instructions carefully. Installation and service
work must comply with local regulations and
accepted codes of good practice.
Observe the safety instructions in the installation
and operating instructions for the product.
1. Symbols used in this document
Warning
If these safety instructions are not observed,
it may result in personal injury.
Warning
If these instructions are not observed, it may lead
to electric shock with consequent risk of serious
personal injury or death.
Warning
The surface of the product may be so hot that
it may cause burns or personal injury.
If these safety instructions are not observed,
it may result in malfunction or damage to the
equipment.
Notes or instructions that make the job easier
and ensure safe operation.
Page
10
14
14
15
17
20
23
25
26
2. General information
These service instructions apply to MGE 71, MGE 80 and
MGE 90, models H and I.
3
3
3
Position numbers of parts (digits) refer to drawings and parts lists;
position numbers of tools (letters) refer to section 5. Service
4
tools.
4
Electrical parts must only be serviced by Grundfos or an
5
authorised service workshop.
5
5
5
5
5
6
7
Before dismantling
7
7
8
8
8
8
9
• Close the isolating valves, if fitted, and make sure that they
cannot be accidentally opened.
• Before starting work on the product, let the product and
pumped liquid cool off.
During assembly
• Lubricate and tighten screws and nuts according to
section 3. Torques and 4. Secondary materials.
After assembly
• If analog or digital inputs, the relay output or the CIM module
has been removed from the functional module, you must
check the communication with external units after service. See
section 7.14 Configuring the controller.
The installation and operating instructions for
this product and for the system which it is part of
must be available during service of the product.
Warnin g
Use personal protective equipment if there is a
risk of getting into contact with the pumped
liquid.
Observe local regulations.
Warnin g
Switch off the power supply and make sure that it
cannot be accidentally switched on. The power
supply must be switched off for at least five
minutes before you start working on the motor.
Check that other pumps or sources do not force
flow through the pump even if the pump is
stopped. This will cause the motor to act like a
generator, resulting in voltage on the terminals.
3. Torques
Pos.DesignationType
152
178Tx3016/10 x 605 - 6*
185Tx3016 x M65 - 6
192Tx3014 x 65 - 6*
251dTx2550 x M55 - 6*
Torx screw
268Tx 2512 x M53.5 - 4
273aTx2032 x M41 - 1.3
277aTx2032 x M41 - 1.3
286Tx4021 x M72.2 - 2.7
288aTx20M41 - 1.3
289aTx3014 x 65 - 6
291UnionM20M20 x 1.51 - 1.3
* Screws of new terminal boxes must be tightened to 7-8 Nm.
Tx2512 x M53.5 - 4
Dimensions
[mm]
English (GB)
Torque
[Nm]
3
Page 4
Torques for terminals
English (GB)
TerminalThread
L1, L2, L3, L, NM41.8
NC, C1, C2, NOM2.50.5
1- 26, A, Y, BM20.5
4. Secondary materials
Pos.Designation
156c
Castrol LMX grease0.100RM4311159d
159e
5. Service tools
Standard tools
ABC
DEF
GH I
JKL
Quantity
[kg]
Max. torque
[Nm]
Product
number
Pos. DesignationFor pos.
Standard tools
AScrewdriver156, 252bStraight slot, 8 mm
BScrewdriver273b, 502 Straight slot, 3 mm
Screwdriver
Screwdriver
C
Screwdriver
Screwdriver286Torx 40
Ratchet spanner with
D
socket
ETorque screwdriver-0.5 - 4 Nm
F+G Torque wrench-4-20 Nm
HBits kit
Plastic hammer or
I
press
JSoft jaws-For vice
Locking-ring pliers,
internal ring
K
Locking-ring pliers,
external ring
LAntistatic service kit-96884939
MBearing heater153, 154
Special tools
Punch156c
Punch156c
N
Punch156c
Puller153, 154
O
Puller + special arms172
273a,
277a, 288a
152, 268,
251d
178, 185,
192, 289a
J, K17 mm
152, 178,
185, 251d,
268, 273a,
277a, 286,
287a,
288a, 289a
156
187∅50 - 65 (62) mm
188∅20 - 30 (25) mm
Further
information
Tor x 2 0
Tor x 2 5
Tor x 3 0
Tx20, Tx25, Tx30,
Tx40
1300 N
(axial force)
∅/∅37.8/20.5
98394718
∅/∅44/25.5
98394719
∅/∅60/30.5
98394720
98394731
M
Special tools
NO
4
Page 5
6. Megging
Caution
Caution
Caution
Note
Caution
Note
Caution
Caution
An installation with MGE motors must not be
megged as this may damage the built-in
electronic parts.
Motor windings may, however, be megged if the
terminal box has been removed.
Never measure between two terminals.
1. Disconnect the power supply.
2. Remove the terminal box.
See section 7.9 Replacing the terminal box.
3. Measure between terminals T1, T2, T3 and earth. As windings
are star-connected, fault in a winding will show when
measuring all terminals.
4. Replace the entire motor unit in case of fault.
See also measurement of winding resistances in section
8.4 Power module.
5. Fit the terminal box.
See section 7.9 Replacing the terminal box.
