Grundfos MAGNA 2000 Series, MAGNA 32-120, MAGNA 65-120, MAGNA 50-60, MAGNA 65-60, MAGNA 50-120, MAGNA 40-120 Installation And Operating Instructions Manual
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
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.
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 машиныдляэк сплуатациивпределах
определенногодиапазоназначенийнапряжения
(2006/95/ЕС).
Применявшиесястандарты: 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 instructions6
Montage- und Betriebsanleitung30
Notice d'installation et d'entretien56
Istruzioni di installazione e funzionamento81
Instrucciones de instalación y funcionamiento106
Instruções de instalação e funcionamento130
Οδηγίεςεγκατάστασηςκαιλειτουργίας156
Installatie- en bedieningsinstructies182
Monterings- och driftsinstruktion206
Asennus- ja käyttöohjeet231
Monterings- og driftsinstruktion255
Instrukcja montażu i eksploatacji279
Руководствопомонтажуиэксплуатации305
5
CONTENTS
1.Symbols used in this document6
2.General description6
3.Applications6
3.1 Pumped liquids6
4.Installation7
4.1 Changing the control box position7
4.2 Twin-head pumps7
4.3 Non-return valve7
4.4 Frost protection8
5.Electrical connection8
5.1 Supply voltage8
5.2 Connection diagram9
6.Start-up10
7.Functions11
7.1 Control modes12
7.2 Selection of control mode13
7.3 Automatic night-time duty14
7.4 Constant-curve duty14
7.5 Max. or min. curve duty14
7.6 Temperature influence14
7.7 External start/stop15
7.8 Signal relay15
7.9 Indicator lights15
7.10 Expansion modules16
7.11 Wiring diagrams for expansion modules17
7.12 GENI module18
7.13 LON module18
8.Setting the pump19
8.1 Factory setting19
8.2 Control panel19
8.3 R100 remote control 21
8.4 R100 display overview22
8.5 Menu OPERATION23
8.6 Menu STATUS24
8.7 Menu INSTALLATION25
8.8 Priority of settings26
9.Fault finding chart27
10. Megging28
11. Technical data29
12. Disposal29
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.
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.
StepAction
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.
StepAction
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 connectionSignal outputStart/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
NCNOC
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
7.2 Selection of control mode
System typeDescription
Typical heating
systems
Relatively great
head losses in
the distribution
pipes and airconditioning
systems
Relatively small
head losses in
the distribution
pipes
Grundfos recommends to let the pump remain in AUTO
This ensures optimum performance at the lowest possible energy
consumption.
1. Two-pipe
heating
systems with
thermostatic
valves and:
• with a dimensioned pump head higher than
4metres,
• very long distribution pipes,
• strongly throttled pipe balancing valves,
• differential pressure regulators,
• great head losses in those parts of the system
through which the total quantity of water flows
(e.g. boiler, heat exchanger and distribution pipe up
to the first branching).
2. Primary circuit pumps in systems with great head losses in the primary
circuit.
3. Airconditioning
systems with
1. Two-pipe
heating
systems with
thermostatic
valves and:
• he at exchangers (fan coils),
• c ooling ceilings,
• cooli ng surfaces.
• with a dimensioned pump head lower than
2metres,
• dimensioned for natural circulation,
• with small head losses in those parts of the system
through which the total quantity of water flows
(e.g. boiler, heat exchanger and distribution pipe up
to the first branching) or
• modified to a high differential temperature between
flow pipe and return pipe (e.g. district heating).
2. Underfloor heating systems with thermostatic valves.
3. One-pipe heating systems with thermostatic valves or pipe balancing
valves.
4. Primary circuit pumps in systems with small head losses in the primary
circuit.
7.2.1 Setpoint setting
If AUTO
ADAPT is selected, the setpoint cannot be set.
The setpoint can be set by pressing or when
the pump is in control mode:
• proportional pressure
• constant pressure
• constant-curve duty.
Set the setpoint so that it matches the system.
A too high setting may result in noise in the system
whereas a too low setting may result in insufficient
heating or cooling in the system.
ADAPT mode.
Select this
control mode
ADAPT
AUTO
Proportional
pressure
Constant
pressure
13
7.3 Automatic night-time duty
To be set on the control panel or with the R100, see
section 8. Setting the pump.
