Grundfos PACOpaQ Installation And Operating Instruction Manual

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PACOpaQ™

HVAC Packaged Systems

Installation and Operating Instructions

GRUNDFOS INSTRUCTIONS

Table of Contents

English (US) Installation and operating instructions

Original installation and operating instructions.

CONTENTS

Page

1. Symbols used in this document 3

2. Terms and Conditions 4

2.1 The contract 4

2.2 Price 4

2.3 Payment terms 4

2.4 Acceptance and inspection 4

2.5 Title and risk of loss 4

2.6 Patent or trademark information 4

2.7 Changes 4

2.8 Cancellation or termination 4

2.9 Delivery and delays 4

2.10 Warranty 5

2.11 Technical documents 5

2.12 Limitation of liability 5

2.13 This company is an equal opportunity 5 employer

2.14 Law and arbitration 5

3. PACOpaQ system installation 6

3.1 General instructions 6

3.2 Lifting and rigging instructions 6

3.3 Storage 6

3.4 Bolt check instruction 6

3.5 Field connection 6

3.6 Assembly of packaged sections (if applicable) 7

3.7 Other package system requirements 7

4. Pump Installation-Mechanical 8

4.1 Pump Identication 8

4.2 Receiving 8

4.3 Temporary storage 8

4.4 Location 8

4.5 Horizontal pump foundation 8

4.6 Securing base plate 9

4.7 Vertical mounting instructions 9

4.8 Piping-general 9

4.9 Suction (inlet) piping 9

4.10 Discharge (outlet) piping 10

4.11 Shaft, sealing-general comments 10

4.12 Packing gland adjustment 10

4.13 Mechanical seals 10

4.14 Coupling alignment (LF) 11

4.15 Coupling alignment (LCS) 11

5. Pump Installation-electrical 11

5.1 Motors general 11

5.2 Installation wiring 11

6. Pump operation 12

6.1 Priming 12

6.2 Pre-start checklist 12

6.3 Motor rotation 12

6.4 Starting the pump 12

6.5 Voltage regulation 13

6.6 Pump shutdown 13

6.7 Short duration shutdown 13

6.8 Extended period shutdown 13

7. Pump Maintenance 13

7.1 Motor lubrication 13

7.2 Pump lubrication 14

7.3 Disassembly of pumps 14

7.3.1 Disassembly of liquid end 14

7.3.2 Disassembly of bearing frame (LF) 14

7.4 Seal replacement (LCS) 14

7.5 Wear ring replacement 15

7.6 Reassembly of pumps 15

7.7 Ordering parts 16

7.8 Type LF, cross section and parts list 17

7.9 Type LC, cross section and parts list 18

7.10 Type LCV, cross section and parts list 19

7.11 Type LCS, cross section and parts list

8. Pump Troubleshooting 21

8.1 Symptom 21

8.2 Possible causes 21

9. Grundfos CUE Variable Frequency Drive 22

9.1 CUE introduction 22

9.2 General description 22

9.3 Applications 23

9.4 References 23

10. CUE safety and warnings 23

10.1 Warning 23

10.2 Safety regulations 23

10.3 Installation requirements 23

10.4 Reduced performance under certain conditions 23

11. Identication 23

11.1 Nameplate 23

11.2 Packaging label 23

12. CUE installation-mechanical 23

12.1 Reception and storage 23

12.2 Transportation and unpacking 23

12.3 Space requirements and air circulation 24

12.4 Mounting 24

13. Electrical connection 24

13.1 Electrical protection 24

13.2 Mains and motor connection 25

13.3 Connecting the signal terminals 30

13.4 Connecting the signal relays 32

13.5

13.6 EMC-correct installation 34

13.7 RFI lters 34

13.8 Output lters 34

14. CUE operating modes 35

15. CUE control modes 35

15.1 Uncontrolled operation (open loop) 35

15.2 Controlled operation (closed loop) 36

16. Menu overview 37

17. Setting by means of the cotnrol panel 40

17.1 Control panel 40

17.2 Back to factory setting 40

17.3 Start-up guide 41

17.4 Menu GENERAL 45

Connecting the MCB 114 sensor input module 33

17.5 Menu OPERATION 45

7. Trouble Shooting

7.1 Symptom

7.2 Possible Causes

Caution

Note

17.6 Menu STATUS 46

17.7 Menu INSTALLATION 48

18. Setting by means of PC Tools E-products 55

19. Priority of setttings 56

19.1 Control without bus signal, local operating 56 mode

19.2 Control with bus signal, remote-controlled 56 operating mode

20. External control signals 56