6. Switch on the power supply.
7. Start the pump.
English (GB)
TM05 7021 0413
Fig. 2 Removing the battery
4. Insert the new battery with the positive pole upwards.
The new battery must comply with the battery
directive (2006/66/EC).
5. Press the battery home with a finger.
6. Fit the terminal box cover. See section 7.1 Replacing the terminal box cover.
Max. test voltageMax. leakage current [mA]
1000 VAC/1500 VDC35
7. Replacing hardware
Always use an antistatic service kit when
handling electronic components. This will
prevent static electricity from damaging
components.
When unprotected, the component must be
placed on the antistatic cloth.
Fig. 1 Antistatic service kit
7.1 Replacing the terminal box cover
1. Loosen the four screws (pos. 251d) and remove terminal box
cover (pos. 251b).
2. Clean the sealing faces of terminal box (pos. 251a) and the
terminal box cover.
3. Fit the terminal box cover and cross-tighten the screws. Make
sure that the position of the terminal box cover is correct in
relation to the control panel (pos. 290).
7.3 Fitting the antenna
1. Disconnect the power supply.
2. Remove the terminal box cover.
See section 7.1 Replacing the terminal box cover.
3. Remove blanking plug (pos. 252b) from the terminal box.
4. Fit union (pos. 291) in the terminal box.
5. Lead the antenna into the union from above and tighten the
top part (close to the wire).
6. Click the antenna wire onto the control panel (pos. 290).
The antenna wire is long enough to be fitted in both positions
of the control panel.
Make sure that the antenna wire is not sharply
bent or pinched when you fit the terminal box
cover.
7. Fit the terminal box cover.
See section 7.1 Replacing the terminal box cover.
7.4 Replacing the control panel
1. Disconnect the power supply.
2. Remove the terminal box cover.
TM05 1590 3211
See section 7.1 Replacing the terminal box cover.
3. Press and hold in the two locking tabs (fig. 3, pos. A) while
gently lifting the control panel (fig. 3, pos. B, and pos. 290).
The control panel can be turned 180 °.
7.2 Replacing the battery
Applies only to the FM300 functional module.
1. Disconnect the power supply.
2. Remove the terminal box cover. See section 7.1 Replacing the terminal box cover.
3. Insert a screwdriver under the battery (pos. 273b) and prise
the battery out of the isolation cover (pos. 277).
The old battery must be disposed off according
to the battery directive (2006/66/EC).
TM05 5353 3612
Fig. 3 Removing the control panel
4. Gently remove the plug for the control panel from functional
module (pos. 273).
5. Connect the plug for the new control panel to the functional
module.
6. Turn the control panel to the desired position (0 ° / 180 °).
Do not twist the flat cable by more than 90 °.
5
Page 6
7. Position the control panel correctly on the four rubber pins
A
B
C
2
3
1
English (GB)
(fig. 4, pos. C). Make sure that the locking tabs (fig. 4, pos. A)
are placed correctly.
Fig. 4 Fitting the control panel
8. Fit the terminal box cover.
See section 7.1 Replacing the terminal box cover.
7.5 Replacing the CIM module
1. Disconnect the power supply.
2. Remove the terminal box cover.
See section 7.1 Replacing the terminal box cover.
3. Remove the plug connection for the CIM module.
4. Remove the cover (pos. 287) of the CIM module by pressing
the locking tab (fig. 5, pos. A) and lifting the end of the cover
(fig. 5, pos. B). Then lift the cover off the hooks (fig. 5, pos. C).
8. Fit the new CIM module by aligning it with the plastic holders
and the connecting plug. Press home the module using your
fingers.
TM05 5355 3612TM05 7029 0413TM05 6711 5012
TM05 7023 0413TM05 7028 0413
Fig. 7 Align the CIM module with the connecting plug.
9. Fit the frame screw in the CIM module.
10. Fit the cover by leading the slits into the end with the plug
connection and clicking the locking taps onto the isolation
cover.
11. Press down the module using your fingers. Check that the
plug has been pressed home.
12. CIM 250 and CIM 270: Put the FCC label on the terminal box.
Fig. 5 Removing the cover of the CIM module
5. Remove the screw connecting the frame connection of the
CIM module to the functional module.
6. Insert a screwdriver at the three plastic holders and loosen
the CIM module from isolation cover (pos. 277). See fig. 6.
7. Gently lift the CIM module away from the isolation cover so
that the connecting plug is not damaged.
Fig. 8 Position of FCC label
13. Fit the terminal box cover.
See section 7.1 Replacing the terminal box cover.
Fig. 6 Removing the CIM module
6
Page 7
7.6 Replacing the isolation cover
The example below shows a three-phase motor.
1. Disconnect the power supply.
2. Remove the terminal box cover. See section 7.1 Replacing the terminal box cover.
3. Remove control panel (pos. 290) from isolating cover
(pos. 277). See section 7.4 Replacing the co ntrol panel .
4. Remove CIM module (pos. 502) from the isolation cover.
See section 7.5 Replacing the CIM module.
5. Pull up/out plug connections (pos. 266) using your fingers.
See fig. 9.
6. Remove screw (pos. 277a) from the isolation cover.
7. You can now remove the isolation cover from the terminal box.
Fig. 9 Removing the plug connections
8. Fit the new isolation cover on the terminal box.
Check that the isolation cover is not clamped.