Once automatic night-time duty has been activated,
the pump automatically changes between normal
duty and night-time duty (duty at low performance).
Changeover between normal duty and night-time
duty is dependent on the flow-pipe temperature.
The pump automatically changes over to night-time
duty when the built-in sensor registers a flow-pipe
temperature drop of more than 10-15 °C within
approx. 2 hours. The temperature drop must be at
least 0.1 °C/min.
Changeover to normal duty takes place without a
time lag when the temperature has increased by
approx. 10 °C.
Automatic night-time duty cannot be
Note
used in air-conditioning systems.
7.4 Constant-curve duty
To be set with the R100, see section 8. Setting the
pump.
The pump can be set to operate according to a
constant curve, like an uncontrolled pump, see
fig. 11.
MAGNA 32-120, 40-120, 50-120, 65-120
Select one of 91 curves between the max. and min.
curves.
MAGNA 50-60, 65-60
Select one of 41 curves between the max. and min.
curves.
H
H
Max.
Min.
Q
Fig. 12 Max. and min. curves
The max. curve mode can be selected if an
uncontrolled pump is required.
The min. curve mode can be used in periods in
which a minimum flow is required. This operating
mode is for instance suitable for manual night-time
duty if automatic night-time duty is not desired.
7.6 Temperature influence
To be set with the R100, see section 8. Setting the
pump.
When this function is activated in proportional- or
constant-pressure control mode, the setpoint for
head will be reduced according to the liquid
temperature.
It is possible to set temperature influence to function
at liquid temperatures below 80 °C or below 50 °C.
These temperature limits are called T
setpoint is reduced in relation to the head set
(= 100 %) according to the characteristics below.
H
H
H
100%
actual
max.
. The
TM00 5547 4596TM01 0626 1797
Max.
Min.
Q
Fig. 11 Operating curves
7.5 Max. or min. curve duty
To be set on the control panel, with the R100 or via
GENI module, see section 8. Setting the pump.
The pump can be set to operate according to the
max. or min. curve, like an uncontrolled pump, see
fig. 12.
This operating mode is available, irrespective of the
control mode.
14
30%
50
T
actual
80
t [°C]
20
Fig. 13 Temperature influence
TM02 0245 0904
In the above example, T
selected. The actual liquid temperature T
causes the setpoint for head to be reduced from
100 % to H
actual
.
= 80 °C has been
max.
The temperature influence function requires:
• Proportional- or constant-pressure control mode.
• The pump must be installed in the flow pipe.
• System with flow-pipe temperature control.
actual
Q
Temperature influence is suitable in:
• systems with variable flows (e.g. two-pipe heating
systems), in which the activation of the
temperature influence function will ensure a
further reduction of the pump performance in
periods with small heating demands and
consequently a reduced flow-pipe temperature.
• systems with almost constant flows (e.g. one-pipe
heating systems and underfloor heating systems),
in which variable heating demands cannot be
registered as changes in the head as is the case
with two-pipe heating systems. In such systems,
the pump performance can only be adjusted by
activating the temperature influence function.
Selection of T
In systems with a dimensioned flow-pipe
temperature of:
• up to and including 55 °C, select T
• above 55 °C, select T
Note
max.
= 50 °C,
max.
= 80 °C.
max.
The temperature influence function
cannot be used in air-conditioning
systems.
7.7 External start/stop
The pump can be started or stopped via an external
potential-free contact or a relay connected to
terminals 7 and 8, see section 5.2 Connection diagram.
Functional diagram: Start/stop input
Start/stop input
H
Q
H
Q
Normal duty
Stop
7.8 Signal relay
The pump incorporates a signal relay, terminals
1, 2 and 3, for a potential-free fault and operating
signal. The function of the signal relay, fault signal
(factory setting) or operating signal, is set with the
R100.
The output, terminals 1, 2 and 3, is electrically
separated from the rest of the controller.
The signal relay is activated as follows:
• Fault signal
The signal relay is activated together with the red
indicator light on the pump, see section
8.2 Control panel.
• Operating signal
The signal relay is activated together with the
green indicator light on the pump, see section
8.2 Control panel.
Functions of signal relay
Signal relay Fault signal
Not activated:
• T he electricity supply has been
132
NC NO C
switched off.
