Grundfos Magna 32-120, Magna 50-120, Magna 65-60, Magna 40-120, Magna 65-120 Service Instructions Manual

Service instructions

MAGNA Series 2000

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

50/60 Hz

1~

1 / 15

96558929 0804

GB

1. Type identification .......................................................................................................................2

1.1 Nameplate...................................................................................................................................................... 2

1.2 Type key ..........................................................................................................................................................2

2. Dismantling and assembly ..........................................................................................................3

2.1 Dismantling the pump................................................................................................................................4

3. Fault correction............................................................................................................................. 5

3.1 Fault finding...................................................................................................................................................5

3.2 Fault correction procedure.........................................................................................................................8

3.3 Fault indications via R100 fault log .......................................................................................................14

4. Winding resistance..................................................................................................................... 15

The pump must be serviced by a qualified person.

Service must be carried out in accordance with local regulations and accepted codes of good practice.

2 / 15

1. Type identification

1.1 Nameplate

1.2 Type key

TM02 8834 0904

Pos. Description Pos. Description

1 Type designation 8 Production code (year + week)
2 Product number 9 Country of origin
3 Model designation 10 Direction of rotation
4 Rated voltage and number of phases 11 Rated frequency
5 Maximum full-load current 12 Liquid temperature limit
6 Maximum input power 13 Enclosure class
7 Mark of conformity 14 Insulation class

Example MAGNA (D) 32 -120 F (N) Model: E

Type rang e
Twi n-head p ump
Nominal flange diameter [mm]
Maximum head [dm]
Pump housing with flanges
Pump housing of stainless steel

32-120F

P/N: 96513625

I

1/1

(A)

P

1

(W)

0.15

1.55

345

22

PC: 0116

Model : E

1 230-240 V

50/60 Hz

IP 44

TF 110

MIN

MAX

MIN

MAX

Class F

MAGNA

1

2

3

4

5
6

14

13

12

11

10

9

8

7

Made in Germany

3 / 15

2. Dismantling and assembly

Before dismantling

• Disconnect the electricity supply to the motor.

• Close the isolating valves, if fitted, or drain the system, as the pumped liquid may be burning hot and
under high pressure.

Before assembly

Gaskets and O-rings should always be replaced when the pump is overhauled.

• Clean and check all parts.

•Order new O-ring kits.

• Replace defective parts by new parts.

The pump must be serviced by a qualified person.

Service must be carried out in accordance with local regulations and accepted codes of good practice.

4 / 15

2.1 Dismantling the pump

2.1.1 Changing the position of the terminal box

1. Remove the inspection screw pos. 1 and the four screws pos. 2 in the stator housing, see Fig. 1

.

2. Turn the stator housing pos. 3 to the position required.

If the stator housing has been prised/lifted off the pump housing, continue with point 2 in 2.1.2

Replacing

the stator unit including the rotor unit.

3. Fit the four screws and the inspection screw.

Fig. 1 Changing the position of the terminal box

2.1.2 Replacing the stator unit including the rotor unit

1. Remove the inspection screw pos. 1 and the four screws pos. 2 in the stator housing, see Fig. 1

.

2. Lift off the stator housing pos. 3.

3. Remove the rotor and the O-ring from the pump housing or stator housing.

4. Check that the O-ring pos. 6 is intact. If the O-ring is damaged, it must be replaced.

5. Fit the rotor and the O-ring on the pump housing.

6. Put a tee key or a long screwdriver through the stator and hold the rotor while fitting the stator on the

pump housing. See Fig. 2

.
The purpose is to protect the O-ring, as otherwise the magnetic force will cause the rotor to jerk up in the
stator.

Fig. 2 Holding the rotor

7. Turn the stator housing pos. 3 to the position required.

8. Fit the four screws and the inspection screw.

TM02 5506 3402 TM02 5507 3402

2

3

1

5

4

6

5 / 15

3. Fault correction

3.1 Fault finding

Fault finding should always start with a check that the external conditions for correct function are OK. This is
done by checking:

• that the mains supply is in accordance with the data on the nameplate,

• that the installation was carried out according to the installation and operating instructions,

• that the external on/off switch has been connected correctly,

• that the desired setpoint signal is available,

• that the requested sensor signal is available.

3.1.1 Printing of data registers

The Grundfos R100 remote control enables the printing of status for the data registers by means of a Hewlett
Packard infrared printer.

The purpose of this is to ensure that the service technician can print out the data registers before starting the
fault finding so that this print stating the original fault information can be enclosed, in case the product is re­turned to Grundfos.