9. Secure the isolation cover to the terminal box with the screw.
10. Push the plug connection into the relevant terminals. They are
marked so that they only fit in the right socket of the functional
module.
11. Fit the CIM module.
See section 7.5 Replacing the CIM module.
12. Fit the control panel. See section 7.4 Replacing the control panel.
13. Fit the terminal box cover.
See section 7.1 Replacing the terminal box cover.
7.7 Replacing the functional module
1. Disconnect the power supply.
2. Remove the terminal box cover.
See section 7.1 Replacing the terminal box cover.
3. Remove control panel (pos. 290) from isolating cover
(pos. 277). See section 7.4 Replacing the co ntrol panel .
4. Remove CIM module (pos. 502) from the isolation cover.
See section 7.5 Replacing the CIM module.
5. Remove isolating cover (pos. 277).
See section 7.6 Replacing the isolation cover.
6. Remove spacer (pos. 286) and screws (pos. 273a).
7. Gently lift the functional module (pos. 273) out of the power
module so that the connecting plug (pos. 275a) is not
damaged.
8. Pull the connecting plug out of the functional module
(or power module). See fig. 10.
Fig. 10 Removing the connecting plug from the functional
9. Insert the connecting plug into the new functional module with
10. Fit the functional module on the power module by means of
11. Fit the spacer on the module.
12. Gently push the connecting plug home.
13. FM300: Put battery in the module.
14. Fit the isolation cover.
15. Fit the CIM module.
TM05 6712 5012
16. Fit the control panel.
17. Fit the terminal box cover.
18. Calibrate the functional module with the power module.
module
the long end towards the module. Lead it through the module
and home.
the five screws. See the order of the screws on the functional
module.
See section 7.6 Replacing the isolation cover.
See section 7.5 Replacing the CIM module.
See section 7.4 Replacing the control panel.
See section 7.1 Replacing the terminal box cover.
See section 7.14 Configuring the controller.
7.8 Replacing the power module
If the power module is replaced, the entire bottom of the terminal
box must be replaced.
1. Disconnect the power supply.
2. Remove the terminal box cover. See section 7.1 Replacing the terminal box cover.
3. Remove control panel (pos. 290) from isolating cover
(pos. 277). See section 7.4 Replacing the control panel.
4. Remove CIM module (pos. 502) from the isolation cover.
See section 7.5 Replacing the CIM module.
5. Remove the isolation cover.
See section 7.6 Replacing the isolation cover.
6. Remove the functional module.
See section 7.7 Replacing the functional module.
7. Pull out plug connection (pos. 266).
8. Remove screws (pos. 178) from terminal box (pos. 251a) and
gently lift the terminal box off the motor (pos. 150).
9. Fit the new terminal box on the motor. Make sure that the plug
connections are aligned.
10. Cross-tighten the screws of the terminal box.
11. Fit the plug connection for power supply.
12. Fit the functional module.
See section 7.7 Replacing the functional module.
13. Fit the isolation cover.
See section 7.6 Replacing the isolation cover.
14. Fit the CIM module.
See section 7.5 Replacing the CIM module.
15. Fit the control panel.
See section 7.4 Replacing the control panel.
16. Fit the terminal box cover.
See section 7.1 Replacing the terminal box cover.
17. Calibrate the functional module with the power module.
See section 7.14 Configuring the controller.
English (GB)
TM05 6717 5012
7
Page 8
7.9 Replacing the terminal box
Note
Env.Type :
Serial no :
IPCL:
PF:
PB
FM
HMIEff
n max:
CIM
Wgt
:
DE
:
kg
NDE
:
T
amb
:
:
CA
V
~
P.C.
:
Made in Hungary
OUTPUT
VARIANT
INPUT
Type
:
P.N.
:
U in:
I
1/1 :
f
in
kW
Hz
P2
rpm
:::
:
:
:
:
o
DK - 8850 Bjerringbro, Denmark
Caution
Caution
English (GB)
1. Disconnect the power supply.
2. Remove the terminal box cover.
See section 7.1 Replacing the terminal box cover.
3. Disconnect all relevant wires.
4. Remove screws (pos. 178) from terminal box (pos. 251a) and
gently lift the terminal box off the motor (pos. 150).
5. Fit the new terminal box on the motor. Make sure that the plug
connections are aligned.
6. Cross-tighten the screws of the terminal box.
7. Move relevant modules to the new terminal box according to
the section above.
8. Connect all relevant wires.
9. Transfer data from the nameplate of the old terminal box to
the nameplate of the new one.
7.11 Replacing the fan
1. Disconnect the power supply.
2. Remove the terminal box. See section 7.10 Replacing the stator housing.
3. Remove screws (pos. 152) and lift off the fan cover (pos. 151).
4. Insert two screwdrivers close to the shaft and remove the fan
(pos. 156).
TM05 7022 0413
Fig. 12 Removing the fan
5. Push the fan on the shaft. Alternatively, gently knock the fan
onto the shaft (pos. 172) by means of a plastic hammer while
holding the drive end of the shaft against a solid surface.
6. Fit the fan cover on stator housing (pos. 150) and tighten
screws (pos. 152).
7. Fit the terminal box on the stator housing and cross-tighten
the screws.