• The p ump has not registered
a fault.
Activated:
12 3
NC NO C
• T he pump has registered a fault.
Signal relay Operating signal
Not activated:
• The p ump has bee n set to stop.
132
NC NO C
• T he pump has registered a fault
and is unable to run.
Activated:
• T he pump is running.
12 3
NC NO C
• T he pump has registered a fault,
but is able to run.
Resetting of fault indications
A fault indication can be reset in one of the following
ways:
• Briefly press , or on the pump. This will
not influence the pump performance set.
• Briefly switch off the electricity supply to the
pump.
• With the R100, see section 8.4 R100 display
overview.
Before the pump can revert to normal duty, the fault
cause must be eliminated.
If the fault disappears by itself, the fault indication
will automatically be reset.
The fault cause will be stored in the pump alarm log.
The latest five faults can be called up with the R100.
7.9 Indicator lights
For position on pump, see fig. 19, section 8.2 Control
panel.
The indicator lights, pos. 2, are used for operating
and fault indication. Furthermore, they indicate
whether the pump is externally controlled.
When the R100 remote control
Note
communicates with the pump, the red
indicator light will flash rapidly.
The function of the operating and fault indicator
lights can be found in section 9. Fault finding chart.
The indicator light for external control is on
• if the pump control panel is inactive,
• if the pump is in constant-curve operating mode,
• if the temperature influence is active or
• if the pump is controlled by an external unit.
15
7.10 Expansion modules
The pump can be fitted with an expansion module
enabling communication with external signals
(signal transmitters).
Two types of expansion module are available:
• GENI module.
• LON module.
The fitting of a module is illustrated in fig. 14.
Open the control box cover and fit the module as
shown in fig. 14.
Warning
Before removing the control box cover,
make sure that the electricity supply
has been switched off for at least
5minutes.
StepAction
1
TM02 0241 0904
2
3
Fig. 14 Fitting an expansion module
16
TM02 0242 0904
TM02 0805 0904
7.11 Wiring diagrams for expansion modules
Min. curve
Max. curve
Analog 0-10 V input
MIN
Twin-head
MAX
10 V
pump
XQZBYA
DC 0-10 V
Bus signal
4
5 6 7 9 10 11 12 2122 23
Bus signal
BA
TM02 0237 0904
Screen
Min.
Max.
TM02 0236 1007
Warning
• Wires connected to
– supply terminals,
– outputs NC, NO, C and
– start/stop inputs, A, Y, B, MIN,
MAX, 10 V
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.
Warning
• Twisted-pair cable.
• Wires connected to
– supply terminals,
– outputs NC, NO, C and
– start/stop inputs, A, B
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.
Fig. 15 GENI moduleFig. 16 LON module
Note:
• If the 0-10 V input is used, there must be a connection across terminals MIN and (input for min. curve
must be closed).
• 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.
Concerning demands on signal wires and signal transmitters, see section 11. Technical data.
Connection examples (GENI module) can be found on pages 338 to 341.
17
7.12 GENI module
The GENI module offers the following functions:
• External analog 0-10 V control
• External forced control
• Bus communication via GENIbus
• Control of twin-head pumps.
7.12.1 Control of twin-head pumps
Twin-head pumps have a GENI module incorporated
in each control box. The modules are internally
connected via a wire.
MasterSlave
7.12.2 Selection of operating mode
Select the operating mode by means of the
mechanical contact in each module.
For connection of the communication cable between
the GENI modules, see pages 340 and 341.
Twin-head pumps are factory-set to the control mode
ADAPT and the operating mode "alternating
AUTO
operation", which is described below.
Operating modes:
• Alternating operation
Pump operation alternates every 24 hours. If the
duty pump stops due to a fault, the other pump
will start.
• Standby operation
One pump is operating continuously. In order to
prevent seizing-up, the other pump will start at a
fixed frequency and run for a short period. If the
duty pump stops due to a fault, the other pump
will start.
In air-conditioning systems, standby
Note
operation is recommended to minimise
condensation inside the pump.
Standby operation
Fig. 18 Mechanical contact
TM03 4635 2406
Operating the pump
Twin-head pumps can be set and operated in the
same way as single-head pumps. The duty pump
uses its setpoint setting, whether it is made on the
control panel, with the R100 or via bus.