20.1 Digital inputs 57

20.2 External setpoint 57

20.3 GENibus signal 57

20.4 Other bus standards 57

21. CUE Maintenance and service 57

21.1 Cleaning the CUE 57

21.2 Service parts and servie kits 57

22. CUE Troubleshooting 58

22.1 Warning and alarm list 58

22.2 Resetting of alarms 58

22.3 Indicator lights 58

22.4 Signal relays 58

23. Technical data 59

23.1 Enclosure 59

23.2 Main dimensions and weight

23.3 Surroundings 60

23.4 Terminal tightening torques 60

23.5 Cable length 61

23.6 Fuses and cable gauge size 61

23.7 Inputs and putputs 63

23.8 Sound pressure level 63

24. Disposal 63

25. CU 352 product description 64

25.1 Indicator lights 64

25.2 Terminals 64

25.3 Potentially explosive environments

26. Identication

27. CU352 installation 65

27.1 Location 66

27.2 Enclosure class 66

27.3 Terminals 66

27.4 Cables 66

28. CU 352 Installation-Mechanical 66

29. EMC-correct installation 67

29.1 Internal GENibus connection 68

29.2 Fieldbus communication interface 68 modules

29.3 Fitting the CIM module 69

30. CU 352 Startup 70

31. Technical data 70

32. Electrical data 70

32.1 Supply voltage 70

32.2 Power consumption 70

32.3 Circuit breaker 70

32.4 Backup fuse 70

32.5 Short-circuit protection 70

32.6 Digital inputs

32.7 Analog inputs

70 70

32.8 Digital outputs (relay putputs) 70

32.9 Conductors 70

32.10 USB port 70

32.11 Battery backup (UPS) 71

32.12 Terminal groups 71

33. Overview of inputs and outputs 72

34. CU 352 Maintenance 73

35. CU 352 Service

36. Replacing the CU 352 73

36.1 Replacing the CIM module

37. CU 352 Dimensions 73

38. CU 352 Disposal 73

39. Suctiondiuser-IOM 74

39.1 Installation 74

39.2 Operation and maintenance 74

39.3 Sectional drawing and components 74

1. Symbols used in this document

The following symbols may be 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

When pumping hazardous liquids, special attention must be paid to the risk of personal injury.

Warning

The surface of the product may be so hot that it may cause burns or personal injury.

Warning

The sound pressure level is so high that hearing protection must be used.

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.

Table of Contents

English (US)

Terms and Conditions

2. Terms and Conditions

2.1 The contract

The Contract shall be comprised of the following terms, together with such terms and conditions as are set forth in Seller's written proposal or quotation (the "Quotation"), including any documents, drawings or specifications incorporated t any additional or different terms proposed in Buyer's purchase order (the "Purchase Order") that are accepted by Seller in writing, which together shall constitute the entire agreement between the parties, provided, however, that preprinted terms on Buyer's purchase order or invoice shall not apply and Seller gives notice of objection to such terms. An offer by Seller in its Quotation that does not stipulate an acceptance date is not binding. This Contract shall be deemed to have been entered into upon written acknowledgment of the Purchase Order by an officer or authorized representative of Seller, which may not be modified, supplemented, or waived except in a writing executed by an authorized representative of the party to be bound.

2.2 Price

The price quoted in the Quotation shall be the Purchase Price unless otherwise agreed in the Purchase Order. The Purchase Price for equipment shall include packing for shipment. Field Services shall be provided at Seller's standard rates. All other costs, including packing for storage, freight, insurance, taxes, customs duties and import/export fees, or any other item not specified in the Contract, shall be paid by Buyer unless separately stated in the Quotation and included in the price quoted. Any sales, use, or other taxes and duties imposed on the transaction or the equipment supplied shall be paid or reimbursed by Buyer.