The pump must be serviced by a qualified person.

Service must be carried out in accordance with local regulations and accepted codes of good practice.

6 / 15

The following figure shows an example of a print of MAGNA Series 2000 pump data registers.

3.1.2 Fault log

MAGNA Series 2000 pumps feature a fault log function:

• The fault log function memory can recall the five latest faults.

• The fault log can be read out via R100.

• The faults log cannot be reset.

• States the type of fault, code and time since the fault arose.

7 / 15

3.1.3 Fault reading via R100

Possible fault and log can be read via R100 in the GENI menu and/or in the OPERATION menu.

Fault indications

The following fault indications can appear:

• Pump blocked.

• Internal fault

•Undervoltage

•Overvoltage

•Overtemperature

• Module fault (fault in the module fitted (GENI, LON...))

• Fault in module communication.
The fault indication can also be reset in this display. If the fault has not disappeared when attempts are made

to remove the fault indication, the indication will return in the display when communicating with the pump.

Alarm log

The alarm log shows the fault code, the fault indication and for how many minutes the pump has been con­nected to supply voltage since the fault arose. The five last fault indications are shown in the alarm log.

List of fault code priority, see

3.3 Fault indications via R100 fault log.

Fig. 3 If the pump is faulty, the cause will appear in the display.

Fig. 4 Example of alarm log

Time since the fault arose

Fault
code

Fault

8 / 15

3.2 Fault correction procedure

The following fault correction procedure is based on indications by the green and red indicator lights on the
terminal box of the MAGNA Series 2000 pump. The next two pages give a complete overview of the possible
signal lights combinations. Remedy for some of the situations is further elaborated on the three next pages (

A1, A2, B1, B2, B3, C1, C2).

Legend for signal lights:

= signal light is off.

= signal light is permanently on

= signal light is flashing

Signal lights

Description Explanation Remedy/reference

Green Red

Pump is not running. Voltage supply to pump has been cut off. Re-establish correct volt-

age supply.

Normal operation

Pump is running. 1. Normal operational state. The pump is keeping up

the pressure according to the setpoint set.

–

2. Pump is running but not as the expected pump type.
Cause: Configuration error

Check the automatic con­figuration of the terminal
box.
See

A1.

3. Pump is running but making noise.
Cause may be:

- Air in the pump

- Inlet pressure too low.

Vent t he pump.
Increase the inlet pressure.

4. Pump is running at too low or high pressure. • Is the pressure set cor-

rect?

• Check the external 0­10 V signal.
See

A2.

Normal operational stoppage

Pump is not running. Pump has been stopped...

­by means of the operating button

-

-via R100 -

- via Grundfos GENIbus -

- by the pump start/stop function.
(Input on terminals STOP - is open meaning that
5 VDC can be measured across the terminals.)

-

Pump is not running. Pump has been stopped due to:

1. Supply voltage outside specified range - automatic
restart.

Re-establish correct volt­age supply.

2. Pump blocked or overloaded - manual restart. Remove blockage/reduce

load.

3. Frequent restarts ­manual restart after stop.
The pump starts and stops at short intervals until it
stops permanently. Replace the terminal box.

4. Fatal fault ­Cause may be:

- Terminal box defective

- Stator winding defective

Automatic and manual restart have been factory-set.

- Replace the terminal box.

- Replace the stator.

9 / 15

Normal operation + indication of fault

Pump is running at nor­mal performance.

Pump has been stopped due to fault and has restarted
automatically.

1. GENI module (if installed)
Max., min., 0-10 V inputs do not react. Fault in internal communi-

cation to the module, see

B1.

2. LON module (if installed).
Pump does not react to changes from the LON input. Fault in internal communi-

cation to the module, see

B1.

3. Setpoint changes cannot be stored. See B2.

4. No signal is registered from the HALL sensor in the
stator.

See B3.

Normal operational stoppage + indication of fault

Pump is not running. Pump has been stopped...

-

by means of the operating button

-via R100

- via Grundfos GENIbus

- by the pump start/stop function.

Pump can run, however, even if there has previously been
a fault.

1. GENI module (if installed).
Max., min., 0-10 V inputs do not react. Fault in internal communi-

cation to the module, see

B1.

2. LON module (if installed).
Pump does not react to changes from the LON input. Fault in internal communi-

cation to the module, see

B1.

3. Setpoint changes cannot be stored. See

B2.

4. No signal is registered from the HALL sensor in the
stator.

See

B3.

Legend for signal lights:

= signal light is off.