Both pumps should be set to the same
setpoint and control mode. Different
Note
settings will result in different
operation when changing between the
two pumps.
7.13 LON module
The LON module offers the possibility of connecting
the pump to a LonWorks network. The module is
used for data transmission between a network and
pumps of the type MAGNA 32-120, 40-120, 50-120,
65-120, 50-60 and 65-60.
For further information, see the documentation files
on the floppy disk supplied with the LON module.
TM02 0243 0904
18
8. Setting the pump
EXT
Q
100%
MAX
STOP
5
4
1
2
3
AUTO
ADAPT
H
For the setting of the pump, use:
• control panel
• R100 remote control
• bus communication (not described in detail in
these instructions, contact Grundfos).
The table shows the application of the individual
operating units and in which section the function has
been described.
control
Constant-pressure control8.2.18.7.1
Setpoint setting8.2.28.5.1
Max. curve duty8.2.38.5.2
Min. curve duty8.2.48.5.2
Constant-curve duty–8.5.2
Temperature influence–8.7.3
Activation/deactivation of
pump buttons
Allocation of pump number–8.7.6
Start/stop8.2.58.5.2
Resetting of fault
indications
Reading of various data–
"–" = not available with this operating unit.
8.1 Factory setting
The pump is factory-set to AUTOADAPT without
automatic night-time duty.
Control
panel
8.2.18.7.1
–8.7.4
8.2.68.5.3
R100
8.6.1 -
8.6.7
8.2 Control panel
Warning
At high liquid temperatures, the pump
may be so hot that only the buttons
should be touched to avoid burns.
The control panel, fig. 19, incorporates:
Pos. Description
1Buttons for setting
• Indica tor lights for operating and fault
indication and
2
• symbol for in dication of external control
3Button for change of control mode
Light symbols for indication of control
4
mode and night-time duty
Light fields for indication of head, flow and
5
operating mode
For further information, see section 9. Fault finding chart.
Fig. 19 Control panel
TM03 8798 2507
19
8.2.1 Control mode setting
H
H
Description of function, see section 7.1 Control
modes.
To change the control mode, press , pos. 3,
according to this cycle:
AUTO
ADAPT
AUTO
+
ADAPT
+
8.2.2 Setpoint setting
Set the setpoint of the pump by pressing or
when the pump has been set to proportionalpressure control, constant-pressure control or
constant-curve duty.
The light fields, pos. 5, on the control panel indicate
the setpoint set.
MAGNA 32-120, 40-120, 50-120, 65-120
The light fields can indicate a maximum setpoint of
10 metres.
+
Fig. 20 Cycle of control modes
Automatic night-time duty can be activated together
with each of the control modes.
The light symbols in pos. 4, see fig. 19, indicate the
pump settings:
Light in Control mode
AUTO
ADAPTAUTOADAPTNO
Proportional
pressure
Automatic
night-time
duty
NO
Constant pressureNO
–Constant curve NO
AUTO
ADAPT
AUTOADAPTYES
Proportional
pressure
YES
Constant pressureYES
–Constant curve YES
"–" = no light.
TM03 1288 1505
Fig. 21 Light fields MAGNA xx-120
MAGNA 50-60, 65-60
The light fields can indicate a maximum setpoint of
5metres.
Fig. 22 Light fields MAGNA xx-60
8.2.3 Setting to max. curve duty
Description of function, see section 7.5 Max. or min.
curve duty.
To change over to the max. curve, press
continuously until "MAX" illuminates, see fig. 23. To
change back, press continuously until the desired
setpoint is indicated.
MAX
TM02 0482 2507TM02 0483 2507TM02 0246 2507
H
Fig. 23 Max. curve
20
8.2.4 Setting to min. curve duty
Description of function, see section 7.5 Max. or min.
curve duty.
To change over to the min. curve, press
continuously until "MIN" illuminates, see fig. 24. To
change back, press continuously until the desired
setpoint is indicated.
8.3 R100 remote control
The pump is designed for wireless communication
with the Grundfos R100 remote control. The R100
communicates with the pump via infra-red light.