7.12 Replacing the bearings
1. Disconnect the power supply.
2. Remove the stator housing from the terminal box.
See section 7.10 Replacing the stator housing.
3. Remove the fan. See section 7.11 Replacing the fan.
4. Remove seal rings (pos. 156c) from shaft (pos. 172).
5. Remove screws (pos. 185) holding the flange (pos. 156b).
6. Place the puller on the non-drive end of the stator housing
(pos. 150). See fig. 13.
7. Gently pull the rotor (pos. 172) out of the stator, holding rotor
and flange to prevent damage.
Keep metallic dust away from the rotor as the
rotor is magnetic.
Fig. 11 Transferring data to new nameplate
10. Fit the terminal box cover.
See section 7.1 Replacing the terminal box cover.
7.10 Replacing the stator housing
1. Disconnect the power supply.
2. Remove screws (pos. 178) and take terminal box (pos. 251a
and 251b) out of stator housing (pos. 150).
Support the terminal box when you remove the
motor.
3. Remove the stator housing according the service instructions
of the system.
4. Install the stator housing in the system according to the
service instructions of the system.
5. Fit the terminal box on the stator housing and cross-tighten
the screws.
8. Remove gasket (pos. 156d) from the flange.
TM05 6954
9. Wrap a piece of cardboard or similar material around the
magnetic rotor part to protect it against damage and dirt.
10. Put the flange in a vice with soft jaws.
11. Remove bearing (pos. 154) with a puller.
12. MGE 90: Remove locking ring (pos. 187) from the flange.
13. Remove the rotor from the flange and place the rotor in the
vice.
Do not tighten the vice on the bearing journal.
14. MGE 90: Remove locking ring (pos. 188) from the shaft.
15. Remove bearing (pos. 153) with a puller.
TM05 7027 0413
Fig. 13 Pushing the rotor out of the stator
8
Page 9
16. Clean the bearing journal with a clean cloth.
Caution
Caution
Note
17. Heat the new bearing (pos. 153) to maximum 110 °C.
Follow the instructions of bearing and bearing
heater.
18. Fit the heated bearing (pos. 153) on the shaft (pos. 172).
Warning
Use heat-resistant gloves.
19. MGE 90: Fit locking ring (pos. 188) on the shaft.
20. Place the flange in the vice and clean the bearing seat with a
clean cloth.
21. Clean the bearing and fit the rotor in the flange.
22. MGE 90: Fit locking ring (pos. 187) so that the bearing is held
by the flange.
23. Clean the bearing journal in the non-drive end with a clean
cloth.
24. Heat bearing (pos. 154) to maximum 110 °C.
Follow the instructions of bearing and bearing
heater.
25. Fit the heated bearing (pos. 154) on the shaft (pos. 172).
Warning
Use heat-resistant gloves.
7.13 Replacing IP55 seal rings with IP66 rings
1. Disconnect the power supply.
2. Remove the stator housing from the terminal box.
See section 7.10 Replacing the stator housing.
3. Remove the fan. See section 7.11 Replacing the fan.
4. Remove seal rings (pos. 156c) from shaft (pos. 172).
5. Lubricate gamma ring (pos. 159d) and fit it on the drive end of
the shaft.
6. Lift the motor so that the non-drive end of the shaft rests on a
solid, vibration-free surface.
7. Gently knock the ring home with the relevant punch.
The distance between flange (pos. 156b) and ring must be 0.8
to 1.3 mm.
The design of the punch ensures correct
tolerances.
8. Support the motor so that it rests on the drive end of the shaft.
9. Lubricate gamma ring (pos. 159e) and fit it on the non-drive
end of the shaft.
10. Gently knock the ring home with the relevant punch.
The distance between stator housing (pos. 150) and ring must
be 0.8 to 1.3 mm.
11. Fit fan and cover.
See section 7.11 Replacing the fan.
12. Fit the terminal box.
See section 7.10 Replacing the stator housing.
English (GB)
26. Remove the cardboard from the rotor when the bearings have
cooled down.
27. Fit the gasket (pos. 156d) on the flange.
28. Check that the corrugated spring water (pos. 158) is correctly
fitted in the stator housing.
29. Gently insert the rotor into the stator.
Warning
Watch your fingers when you insert the rotor, as
the magnet will pull rotor and stator together with
big force.
30. Unscrew the puller to slowly insert the rotor into the stator.
Press flange and stator together when the bearing (pos. 154)
has engaged with the stator housing. Check that the drain
hole of the flange faces downwards.
31. Remove the puller and cross-tighten screws (pos. 185).
32. Lubricate shafts ends and fit seal rings.
33. Check that the shaft can rotate freely.
34. Fit fan and cover.
See section 7.11 Replacing the fan.
35. Fit the terminal box.
See section 7.10 Replacing the stator housing.
9
Page 10
7.14 Configuring the controller
Caution
English (GB)
The terminal box is configured from factory for the intended
application and pump type. The configuration file number appears
from the terminal box configuration label which is placed inside
the terminal box. See fig. 14.
Fig. 14 Position of configuration label
If the terminal box, functional module or power module is
replaced or mounted on another motor, it must be reconfigured.
Use PC Tool E-products for that purpose. To establish connection
to the motor, use Grundfos GO Remote MI 301 or PC Tool Link.