= signal light is permanently on

= signal light is flashing

Signal lights

Description Explanation Remedy/reference

Green Red

10 / 15

A1

A2

Description

Pump is running but not as the expected pump type.

Explanation

Configuration error
In case the terminal box cannot identify the stator type, the pump will run default as a 40-120 or a 65-120.

Check/remedy

Check by means of R100 which pump type the terminal
box has registered:

1. Switch R100 to service mode.

2. Go into the GENI menu in the display on the right.

3. Enter code 13.

R100 will now show which pump type the terminal box has registered. Check that the indication corresponds to
the actual pump type.
In case of error in the stator coding, the indication will be "ERR".

Is the pump type correct?

YES:

NO:

Fault is not due to a configuration error, but
possibly to a setting error or a system fault.
Check the stator coding according to the
drawing.

See

C2.

In new R100 software updates the pump type can be read in the start-up display.

Description

The twin-head pump does not control its performance optimally.

Explanation

Configuration error
The terminal box uses a wrong set of parameters.

Check/remedy

As the right and the left pump head do not have the same hydraulic performance, there are a right and left set of
parameters.
Correct configuration is carried out by means of the GENI modules where the Master module must always be fit­ted on the right pump head. (Terminals X and Q are short-circuited.) The modules must be product number
605945VO1 or higher.
If no GENI modules are used on the twin-head pumps, the configuration can be carried out by means of R100
Tur bo.

Description

Pump is running at too low or high pressure.

Explanation

Setpoint setting is incorrect.

Check/remedy

1. Is an external setpoint signal connected?

NO:
YES:

Set setpoint according to system specifications.
Check the connection to the GENI module and the external setpoint signal. Note that the termi­nals MIN - must be closed for the setpoint setting to work.

2.

Does the pump speed vary (listen to the pump) according to the input signals on terminals 10 V - ?

YES:
NO:

Pump is OK.
Proceed to point

B1.

11 / 15

B1

B2

B3

Description

Pump is running at normal performance.

Explanation

Pump has been stopped due to fault and has restarted automatically.
The fault may be due to fault in the GENI module or the LON module.

Check/remedy

1. Is the GENI module connected?

YES:
NO:

Proceed to points 2, 3 and 4.
Proceed to point 5.

2.

Short-circuit terminals MAX - .
Is the MAX diode on?

YES:
NO:

GENI module is OK.
Replace the GENI module.

3.

Short-circuit terminals MIN - .
Is the MIN diode on?

YES:
NO:

GENI module is OK.
Replace the GENI module.

4. Change the signal to the 0-10 V input.
Does the pump change speed accordingly (listen to the pump)?

YES:
NO:

GENI module is OK.
Replace the GENI module.

5. LON module is connected.
Get assistance from the LON system administrator to change the operating conditions of the pump.
Does the pump react to this?

YES:
NO:

LON module is OK.
Replace the LON module.

Description

Pump is running at normal performance.

Explanation

The fault may be that setpoint changes cannot be stored.

Check/remedy

Change the setpoint by means of the operating buttons.
Is the new setting saved when the supply voltage is switched off (the pump is completely off) and then switched
on again?

YES:
NO:

Setpoint function is OK.
Replace the terminal box.

Description

The pump is running at reduced performance and cannot be controlled.

Explanation

No signal is registered from the HALL sensor in the stator.

Check/remedy

Test the HALL sensor in the stator by means of a multimeter according to the description under

C1.

Sensor OK?

YES:
NO:

Replace the terminal box.
Replace the stator.

12 / 15

C1

The HALL sensor in the stator can be tested by measuring the winding resistance using an ordinary multime­ter. The test is more than 95% reliable.

All three measurements must be OK.

≥ 1.7 MΩ

Approx. 21 kΩ≥ 1.7 MΩ

ID 1 ID 2 ID 3 GND

135 7 9 11 1315

2 4 6 8 10 12 14

UV W X Y Z

Wire colours from HALL
sensor in stator

Black Red White

Å

HALL sensor in stator

TM02 8950 1104

Fig. 5 Numbering of the pump's terminal block

15

14

1

2

3

-

-

-

+

+

+

13 / 15

C2

Comments to the diagram:

"O" indicates that the coding wire must be connected to the terminal block of the stator (Magmate).
All combinations are to be connected to GND (13).
Combination 1 is not allowed (corresponds to a situation where no terminal box fitted).
Combination 8 is free for a future pump type.