2.3 Payment terms

Payment shall be due within 30 days of the date of Seller's invoice in U.S. funds unless otherwise agreed. If Buyer does not observe the agreed dates of payment, Buyer shall pay interest to Seller on overdue amounts at a rate that is the higher of: 9 % per annum or a rate 5 % in excess of the rate borne from time to time by new issues of six-month United States Treasury bills. Seller shall be entitled to issue its invoice for the Purchase Price for equipment upon the earlier of shipment, or notice to Buyer that Seller is ready to ship, and for services, upon completion. If the Purchase Price exceeds $250,000 USD, Buyer shall pay the Purchase Price in Progress payments as follows: Fifteen percent (15 %) upon submittal of general arrangement drawings, thirty five percent (35 %) after receipt of first Bowl Casting, twenty percent (20 %) after first case/bowl hydro test or bowl machining and thirty percent (30 %) after notification of ready to ship.

2.4 Acceptance and inspection

All equipment shall be finally inspected and accepted by Buyer within 14 days after delivery or such other period of time as is agreed in the Purchase Order. Buyer shall make all claims (including claims for shortages), excepting only those provided for under the warranty clause contained herein, in writing within such 14 day period or they are waived. Services shall be accepted upon completion. Buyer shall not revoke its acceptance. Buyer may reject the equipment only for defects that substantially impair its value, and Buyer's remedy for lesser defects shall be in accordance with Section 10, Warranty. If tests are made by Buyer to demonstrate the ability of the equipment to operate under the contract conditions and to fulfill the warranties in Section 10, Buyer is to make all preparations and incur all expenses incidental to such tests. Seller will have the right of representation at such tests at its expense, and the right to technically direct the operation of the equipment during such tests, including requiring a preliminary run for adjustments.

herein by reference, and

2.5 Title and risk of loss

Full risk of loss (including transportation delays and losses) shall pass to Buyer upon delivery, regardless of whether title has passed to Buyer, transport is arranged or supervised by Seller, or start-up is carried out under the direction or supervision of Seller. Delivery shall be ex works, INCOTERMS 2000. Loss or destruction of the equipment or injury or damage to the equipment that occurs while the risk of such loss or damage is borne by Buyer does not relieve Buyer of its obligation to pay Seller for the equipment.

2.6 Patent or trademark information

If the equipment sold he manufactured according to Buyer's specifications, Buyer shall indemnify Seller and hold it harmless from any claims or liability

r patent or trademark infringement on account of the sale of

fo such goods.

reunder is to be prepared or

2.7 Changes

Buyer may request, in writing, changes in the design, drawings, specifications, shipping instructions, and shipment schedules of the equipment. As promptly as practicable after receipt of such request, Seller will advise Buyer what amendments to the Contract, if any, may be necessitated by such requested changes, including but not limited to amendment of the Purchase Price, specifications, shipment schedule, or date of delivery. Any changes agreed upon by the parties shall be evidenced by a Change Order signed by both parties.

2.8

Buyer shall have the right to cancel the Contract upon 15 day prior upo Buyer. If Buyer cancels the Contract, it shall pay: (a) the agreed unit price for equipment or components completed and delivered, (b) additional material and labor costs incurred, and for engineering services supplied by Seller with respect to the canceled items, which shall be charged to Buyer at Seller's rates

n effect at the time of cancellation, but which shall not exceed the

i contract price for such items, and (c) such other costs and expenses, including cancellation charges under subcontracts, as Seller may incur in connection with such cancellation or termination.

ellation or

Canc

en notice

writt

n the receipt of such notice except as otherwise agreed with

ermination

to Seller, and Seller shall stop its performance

2.9 Delivery and delays

Seller shall use its best efforts to meet quoted delivery dates, which are estimated based on conditions known at the time 16 A1d.1 606 supercedes 9/05 PACO PUMPS of quotation. Seller shall not be liable for any nonperformance, loss, damage, or delay due to war, riots, fire, flood, strikes or other labor difficulty, governmental actions, acts of God, acts of the Buyer or its customer, delays in transportation, inability to obtain necessary labor or materials from usual sources, or other causes beyond the reasonable control of Seller. In the event of delay in performance due to any such cause, the date of delivery or time for completion will be extended to reflect the length of time lost by reason of such delay. Seller shall not be liable for any loss or damage to Buyer resulting from any delay in delivery.