7.14.1 Connection to motor by means of Grundfos GO
Remote MI 301
Configuration can be done in three ways:
• Radio Scan
• Direct Connect
• IR Connect.
IR Connect
1. Switch on the power supply to the pump.
2. Connect the MI 301 to the PC.
3. Start the PC Tool. The first time the program is started, the
message "No COM port selected" will be shown. Click [OK].
Fig. 15 No COM port selected
4. Select "Preferences" in the main menu under "Files".
TM05 5967 4212
5. Open the dropdown menu "Select interface" and select
"MI 301". See fig. 16.
If the power supply to the pump is interrupted
during configuration, the update will be lost.
This will, however, not damage the controller.
Start from the beginning.
Equipment
• PC Tool E-products, version 14.00.00 or newer
• MI 301 (PN 98046408) with USB cable.
Fig. 16 Selecting the user interface
6. Open the dropdown menu "Select port" and select the port
"PCTool-Link". See fig. 16. Click [Apply].
7. Point the MI 301 at the IR eye of the pump.
Distance: max. 20 cm. See fig. 17.
Fig. 17 IR connection via MI 301
8. Click [IR Connect]. See fig. 18. Wait while connection to the
pump is established (10-20 seconds).
Fig. 18 IR Connect
9. To find the GSC file, see section 7.14.3 Configuration with PC Tool E-products.
10
Page 11
Radio Scan
Note
1. Switch on the power supply to the pump.
2. Connect the MI 301 to the PC.
3. Place the MI 301 at a distance of maximum 10 metres from
the pump.
4. Start the PC Tool. The first time the program is started, the
message "No COM port selected" will be shown. Click [OK].
Fig. 19 No COM port selected
5. Select "Preferences" in the main menu under "Files".
6. Open the dropdown menu "Select interface" and select
"MI 301". See fig. 20.
9. Mark the pump to be connected and click [Connect].
See figures 22 and 23.
English (GB)
TM05 7211 0713TM05 7044 0513TM05 7212 0713
Fig. 22 Selection of unit
TM05 6928 0313TM05 7037 0413TM05 6932 0313
Fig. 23 Establish connection to the pump
10. Click the button for radio communication. See fig. 24. Status
in the PC Tool will change to "Connected". See fig. 25.
Fig. 20 Selecting the user interface
7. Open the dropdown menu "Select port" and select the port
"PCTool-Link". See fig. 20. Click [Apply].
8. Click [Radio Scan]. See fig. 21. Wait until connection has
been established to the products the MI 301 can communicate
with (10-20 sec.).
Fig. 24 Connection via radio communication
Click [Connect] if the pump is "Unlocked".
See fig. 22.
TM05 7039 0412
Fig. 25 Connection established
11. Find the GSC file for the motor by means of
section 7.14.3 Configuration with PC Tool E-products.
Fig. 21 Radio Scan
11
Page 12
Direct Connect
A Y B
English (GB)
1. Switch on the power supply to the pump.
2. Connect the MI 301 to the PC.
3. Place the MI 301 at a distance of maximum 10 metres from
the pump.
4. Start the PC Tool. The first time the program is started, the
message "No COM port selected" will be shown. Click [OK].
Fig. 26 No COM port selected
5. Select "Preferences" in the main menu under "Files".
6. Open the dropdown menu "Select interface" and select
"MI 301". See fig. 27.
7.14.2 Connection to motor via PC Tool Link
Equipment
• PC Tool E-products, version 14.00.00 or newer
• Grundfos PC Tool Link
• GENIbus cable (RS-485).
Procedure
1. Disconnect the power supply.
2. Remove the terminal box cover.
See section 7.1 Replacing the terminal box cover.
3. Connect PC Tool link to the GENIbus terminals on the motor
by means of the GENIbus cable.
7. Open the dropdown menu "Select port" and select the port
"PCTool-Link". See fig. 27. Click [Apply].
8. Click [Direct Connect]. See fig. 28. Wait until connection has
been established to the products the MI 301 can communicate
with (10-20 sec.).
4. Connect the mains supply to the pump.
Fig. 28 Direct Connect
9. Click the motor button for radio communication.
Connection has now been established.
Fig. 29 Connection via radio communication
10. Find the GSC file for the motor by means of
section 7.14.3 Configuration with PC Tool E-products.
12
Page 13
7.14.3 Configuration with PC Tool E-products
4
1
2
3
5
6
Find the desired configuration file in PC Tool E-products in this
way:
1. Start the PC Tool.
2. Find the desired configuration file in PC Tool E-products in
one of these ways:
• Search by the configuration number. See fig. 31.
• Search on the basis of the application that MGE is part of.
• Choose the file position on the PC hard disk via the PC Tool
E-products browser.
Searching by configuration number
English (GB)
1. Select "Standard configuration".
2. Select "Number".
3. Enter a number or part of a
number.
4. Click [Search now].
Fig. 31 Configuration of terminal box by searching by the GSC number
3. End the PC Tool and remove the MI 301.
5. Select the configuration file in the
list of search results.
6. Click [Send] to download the
configuration file to the MGE.
TM04 2563 2608
13
Page 14
8. Fault finding
Note
Note
English (GB)
8.1 General information
1. Check the mains supply to the pump.
2. Read fault messages by means of Grundfos Eye,
Grundfos GO Remote, PC Tool or R100.
