsgrenzen (2006/95/EG).
Normen, die verwendet wurden: EN 60335-1: 2002 und
EN 60335-2-51: 2003, SAP96732176.

– Elektromagnetische Verträglichkeit (2004/108/EG).

Norm, die verwendet wurde: EN 61800-3.

Dichiarazione di Conformità

Noi Grundfos dichiariamo sotto la nostra esclusiva responsabilità che i
prodotti MAGNA Serie 2000 ai quali questa dichiarazione se riferisce
sono conformi alle Direttive del Consiglio concernente il ravvicinamento
delle legislazioni degli Stati membri CE relative a

– Macchine (98/37/CE).
– Materiale elettrico destinato ad essere utilizzato entro certi limiti

di tensione (2006/95/CE).
Standard usati: EN 60335-1: 2002 e EN 60335-2-51: 2003,
SAP96732176.

– Compatibilità elettromagnetica (2004/108/CE).

Standard usato: EN 61800-3.

Declaração de Conformidade

Nós Grundfos declaramos sob nossa única responsabilidade que os
produtos MAGNA Série 2000 aos quais se refere esta declaração estão
em conformidade com as Directivas do Conselho das Comunidades
Europeias relativas à aproximação das legislações dos Estados Mem­bros respeitantes à
– Máquinas (98/37/CE).
– Material eléctrico destinado a ser utilizado dentro de certos limites

de tensão (2006/95/CE).
Normas utilizadas: EN 60335-1: 2002 e EN 60335-2-51: 2003,
SAP96732176.

– Compatibilidade electromagnética (2004/108/CE).

Norma utilizada: EN 61800-3.

Overeenkomstigheidsverklaring

Wij Grundfos verklaren geheel onder eigen verantwoordelijkheid dat de
produkten MAGNA Serie 2000 waarop deze verklaring betrekking heeft
in overeenstemming zijn met de Richtlijnen van de Raad inzake de
onderlinge aanpassing van de wetgevingen van de
Lid-Staten betreffende
– Machines (98/37/EG).
– Elektrisch materiaal bestemd voor gebruik binnen bepaalde

spanningsgrenzen (2006/95/EG).
Normen: EN 60335-1: 2002 en EN 60335-2-51: 2003,
SAP96732176.

– Elektromagnetische compatibiliteit (2004/108/EG).

Norm: EN 61800-3.

Vastaavuusvakuutus

Me Grundfos vakuutamme yksin vastuullisesti, että tuotteet
MAGNA Sarja 2000, jota tämä vakuutus koskee, noudattavat direktii-

vejä jotka käsittelevät EY:n jäsenvaltioiden koneellisia laitteita
koskevien lakien yhdenmukaisuutta seur.:

– Koneet (98/37/EY).
– Määrättyjen jänniterajoitusten puitteissa käytettävät sähköiset

laitteet (2006/95/EY).
Käytetyt standardit: EN 60335-1: 2002 ja EN 60335-2-51: 2003,
SAP96732176.

– Elektromagneettinen vastaavuus (2004/108/EY).

Käytetty standardi: EN 61800-3.

2

Overensstemmelseserklæring

Vi Grundfos erklærer under ansvar, at produkterne
MAGNA Serie 2000, som denne erklæring omhandler, er i overens-

stemmelse med Rådets direktiver om indbyrdes tilnærmelse til EF
medlemsstaternes lovgivning om

– Maskiner (98/37/EF).
– Elektrisk materiel bestemt til anvendelse inden for visse spændings-

grænser (2006/95/EF).
Anvendte standarder: EN 60335-1: 2002 og EN 60335-2-51: 2003,
SAP96732176.

– Elektromagnetisk kompatibilitet (2004/108/EF).

Anvendt standard: EN 61800-3.

Декларация о соответствии

Мы, фирма Grundfos, со всей ответственностью заявляем, что
изделия MAGNA серии 2000, к которым и относ ится данное
свид етельст во, отвечают требованиям следующих указаний Совета
ЕС об унификации законодательных предписаний стран-членов ЕС:

– Машиностроение (98/37/ЕС).
– Элек трич еские машины для эк сплуатации в пределах

определенного диапазона значений напряжения
(2006/95/ЕС).
Применявшиеся стандарты: Евростандарт EN 60335-1: 2002 и
EN 60335-2-51: 2003, SAP96732176.

– Электромагнитная

Применявшиеся стандарты: Евростандарт EN 61800-3.