During communication, the R100 must be pointed at
the pump control panel. When the R100 is
communicating with the pump, the red indicator light
will flash rapidly.
The R100 offers additional possibilities of setting and
status displays for the pump.
H MIN
Fig. 24 Min. curve
8.2.5 Start/stop of pump
To stop the pump, press continuously until
"STOP" illuminates. When the pump is stopped, the
green indicator light will be flashing.
To start the pump, press continuously.
If the pump is to be stopped, it is
recommended to use the start/stop
input, the R100 or to switch off the
Note
electricity supply. In this way, the
setpoint will remain unchanged when
the pump is started again.
8.2.6 Resetting of fault indications
The fault indications are reset by briefly pressing
any button. The settings remain unchanged. If the
fault has not disappeared, the fault indication will
reappear. The time until the fault reappears may vary
from 0 to 255 seconds.
TM02 0247 2507
21
8.4 R100 display overview
The R100 displays are divided into four parallel
menus, see fig. 25:
0. GENERAL, see operating instructions for R100
1. OPERATION
2. STATUS
3. INSTALLATION
This display appears only once, i.e. when the R100
gets contact with the pump.
8.5.1
The number stated at each individual display in
fig. 25 refers to the section in which the display is
described.
3. INSTALLATION2. STAT US0. GENERAL1. OPERATION
8.6.1
8.7.1
8.5.2
8.5.3
8.5.4
Fig. 25 Menu overview
8.6.2
8.6.3
8.6.4
8.6.5
8.6.6
8.6.7
8.7.2
8.7.3
8.7.4
8.7.5
8.7.6
22
8.5 Menu OPERATION
When the communication between the R100 and the
pump has been established, "Contact with" appears
in the display. When the "arrow down" on the R100 is
pressed, menu OPERATION appears.
The display "Contact with" appears
Note
only once, i.e. when the R100 gets
contact with the pump.
8.5.1 Setpoint
This display depends on the control mode selected
in the display "Control mode" in menu
INSTALLATION.
If the pump is forced-controlled via external signals,
the number of possible settings will be reduced, see
section 8.8 Priority of settings. Attempts to change
the settings will result in an indication in the display
saying that the pump is forced-controlled and
changes therefore cannot be made.
This display will appear when the pump is in
ADAPT mode.
AUTO
Set the desired setpoint by pressing the buttons
"+" and "–" on the R100 (not possible when the pump
is in AUTO
Furthermore, it is possible to select one of the these
operating modes:
• Stop
• Min. (min. curve)
• Max. (max. curve).
The display is different if proportional pressure,
constant pressure or constant curve has been
selected.
The actual duty point of the pump is indicated by a
square in the Q/H field. No indication at low flow.
8.5.2 Operating mode
ADAPT mode).
8.5.3 Fault indications
If the pump is faulty, the cause will appear in this
display.
Possible causes:
• Pump blocked
• Internal fault
• Overvoltage
• Undervoltage
• Overtemperature
• Module fault
• Fault in module communication.
The fault indication can be reset in this display.
If the fault has not disappeared when resetting is
attempted, the fault indication will reappear in the
display when communicating with the pump.
8.5.4 Alarm log
The alarm code with text appears in this display.
The display also shows the number of minutes the
pump has been connected to the electricity supply
after the fault occurred.
The last five fault indications will appear in the alarm
log.
Select an operating mode:
• Stop
• Min. (min. curve)
• Normal (AUTO
ADAPT, proportional pressure,
constant pressure or constant curve)
• Max. (max. curve).
23
8.6 Menu STATUS
The displays appearing in this menu are status
displays only. It is not possible to change or set
values.
The actual values in the display are indicative and
based on estimation.
8.6.1 Actual setpoint
Field "Actual setpoint":
Actual setpoint of pump.
Field "corresponding to":
Actual setpoint in % of the setpoint set if the pump is
connected to an external analog 0-10 V signal
transmitter or if temperature influence or
proportional-pressure control is activated.
8.6.2 Operating mode
8.6.5 Liquid temperature
The actual temperature of the pumped liquid.
8.6.6 Power input and power consumption
Actual power input and power consumption of the
pump.
The value of power consumption is an accumulated
value and cannot be set to zero.