HALL sensor in stator

"+5V" Output

Black Red White

Å

Wire colours

ID 1 ID 2 ID 3 GND

13579111315

2 4 6 8 10 12 14

UVWXY Z

TM02 8950 1104

Fig. 6 Numbering of the pump's terminal block

1. Coding definition

Combination Pump ID 1 (1) ID 2 (3) ID 3 (5) GND (13)

1. Undefined No connections

2. 32-120 O O

3. 40-120 O O

4.50-60 OOO

5. 65-60 O O

6. 50-120 O O O

765-120 O O O

8UndefinedOOOO

15

14

1

2

3

14 / 15

3.3 Fault indications via R100 fault log

The table shows the fault log possibilities in prioritized order.
If two faults occurs at the same time, the fault with the highest priority will be shown!

* Depending on the expansion module.

Prior-

ity

Code

(faul

t log)

Fault indication

Pump

reaction

Cause Remedy Start after fault

R100 PMU 2000

151

Pump
blocked

Blocked Stopped • Motor, rotor, impeller or

pump blocked

• Fault in terminal box

• Disassemble pump and
remove blockage.

• Replace the terminal
box.

The fault must be reset man­ually before the pump can
run.

373

Internal
fault

Fault Stopped The terminal box current

limit has been exceeded
which may be caused by:

• Fault in the terminal
box

• Fault in the stator

• Replace the terminal
box.

• Replace the stator.

Pump will start automati­cally when the fault has dis­appeared and the red indica­tor light is no longer on.
The pump tries to restart
once every minute.

467

Overtem­perature

Fault Stopped A too high temperature has

been measured in the
pump, which may be caused
by:

• Too high motor temper­ature due to stator fault

• Extremely high liquid
temperature

•Extremely high ambi­ent temperature

• Fault in the terminal
box

• Replace the stator.

• Reduce the liquid tem­perature.

• Reduce the ambient
temperature.

• Replace the terminal
box.

Pump will start automati­cally when the fault has dis­appeared and the red indica­tor light is no longer on.

540

Undervolt­age

Undervolt­age

Stopped The supply voltage from

mains is too low.

Check that the supply volt­age is in accordance with
the data on the nameplate.

Pump will start automati­cally when the fault has dis­appeared and the red indica­tor light is no longer on.

632

Overvoltage Overvoltage Stopped The supply voltage from

mains is too high.

Check that the supply volt­age is in accordance with
the data on the nameplate.

Pump will start automati­cally when the fault has dis­appeared and the red indica­tor light is no longer on.

790

Internal
fault

No fault
indication

Pump is
running.

The terminal box registers
no signal from the HALL sen­sor in the stator.

• Replace the stator

• Replace the terminal
box.

When the fault has disap­peared, the red indicator
light goes out automatically.

875

Internal
fault

No fault
indication

Pump is
running.

Too low DC voltage meas­ured in the terminal box.

• Reset the fault indica­tion.

• If the fault re-occurs, re­place the terminal box.

When the fault has disap­peared, the red indicator
light goes out automatically.

983

Internal
fault

No fault
indication

Pump is
running.

Fault in the storing of set
values (pressure) or meas­ured values (hour counter)
in the internal memory of
the terminal box.

• Cut off the supply volt­age, wait for approx. 1
minute, then cut in the
supply voltage again. A
new setpoint has now
been stored, and if no
fault is indicated, the
fault was temporary.

• If the fault re-occurs, re­place the terminal box.

Once it has occurred, the
fault will be indicated peri­odically.
See "Remedy".

10 152

Fault in
module
communi­cation

No fault
indication

Pump is
running.

The terminal box cannot
communicate with the
module fitted (GENI or LON).
(The fault also occurs if the
module is removed while
the pump is operating.)

• Check that the connec­tion between module
and terminal box is OK.
See point 3 in section

B1.

When the fault has disap­peared, the red indicator
light goes out automatically.

11 *

Fault in
module

No fault
indication

Pump is
running.

The terminal box has
received a feedback from
the expansion module fit­ted. There is a fault in the
expansion module.

• Replace the expansion
module.

When the fault has disap­peared, the red indicator
light goes out automatically.

15 / 15

4. Winding resistance

Pump

type

Ter mina l num ber

2-8 4-10 6-12

32-120 5.0 Ω 5.0 Ω 5.0 Ω

40-120 5.0 Ω 5.0 Ω 5.0 Ω

50-60 11.7 Ω 11.7 Ω 11.7 Ω

50-120 3.7 Ω 3.7 Ω 3.7 Ω

65-60 11.7 Ω 11.7 Ω 11.7 Ω

65-120 3.7 Ω 3.7 Ω 3.7 Ω