Make a copy of motor settings.
3. If possible, test if the motor can run without load. Remove the
coupling to the pump (if possible) and set the operating signal
to max. by means of PC Tool, Grundfos GO Remote or R100.
You can reset a fault indication in the following ways:
• When the fault cause has been eliminated and the pump is
switched on, the pump will revert to normal duty.
• If the fault disappears by itself, the fault indication will
automatically be reset.
The fault cause will be stored in the pump alarm or warning log.
Fault indications via Grundfos Eye
See the indication of motor status by means of the Grundfos Eye
and the contact positions of signal relays in the installation and
operating instructions for the MGE motor.
Fault indications via Grundfos GO Remote
See the description of the Grundfos GO Remote control panel
and possibilities of communication in the installation and
operating instructions for the MGE motor.
IMG_0042 & IMG_0043
Fig. 33 Alarm and warning log of the MI 201
For a detailed description the fault, see display "Assisted fault
advice".
Fig. 32 Alarms and warnings shown on the MI 201
Fig. 34 Detailed fault description
Fault indications via R100
The R100 must be updated to be used for
IMG_0041
See the description of the R100 display and possibilities of
MGE 71, MGE 80 and MGE 90, model H/I.
communication in the installation and operating instructions for
the MGE motor.
IMG_0047
14
Page 15
8.2 Fault indications
The fault indication below can be read by means of the number in
brackets, as text or as status indications on the control panel,
depending on the equipment available.
Grundfos EyeCondition/causeRemedy
External fault (3)
An external signal has reported an
"External fault" to the digital input set up
Two opposite red indicator lights
flashing simultaneously.
One yellow indicator light permanently
on.
One yellow indicator light permanently
on.
for this function.
Too many restarts (4)
The pump has restarted to many times in
connection with a fault that forced the
pump to stop and restart automatically.
Overvoltage (32)
Supply voltage to the pump too high.
Undervoltage (40)
Supply voltage to the pump too low.a) Check that the power supply is within the
Overload (49)
The motor is overloaded and has
automatically reduced the speed and thus
the pump performance.
Blocked pump (51)
The pump is blocked.
Pump communication fault (10)
Communication fault between this pump
and the other pumps of the multipump
system.
Forced pumping (29)
Other pumps or sources force flow
through the pump even if the pump is
stopped.
Dry running (56, 57)
No water at the pump inlet or the water
contains too much air.
Internal fault (72, 83, 85, 155, 157, 163)
Internal fault in the pump electronics.
High motor temperature (65, 66)
1. The motor temperature is too high.a) Check that the ambient temperature is within the
Internal communication fault (76)
1. Communication fault between different
parts of the electronics.
Soft pressure buildup, timeout (215)
1. The system has been in the mode
"soft pressure buildup" longer than the
set time limit.
English (GB)
Check the parameter or the unit reporting the
external fault. Correct the fault.
a) Check the warning and alarm log for faults that
caused to many restarts.
b) Replace the pump if the fault cannot be found.
a) Check that the power supply is within the
specified range.
specified range.
a) Check that the viscosity and temperature of the
pump liquid is within the limits for the pump.
If not, change the properties of the liquid.
b) Dismantle the pump, and remove any foreign
matter or impurities preventing the pump from
rotating.
c) If none of the above causes are present, replace
the pump.
a) Dismantle the pump, and remove any foreign
matter or impurities preventing the pump from
rotating.
a) Check that all pumps of the multipump system
have been correctly set up.
a) Check the system for defective non-return
valves and replace, if necessary. Check the
system for correct position of non-return valves,
etc.
a) Prime and vent the pump before a new start-up.
Check that the pump is operating correctly.
If not, replace the pump.
a) Replace the functional module, power module or
terminal box.
specified range.
b) Check that the pump is not covered by dust, dirt
or other foreign matter which reduces the air
cooling of the pump.
c) If none of the above causes are present, replace
the motor.
a) Replace the terminal box.
a) Check the system for leakages.
15
Page 16
English (GB)
One yellow indicator light rotating in
the direction of rotation of the motor
when seen from the non-drive end.
Grundfos EyeCondition/causeRemedy
Replace motor bearings (30)
1. The bearings must be replaced.a) Follow the instructions for the pump.
See section 7.12 Replacing the bearings.
Internal sensor fault (88)
1. The pump is receiving a signal from
the internal sensor which is outside
the normal range.
Pt100/1000 sensor 1 (91) and 2 (175)
1. Pt100/1000 input 1 is receiving a
signal which is outside the normal
range.
Supply fault, 5 V (161)
1. Fault in the output voltage to sensor or
potentiometer.
Supply fault, 24 V (162)
1. Fault in the output voltage.a) Check the output voltage and wire.
Signal fault, LiqTec-sensor (164)
1. The pump is receiving a signal from
the LiqTec sensor which is outside the
normal range.
Signal fault, sensor 1 (165), 2 (166) and 3 (167)
1. Analog input 1, 2 or 3 is receiving a
signal which is outside the normal
range.