8.6.7 Operating hours
This display shows the actual operating mode (Stop,
Min., Normal or Max.) and where it was selected
(Pump, R100, BUS or External).
8.6.3 Head and flow
The actual head and flow of the pump.
If "<" is indicated in front of the flow, the flow is less
than the displayed value.
8.6.4 Speed
The actual pump speed.
24
Operating hours of the pump.
The value of operating hours is an accumulated
value and cannot be set to zero.
8.7 Menu INSTALLATION
This menu shows the settings that should be
considered when installing the pump.
8.7.1 Control mode
Description of function, see section 7.1 Control
modes or section 7.4 Constant-curve duty.
Select one of the control modes:
•AUTO
• Prop. pressure (proportional pressure)
• Const. pressure (constant pressure)
• Const. curve (constant curve).
Setting of setpoint and curve is carried out in display
8.5.1 Setpoint in menu OPERATION (not possible
when the pump is in AUTO
8.7.2 Automatic night-time duty
In this display, automatic night-time duty can be
activated or deactivated.
Automatic night-time duty can be set to:
• Active
• Not active,
irrespective of the control mode selected.
8.7.3 Temperature influence
Description of function, see section 7.6 Temperature
influence.
ADAPT
ADAPT mode).
In the case of temperature influence, the pump must
be installed in the flow pipe. It is possible to choose
between maximum temperatures of 50 °C and 80 °C.
When the temperature influence is active, a small
thermometer is shown in the display "Setpoint" in
menu OPERATION, see section 8.5.1 Setpoint.
8.7.4 Buttons on pump
To prevent unauthorised persons from operating the
pump, the function of the buttons , and can
be deactivated in this display. The buttons can be
reactivated only with the R100.
The buttons can be set to:
• Active
• Not active.
8.7.5 Signal relay
In this display, the function of the internal signal relay
can be set:
• Fault (functions as a fault signal relay)
• Operation (functions as an operating signal
relay).
8.7.6 Pump number
If the pump is in control mode
AUTO
Note
ADAPT or constant curve, the
temperature influence cannot be set
with the R100.
The temperature influence function can be activated
in this display when the control mode is proportional
pressure or constant pressure, see section
8.7.1 Control mode.
A number from 1 up to and including 64 can be
allocated to a pump or can be changed so that the
R100, Pump Management System 2000 or other
systems can distinguish between two or more
pumps.
25
8.8 Priority of settings
The external forced-control signals will influence the
settings available on the pump control panel and with
the R100. However, the pump can always be set to
max. curve duty or to stop on the pump control panel
or with the R100.
If two or more functions are activated at the same
time, the pump will operate according to the setting
with the highest priority.
The priority of the settings is as shown in the table.
Example: If the pump has been forced to stop via an
external signal, the pump control panel or the R100
can only set the pump to max. curve.
Pump control
panel or R100
External signals
With expansion module
Priority
1Stop
2Max. curve
3Stop
4
5
6
As illustrated in the table, the pump does not react to
external signals (max. curve and min. curve) when
the pump is controlled via bus.
If the pump is to react to external signals (max. curve
and min. curve), the system must be configured for
that function.
For further details, please contact Grundfos.
Possible settings
Pump
control
panel
or R100
Min. curve Min. curve Min. curve
Setpoint
setting
Not active when the pump is controlled
via bus.
Only active when the pump is
controlled via bus.
External
signals
Max.curve Max.curve
Bus
signal
Stop
Setpoint
setting
26
9. Fault finding chart
Warning
Before removing the control box cover, make sure that the electricity supply has been
switched off for at least 5 minutes.
The pumped liquid may be scalding hot and under high pressure. Before any removal or
dismantling of the pump, the system must therefore be drained or the isolating valves on
either side of the pump must be closed.
Indicator light is off.
Indicator light is on.
Indicator light is flashing.
Indicator
lights
Green Red
FaultCauseRemedy
The pump is not
running.
The pump is not
running.
The pump has
stopped due to a
fault.
The pump is
running but is
faulty.
The pump has
been set to stop
and is faulty.
One fuse in the installation is
blown/tripped out.
The current-operated or voltageoperated circuit breaker has tripped
out.
The pump may be defective.Replace the pump or call
The pump has been stopped in one
of the following ways:
1. With the button .
2. With the R100.
3. External on/off switch in position
off.