совместимость (2004/108/ЕС).

Deklaracja zgodności

My, Grundfos, oświadczamy z pełną odpowiedzialnością, ż e nasze
wyroby MAGNA seria 2000 których deklaracja niniejsza dotyczy, są
zgodne z następującymi wytycznymi Rady d/s ujednolicenia przepisów
prawnych krajów członkowskich EG:

– maszyny (98/37/EG).
– wyposażenie elektryczne do stosowania w określonym zakresie

napięć (2006/95/EG),
zastosowane normy: EN 60335-1: 2002 i EN 60335-2-51: 2003,
SAP96732176.

– zgodność elektromagnetyczna (2004/108/EG),

zastosowana norma: EN 61800-3.

Bjerringbro, 1st August 2007

Svend Aage Kaae
Technical Director

3

4

GRUNDFOS MAGNA

Series 2000

MAGNA 32-120, 40-120, 50-120, 65-120, 50-60, 65-60

Installation and operating instructions 6

Montage- und Betriebsanleitung 30

Notice d'installation et d'entretien 56

Istruzioni di installazione e funzionamento 81

Instrucciones de instalación y funcionamiento 106

Instruções de instalação e funcionamento 130

Οδηγίες εγκατάστασης και λειτουργίας 156

Installatie- en bedieningsinstructies 182

Monterings- och driftsinstruktion 206

Asennus- ja käyttöohjeet 231

Monterings- og driftsinstruktion 255

Instrukcja montażu i eksploatacji 279

Руководство по монтажу и эксплуатации 305

5

CONTENTS

1. Symbols used in this document 6

2. General description 6

3. Applications 6

3.1 Pumped liquids 6

4. Installation 7

4.1 Changing the control box position 7

4.2 Twin-head pumps 7

4.3 Non-return valve 7

4.4 Frost protection 8

5. Electrical connection 8

5.1 Supply voltage 8

5.2 Connection diagram 9

6. Start-up 10

7. Functions 11

7.1 Control modes 12

7.2 Selection of control mode 13

7.3 Automatic night-time duty 14

7.4 Constant-curve duty 14

7.5 Max. or min. curve duty 14

7.6 Temperature influence 14

7.7 External start/stop 15

7.8 Signal relay 15

7.9 Indicator lights 15

7.10 Expansion modules 16

7.11 Wiring diagrams for expansion modules 17

7.12 GENI module 18

7.13 LON module 18

8. Setting the pump 19

8.1 Factory setting 19

8.2 Control panel 19

8.3 R100 remote control 21

8.4 R100 display overview 22

8.5 Menu OPERATION 23

8.6 Menu STATUS 24

8.7 Menu INSTALLATION 25

8.8 Priority of settings 26

9. Fault finding chart 27

10. Megging 28

11. Technical data 29

12. Disposal 29

Warning
Prior to installation, read these

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

Page

1. Symbols used in this document

Warning
If these safety instructions are not

observed, it may result in personal
injury!

If these safety instructions are not

Caution

observed, it may result in malfunction
or damage to the equipment!

Notes or instructions that make the job

Note

easier and ensure safe operation.

2. General description

The GRUNDFOS MAGNA Series 2000 is a complete
range of circulator pumps with integrated differential
pressure control enabling adjustment of pump
performance to the actual system requirements.
In many systems, this will reduce the power
consumption considerably, reduce noise from
thermostatic valves and similar fittings, and improve
the control of the system.

The desired head can be set on the pump control
panel.

3. Applications

The GRUNDFOS MAGNA is designed for circulating
liquids in heating and air-conditioning systems. The
pump can also be used in domestic hot-water
systems.

The pump range is primarily used in

• systems with a variable flow.
The pump range can also be used in

• systems with a constant flow where it is
desirable to optimise the setting of the pump duty
point,

• systems with variable flow-pipe temperature.

3.1 Pumped liquids

Thin, clean, non-aggressive and non -explosive liquids,
not containing solid particles, fibres or mineral oil.

In heating systems, the water should meet the
requirements of accepted standards on water quality
in heating systems, e.g. the German standard
VDI 2035.

In domestic hot-water systems, it is advisable to
use GRUNDFOS MAGNA pumps only for water with
a degree of hardness lower than approx. 14 °dH.

Warning
The pump must not be used for the

transfer of inflammable liquids such as
diesel oil, petrol or similar liquids.