Limit 1 exceeded (190) and limit 2 exceeded (191)
1. Limit 1 or 2 has reached the limit for
warning/alarm.
a) Check that the plug and cable are connected
correctly to the sensor. The sensor is on the
back of the pump housing.
b) Replace the sensor.
a) Check that the sensor resistance corresponds to
≈ 100 or 1000 ohm. If not, replace the sensor.
b) Check the sensor cable for damage.
c) Check the cable connection at the pump and at
the sensor. Correct the connection, if required.
d) Replace the sensor.
a) Check the output voltage and wire to sensor or
potentiometer.
a) Check that the plug and cable are connected
correctly to the sensor.
b) Replace the sensor.
a) Check the setup of the analog input corresponds
to the sensor output as regards electrical
(0.5 - 3.5 V, 0-5 V, 0-10 V, 0-20 mA or 4-20 mA).
If not, change the setting, or replace the sensor
with one that matches the setup.
b) Check the sensor cable for damage.
c) Check the cable connection at the pump and at
the sensor. Correct the connection, if required.
d) Check if the sensor has been removed, but the
input was not deactivated.
e) Replace the sensor.
a) Identify and remove the fault cause.
16
Page 17
8.3 Functional module
D41
D26
Warning
The terminals of the power module are live.
Relay RL1 may also be live.
Warning
Measuring equipment must be free of static
electricity or have same potential as the motor
before being used for measurement without
isolation cover.
1. The status diode of the functional module flashes
40-80 times/minute when the software is running correctly.
See fig. 35. The functional module can only function if the
power module is in operation, as the power module supplies
voltage to the functional module.
See section 8.3 Functional module.
StatusFault
The microprocessor is frozen.
Permanently on.
Light off.
Flashing
40-80 times/minute.
The functional module is
defective.
See section 7.7.
The functional module is
defective.
See section 7.7.
The processor of the functional
module is functional.
English (GB)
Fig. 35 Status diode of functional module
2. If the light diode is flashing, the functional module is working
correctly. The fault may then be in the control panel.
See section 7.4 Replacing the control panel.
TM05 7124 0513
17
Page 18
3. If the status diode of the functional module is off, check if the
1
ref.
2
3
4
5
6
6
5
J15
VFE
Note
English (GB)
power module supplies voltage by measuring 8.5 VDC on the
VFE plug connection between functional module and power
module. If no voltage is measured, the connection between
the modules or the power module is defective.
If the VFE voltage to the functional module is okay, check if
the voltage between the reference point and the other
measuring points is okay. The voltage values apply to an
operating motor.
TM05 7121 0613
Fig. 36 Measuring voltage on the functional module
Replace the functional module if the voltage is not correct.
See section 7.7 Replacing the functional module.
MinimumNominalMaximum
Control voltage [VDC]
8.5
18
Page 19
8.3.1 Checking input and outputs
Note
A
P
V
+ 5 VAI
ȍ
DI
A12 mA
GND
DO
V
0-5 V
GND
Make a copy of motor settings.
Pt100/1000
Use a 100 Ω resistance and decide on the basis on the motor
settings which value this resistance will show in the display when
connected to the terminals instead of the Pt100/1000 sensor.
Analog input, AI
It is possible to measure on the analog input to determine if its
function is correct.
During current state, a 292 Ω resistance in the input converts a
current signal (e.g. 0-20 mA) from the sensor to a voltage signal
for the processor.
Measure the voltage across the input and read the current in the
circuit by means of Grundfos GO Remote or PC Tool. The current
value must be equal to voltage divided with resistance.
Alternatively, a milliammeter can be connected in series with the
circuit.
Digital input, DI
See the settings of the input in PC Tool.
Connect the digital input to frame (GND) by means of an
ammeter. The value measured must now be approximately
12 mA. Check that PC Tool shows a corresponding value.
English (GB)
TM05 7118 0613TM05 7118 0613
Fig. 40 Testing the digital input
Digital output, DO/open collector, OC
See the settings of the output in PC Tool.
Measure on the output. If the value in PC Tool differs from the
value measured with the measuring instrument, remove the load.
If the values still differ, the module is defective.
The voltage of an active output is approx. 5 V.
TM05 7115 0613TM05 7116 0613TM05 7117 0613
Fig. 37 Measuring on analog input
Next step is to test the input in voltage state. Change the setup of
the input to voltage state (0-10 V). Fit a jumper between terminal
5 (+5 V) and the analog input. 5 V must now be read be means of
PC Tool.
Fig. 41 Measuring voltage on the digital output
LiqTec sensor
Connect a new LiqTec sensor to check the input. Immerse the
sensor into water and take it up. The motor must now report fault
within 20 seconds.
Fig. 38 Testing the input during voltage state
Change the setup of the input to current state and measure on
the input using an ohmmeter. The resistance must be 292 Ω.
In voltage state the resistance will be 122 kΩ.
Signal relay
See the settings of the output in PC Tool.
Check if the relay reacts to the signals of the controller according
to the configuration of the controller.
CIM
Test the CIM module according to its manual.
Radio
If there are problems in the radio connection between
Grundfos GO Remote and the motor, remove the terminal box
cover. See section 7.1 Replacing the terminal box cover.
Replace the control panel if there is still no connection.
See section 7.4 Replacing the control panel.
Battery
Make the motor dead for a short period. When you switch on the
power to the pump again, the clock must show correct time in
Fig. 39 Measuring resistance in current and voltage state
relation to how long it was dead.