4. Via bus signal.
Electricity supply failure.Check that the electricity supply falls
Pump blocked and/or impurities in
the pump.
The pump may be defective. Use the R100 for fault finding, see
The pump is faulty, but is able to
operate.
The pump is faulty, but is able to
operate (has been set to STOP).
Replace/cut in the fuse.
Check that the electricity supply falls
within the specified range.
Cut in the circuit breaker.
Check that the electricity supply falls
within the specified range.
GRUNDFOS SERVICE for
assistance.
1. Start the pump by pressing .
2. Start the pump with the R100 or
by pressing .
3. Switch on the on/off switch.
4. Start the pump via bus signal.
within the specified range.
Dismantle and clean the pump.
section 8.5.3 Fault indications.
Replace the pump or call
GRUNDFOS SERVICE for
assistance.
The pump is able to operate.
Try to reset the fault indication by
briefly switching off the electricity
supply or by pressing the button ,
or .
Use the R100 for fault finding, see
section 8.5.3 Fault indications.
In the case of repeated faults,
contact GRUNDFOS SERVICE.
27
Indicator
lights
FaultCauseRemedy
Green Red
Noise in the
system.
Air in the system.Vent the system.
The flow is too high.Reduce the setpoint and possibly
The pressure is too high.Reduce the setpoint and possibly
Noise in the
pump.
Note
The R100 can also be used for fault finding.
Air in the pump.Vent the pump.
The inlet pressure is too low.Increase the inlet pressure and/or
10. Megging
Megging of an installation incorporating a
GRUNDFOS MAGNA pump is not allowed, as the
built-in electronics may be damaged. If megging of
the pump is necessary, the pump should be
electrically separated from the installation.
Megging of the pump can be carried out as
described below.
Megging of pumps
change over to AUTO
constant pressure.
change over to AUTO
ADAPT or
ADAPT or
proportional pressure.
check air volume in the expansion
tank (if installed).
1. Switch off the electricity supply.
2. Remove the wires from terminals L and N and the earth
conductor.
3. Short-circuit terminals L and N using a short wire
(see B).
4. Remove the screw for electronics frame connection
(see A).
5. Test between terminals L/N and earth (see C).
Maximum test voltage: 1000 VAC/1500 VDC.
Note: Never test between supply terminals (L and N).
Maximum permissible leakage current: < 35 mA.
6. Fit the screw for electronics frame connection (see A).
7. Remove the short wire between terminals L and N
(see B).
8. Fit the supply wires to terminals L and N and the earth
conductor.
9. Switch on the electricity supply.
28
A
B
C
TM02 0238 0904
11. Techn ical data
Supply voltage
1 x 230-240 V – 10 %/+ 6 %, 50/60 Hz.
Motor protection
The pump requires no external motor protection.
Enclosure class
IP 44.
Insulation class
F.
Relative air humidity
Maximum 95 %.
Ambient temperature
0 °C to +40 °C.
Temperature class
TF110 to EN 60335-2-51.
Liquid temperature
Maximum +110 °C.
Continuously: +2 °C to +95 °C.
Pumps in domestic hot-water systems:
Continuously: +2 °C to +60 °C.
Ambient
temperature
[°C]
0 2 95/110
30 2 95/110
35 2 90/90
40 2 70/70
Maximum system pressure
The maximum system pressure is indicated on the
pump flanges: PN 6 / PN 10: 10 bar/1.0 MPa.
Number of bolt holes in the pump flange: 4.
Inlet pressure
Recommended inlet pressures:
• Min. 0.15 bar at +75 °C.
• Min. 0.45 bar at +95 °C.
EMC (electromagnetic compatibility)
EN 61800-3.
Sound pressure level
The sound pressure level of the pump is lower than
54 dB(A).
Leakage current
The pump mains filter will cause a discharge current
to earth during operation. I
Standby loss
Lower than 3 W.
Liquid temperature
Min. [°C] Max. [°C]
< 3.5 mA.
leakage
Pump inputs and outputs
Internal potential-free changeover contact.
Signal output
Maximum load:
250 V, 2 A, AC1.
Minimum load: 5 V, 100 mA.
Screened cable depending on
signal level.
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