6

4. Installation

Arrows on the pump housing indicate the liquid flow
direction through the pump.

4.1 Changing the control box position

Warning
Before any dismantling of the pump,

the system must be drained or the
isolating valves on either side of the
pump must be closed as the pumped
liquid may be scalding hot and under
high pressure.

Change the control box position as follows:

1. Remove the inspection screw (1) and the four
screws (2) in the stator housing, see fig. 1.

2. Lift off the stator housing (3). Keep the rotor (4) in
place using a suitable tool, e.g. a T-key (M8) (5),
see fig. 2.

3. Check that the O-ring (6) is intact.
A defective O-ring must be replaced.

4. Hold the stator housing/control box (3) in the
desired position.

5. Lower the stator housing over the rotor.
Keep the rotor in place as described in point 2.

6. Fit and tighten the four screws and the inspection
screw.

1

3

2

Fig. 1 Rem oving the control box

Pos. Description

1 Inspection screw
2Screw
3 Stator housing/control box
4 Rotor
5T-key
6 O-ring

4.2 Twin-head pumps

Twin-head pumps are supplied fitted with a GENI
module on each control box. The modules are
connected via a cable. The modules determine the
operating mode of the pump, see section

7.12.1 Control of twin-head pumps.

Twin-head pumps mounted in
horizontal pipes must be fitted with an

Caution

automatic air vent (Rp 1/4) in the upper
part of the pump housing, see fig. 3.

The automatic air vent is not supplied with the pump.

Fig. 3 Automatic ai r vent

4.3 Non-return valve

If a non-return valve is fitted in the pipe system, see
fig. 4, it must be ensured that the set minimum
discharge pressure of the pump is always higher

TM02 5506 3402TM02 5507 3402

than the closing pressure of the valve. This is
especially important in proportional-pressure control
mode (reduced head at low flows).

TM03 8831 2607TM02 0640 0301

5

4

6

Fig. 2 Chan ging the control box position

Fig. 4 Non- return v alve

7

4.4 Frost protection

If the pump is not used during periods of frost,
necessary steps must be taken to prevent frost
bursts.

Additives with a density and/or
kinematic viscosity higher than those/

Note

that of water will reduce the hydraulic
performance.

5. Electrical connection

The electrical connection and protection should be
carried out in accordance with local regulations.

Warning
Never make any connections in the

pump control box unless the electricity
supply has been switched off for at
least 5 minutes.

The earth terminal of the pump must be
earthed.

The pump must be connected to an
external mains switch with a contact
separation of at least 3 mm in each
pole.

Earthing or neutralisation can be used
for protection against indirect contact.

Megging must be carried out as
described in section 10. Megging.

If the pump is connected to an electric
installation where an earth leakage
circuit breaker (ELCB) is used as
additional protection, this circuit
breaker must trip out when earth fault
currents with DC content (pulsating
DC) occur.
The earth leakage circuit breaker must
be marked with the symbol shown:

Open the control box cover as shown in fig. 5.

Step Action

1

2

Fig. 5 Opening the control box

If the control box cover cannot be lifted sufficiently, it
can be removed as shown in fig. 6.

Step Action

1

TM02 0456 3503

TM02 0457 3503

• The pump requires no external motor protection.

• The operating voltage and frequency are marked
on the pump nameplate. Please make sure that
the motor is suitable for the electricity supply on
which it will be used.

8

TM02 7441 3503

2

TM02 7442 3503

Fig. 6 Removing the con trol box cover

5.1 Supply voltage

1 x 230-240 V – 10 %/+ 6 %, 50/60 Hz.

5.2 Connection diagram

Supply connection Signal output Start/stop input

78

L

N

Fig. 7 Conn ection diagram

Warning

• Wires connected to
– supply terminals,
– outputs NC, NO, C and
– start/stop input

must be separated from each other
and from the supply by reinforced
insulation.

• All wires connected to a terminal
block must be tied up at the
terminals.

Concerning demands on signal wires and signal
transmitters, see section 11. Technical data.

A connection example can be found on page 337.

213

NC NO C

NC NO C

Note:

• If no external on/off switch is connected, the
connection across terminals STOP and should
be maintained.

• All cables used must be heat-resistant up to
+85 °C.

• All cables used must be installed in accordance
with EN 60204-1 and EN 50174-2: 2000.

• If a GENI module is fitted, the screen must be
connected to . See page 339.