Control panel (HMI)
Analog output, AO
The analog input is protected against short-circuit and will shut
Check the flat cable to the functional module. Replace the control
panel if the connection is correct, and it did not solve the problem.
down the signal in case of short-circuit. If you suspect a
short-circuit, remove the load and compare the value read via
PC Tool with the value measured by means of the measuring
instrument.
If the values are not identical, the module is defective.
19
Page 20
8.4 Power module
Note
LED D54 5VLED D19 Micro Controller
LED D54 5VLED D7 Micro Controller
English (GB)
Warning
The terminals of the power module are live.
Warning
Measuring equipment must be free of static
electricity or have same potential as the motor
before being used for measurement without
isolation cover.
If reading of fault codes does not provide a clear answer as to
whether the power module is functioning correctly, you can
proceed as described below.
1. Check that the voltage to the module is within the limit values
stated on the nameplate. Check all phases of a three-phase
motor.
2. If there are signs of moisture in the terminal box, take
necessary precautions to prevent similar faults.
3. Check the two status diodes of the power module
(the functional module must be connected) by looking under
the power module from the side. Status diode D54 must be
permanently on when connected to mains. Status diode D7
(three-phase model) or D19 (single-phase model) flashes
when the functionality is correct. See table below.
It may be necessary to dim the light as the diode
light is weak.
Status, three-phaseFault
• The microprocessor is frozen.
• No initialising message from
the functional module.
D7 is permanently on.
Switch the power supply off and
on. If this does not solve the
problem, replace the power
module. See section 7.8.
D7 is off.
D7 is flashing
40-80 times/minute.
D54 is permanently on.
D54 is off.
The power module is defective.
See section 7.8.
The processor of the power
module is functional.
The processor of the power
module is functional.
The power module is defective.
See section 7.8.
Status, single-phaseFault
• The microprocessor is frozen.
• No initialising message from
the functional module.
D19 is permanently on.
Switch the power supply off and
on. If this does not solve the
problem, replace the power
module. See section 7.8.
D19 is off.
The power module is defective.
See section 7.8.
D19 is flashing
40-80 times/minute, and
The power module is functional.
D54 is permanently on.
D54 is off.
D19 and D54 are flashing
40-80 times/minute.
The power module is defective.
See section 7.8.
Short-circuit in the connection to
the functional module or in the
functional module.
TM05 7125 0613
Fig. 43 Status diodes of power module, three-phase
Fig. 42 Status diode of power module, single-phase
20
TM05 7126 0613
Page 21
4. The DC voltage across the capacitor of the intermediate
+
_
circuit on the single-phase power module can be measured to
make sure that the capacitor is not short-circuited. If the
function is correct, the voltage must be ≥ 350 V (at a mains
voltage of 230 V). See fig. 44. If not, the module is defective.
English (GB)
Fig. 44 Measuring the DC voltage on single-phase power board
TM05 7127 0613
21
Page 22
5. The DC voltage across the capacitors of the intermediate
DC+
GND
DC+GND
English (GB)
circuit on the three-phase power module can be measured to
make sure that the capacitors are not short-circuited. If the
function is correct, the voltage must be ≥ 566 V (at a mains
voltage of 400 V). See fig. 45. If not, the module is defective.
Fig. 45 Measuring the DC voltage on three-phase power board
TM05 7421 0913
22
Page 23
8.5 Winding resistance
As the motor is star-connected, the easiest way to measure the
winding resistance is to measure across two phases. Measure at
the coil temperatures stated in the table below. It may be
necessary to let the motor cool off if it has been running or if it
was stopped because of short-circuit or overload.
Measure between terminals T1 and T2, and between T2 and T3.
~
T1T2
T3
English (GB)
TerminalDescription
T1, T2, T3Input for the three phases
Fig. 46 Motor terminals
TM05 7024 0413TM05 7025 0413
Fig. 47 Wiring diagram
24
Page 25
9. Exploded view
English (GB)
Fig. 48 MGE 90
TM05 7026 0413
25
Page 26
10. Disposal
English (GB)
This product or parts of it must be disposed of in an environmentally sound way:
1. Use the public or private waste collection service.
2. If this is not possible, contact the nearest Grundfos company
or service workshop.
Subject to alterations.
26
Page 27
Argentina
Bombas GRUNDFOS de Argentina S.A.
Ruta Panamericana km. 37.500 Centro
Industrial Garin
1619 Garín Pcia. de B.A.
Phone: +54-3327 414 444
Telefax: +54-3327 45 3190
Australia
GRUNDFOS Pumps Pty. Ltd.
P.O. Box 2040
Regency Park
South Australia 5942
Phone: +61-8-8461-4611
Telefax: +61-8-8340 0155
GRUNDFOS Sarajevo
Trg Heroja 16,
BiH-71000 Sarajevo
Phone: +387 33 713 290
Telefax: +387 33 659 079
e-mail: grundfos@bih.net.ba
Brazil
BOMBAS GRUNDFOS DO BRASIL
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
Bulgaria
Grundfos Bulgaria EOOD
Slatina District
Iztochna Tangenta street no. 100
BG - 1592 Sofia
Tel. +359 2 49 22 200
Fax. +359 2 49 22 201
email: bulgaria@grundfos.bg