S
T
O

P

TM02 0235 1007

9

6. Start-up

Do not start the pump until the system has been filled
with liquid and vented. Furthermore, the required
minimum inlet pressure must be available at the
pump inlet, see section 11. Technical data.
The system cannot be vented through the pump.

The pump can be vented by slackening the
inspection screw.

Warning
If the inspection screw is to be

slackened, see fig. 8, care should be
taken to ensure that the escaping,
scalding hot liquid does not cause
personal injury or damage to
components.

Inspection screw

Fig. 8 Venting the pump

TM02 5508 3402

10

7. Functions

Most functions can be selected on the pump control panel. However, some functions can only be selected with
the R100 or via expansion modules.

On the pump control panel, see fig. 19, page 19:

• AUTO

ADAPT (factory setting)

Recommended for most heating installations.
During operation, the pump automatically makes the necessary adjustment to the actual system
characteristic. This setting ensures minimum energy consumption and noise level which reduces operating
costs and increases comfort.

• Proportional-pressure control
The pump head is changed continuously in accordance with the water demand in the system. The desired
setpoint can be set on the pump control panel.

• Constant-pressure control
A constant head is maintained, irrespective of water demand. The desired setpoint can be set on the pump
control panel.

• Automatic night-time duty
The pump changes automatically between normal duty and night-time duty depending on the flow-pipe
temperature. Automatic night-time duty can be combined with the above-mentioned control modes.

Further functions:
Via the digital input:

• External start/stop

The pump can be started or stopped via the digital input.

With the R100 remote control:

• Constant-curve duty

The pump runs at a constant speed, on or between the max. and min. curves.

• Temperature influence

The head varies depending on the liquid temperature.

• External fault and operating signal

The pump controls an external fault or operating signal device via a potential-free output.

Via expansion modules:
GENI module

• External analog control of head or speed via a signal from an external 0-10 V signal transmitter.

• External forced control via inputs for:

- Max. curve,

- Min. curve.

• Bus communication via GENIbus

The pump can be controlled and monitored by a GRUNDFOS Pump Management System 2000,
a building management system or another type of external control system.

• Control of twin-head pumps

The control of twin-head pumps is described in section 7.12.1.

LON module

• Bus communication via LON

This module enables connection to a network based on LonWorks
are based on this communication standard.

®

technology and to other units which

11

7.1 Control modes

A GRUNDFOS MAGNA pump can be set to the
control mode which is most suitable for the individual
system.

Possible control modes:

ADAPT (factory setting)

•AUTO

• Proportional pressure

• Constant pressure.
Each of the control modes can be combined with

automatic night-time duty, see section 7.3 Automatic
night-time duty.

ADAPT

AUTO

To be set on the control panel or with the R100, see
section 8. Setting the pump.

The control mode AUTO
the pump performance.

The setpoint of the pump has been factory-set as
follows and cannot be changed manually:

• MAGNA 32-120, 40-120, 50-120, 65-120 to

6.5 metres.

• MAGNA 50-60, 65-60 to 3.5 metres.
When the pump registers a lower pressure on the

max. curve, A
automatically selects a correspondingly lower control
curve, H

2

, thus reducing the energy consumption.

set2

H

H

max.

ADAPT continuously adapts

, the AUTOADAPT function

Proportional-pressure control

To be set on the control panel or with the R100, see
section 8. Setting the pump.

The pump head is reduced at decreasing water
demand and increased at rising water demand, see
fig. 10.

Constant-pressure control

To be set on the control panel or with the R100, see
section 8. Setting the pump.

The pump maintains a constant pressure,
irrespective of water demand, see fig. 10.

Q

H

H

set

Constant
pressure

Q

H

H

set

H

set

2

2

Proportional
pressure

Fig. 10 Pressure control

TM00 5546 4596

H

fac.

Fig. 9 AUTO

A

1

ADAPT

H

set1

H

set2

A

2

A

3

Q

A1: Original duty point.
A

: Lower registered pressure on the max. curve.

2

: New duty point after AUTOADAPT control.

A

3

: Original setpoint.

H

set1

H

: New setpoint after AUTOADAPT control.

set2

: Factory-set setpoint.

H

fac.

The AUTO
the button for approx. 10 seconds until the control
mode is back to the starting point (AUTO
AUTO

ADAPT function can be reset by pressing

ADAPT with automatic night-time duty).

ADAPT or

12

TM02 0251 4800