2.10 Warranty

English (US)

3.2 Receiving

• Check pumping unit for shortage and damage immediately upon arrival. Pump accessories when required are packaged in a separate container and shipped with the unit.

• If equipment is damaged in transit, promptly report this to the carrier's agent. Make complete notations on the freight bill to speed satisfactory adjustment by the carrier.

• Unload and handle the unit with a sling. Do not lift unit by eye bolts on the motor!

3.3 Temporary storage

• If pump is not to be installed and operated soon after arrival, store it in a clean, dry area of moderate ambient temperature.

English (US)

2.14 law and arbitration

The Contract shall be governed by the law of the State of Texas. Any disputes arising out of this Contract shall be resolved by informal mediation in any manner that the parties may agree within 45 days of written request for mediation by one party to the other. Any dispute that cannot be resolved through mediation shall be resolved by binding arbitration conducted in English in Portland, Oregon under the Commercial Rules of the American Arbitration Association except as otherwise provided in this Section. The arbitration shall be conducted by three arbitrators chosen in accordance with said Rules. The arbitrators are not entitled to award damages in excess of compensatory damages. Judgment upon the award may be entered in any court having jurisdiction.

3.2 Receiving

• Check pumping unit for shortage and damage immediately upon arrival. Pump accessories when required are packaged in a separate container and shipped with the unit.

• If equipment is damaged in transit, promptly report this to the carrier's agent. Make complete notations on the freight bill to speed satisfactory adjustment by the carrier.

• Unload and handle the unit with a sling. Do not lift unit by eye bolts on the motor!

3.3 Temporary storage

• If pump is not to be installed and operated soon after arrival, store it in a clean, dry area of moderate ambient temperature.

• Rotate the shaft by hand periodically to coat bearing with lubricant to retard oxidation and corrosion.

• Follow motor manufacturer's storage recommendations where applicable.

3.4 Location

• Locate the pump as close to the suction supply as possible. Use the shortest and most direct suction piping practical. Refer to 3.9 Suction (inlet) piping.

• Locate the pump below system level wherever possible. This will facilitate priming, assure a steady liquid flow, and provide a positive suction head.

• Make sure sufficient NPSH (Net Positive Suction Head) is provided at the suction end by considering the pump's location in relation to the entire system. Available NPSH must always equal or exceed required NPSH specified on the pump performance curve.

Seller warrants that the equipment or services supplied will be free from

24 months from the d 30 months from the date of shipment, whichever shall first

occur. In the case of spare or replacement parts manufactured by Seller, the warranty period shall be for a period of six months from shipment. Repairs shall be warranted for 24 months or, if the repair is performed under this warranty, for the remainder of the original warranty period, whichever is less. Buyer shall report any claimed defect in writing to Seller immediately upon discovery and in any event, within the warranty period. Seller shall, at its sole option, repair the equipment or furnish replacement equipment or parts thereof, at the original delivery point. Seller shall not be liable for costs of removal, reinstallation, or gaining access. If Buyer or others repair, replace, or adjust equipment or parts without Seller's prior written approv Buyer under this section with respect to such equipment or parts. The repair or replacement of the equipment or spare or replacement parts by Seller under this section shall constitute Seller's sole obligation and Buyer's sole and for all claims of defects. SELLER MAKES NO OTHER WARRANTY OR RESPECT TO THE EQUIPMENT OR SERVICES OTHER THAN AS SPECIFIED IN THIS SECTION 10. ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR

PURPOSE, ARE HEREBY DISCLAIMED. For purposes of this Section, the equipment warranted shall not include equipment, parts, and work not manufactured or performed by Seller. With respect to such equipment, parts, or work, Seller's only obligation shall be to assign to Buyer any warranty provided to Seller by the manufacturer or supplier providing such equipment, parts or work. No equipment furnished by Seller shall be deemed to be defective by reason of normal wear and tear, failure to resist erosive or corrosive action of any fluid or gas, Buyer's failure to properly store, install, operate or maintain the equipment in accordance with good industry practices or specific recommendations of Seller, or Buyer's failure to provide complete and accurate information to Seller concerning the operational

application of the equipment.

defects in material, and workmanship for a period of

ate of initial operation of the equipment, or

al, Seller is relieved of any further obligation to

exclusive remedy

REPRESENTATION OF ANY KIND WITH

Warning

Prior to installation, read these installation and

operating instructions. Installation and operation

must comply with local regulations and accepted

codes of good practice.

Warning

The use of this product requires experience with

and knowledge of the product. Persons with reduced physical, sensory or mental

capabilities must not use this product, unless

they are under supervision or have been

instructed in the use of the product by a person

responsible for their safety. Children must not use or play with this product.

2.11 Technical documents

Technical documents furnished by Seller to Buyer, such as drawings, descriptions, designs and the like, shall be deemed provided to Buyer on a confidential basis, shall remain Seller's exclusive property, shall not be provided in any way to third parties, and shall only be used by Buyer for purposes of installation, operation and maintenance. Technical documents submitted in connection with a Quotation that does not result in a Purchase Order shall be returned to Seller upon request.

2.12 Limitation of liability

Seller shall in no event be liable for any consequential, incidental, indirect, special or punitive damages arising out of the Contract, or out of any breach of any of its obligations hereunder, or out of any defect in, or failure of, or malfunction of the equipment, including but not limited to, claims based upon loss of use, lost profits or revenue, interest, lost goodwill, work stoppage, impairment of other equipment, environmental damage, nuclear incident, loss by reason of shutdown or nonoperation, increased expenses of operation, cost of purchase of replacement power or claims of Buyer or customers of Buyer for service interruption whether or not such loss or damage is based on contract, tort (including negligence and strict liability) or otherwise. Seller's maximum liability under this Contract shall not exceed the Purchase Order amount of the equipment or portion thereof upon which such liability is based. All such liability shall terminate upon the expiration of the warranty period, if not sooner terminated.

2.13 This company is an equal opportunity employer

This agreement incorporates by reference applicable provisions and requirements of Executive Order 11246 and FAR Section

52.222-26 (covering race, color, religion, sex and national origin); the Vietnam Era Veterans Readjustment Assistance Act of 1974 and FAR Section 52.222-35 (covering special disabled and Vietnam era veterans); and the Rehabilitation Act of 1973 and FAR Section 52.222-36 (covering handicapped individuals). By acceptance of this agreement Buyer certifies that it does not and will not maintain any facilities in a segregated manner, or permit its employees to perform their services at any location under its control where segregated facilities are maintained, and further that appropriate physical facilities are maintained for both sexes. Buyer agrees that it will obtain a similar certificate prior to award of any nonexempt lower-tier subcontracts.

2.14 law and arbitration

Terms and Conditions

PACOpaQ System Installation

Installation instructions

Assembly of packaged sections (if applicable):

1. Refer to specic installation documents or

drawings for the package system.

2. Familiarity with the parts requirements and any referenced documents or drawings will aid in the piping assembly. All hardware and gaskets required for re-assembly are supplied. Final package system connections hardware by others.

3. Check pipe/pump/ttings/valves end

connections. Any loose scale, paint or dirt must be removed.

4. Ensure alignment of end connections

between pump/pipe/ttings/valves

Connections must be square.

5. Package piping must be supported independent of the pump. If package pipe support is not part of the original package others should supply it. Package steel base is designed to provide a structural support beginning.

6. Use proper gasket (if required) and install

the individual pump suction & discharge pipe/

ttings/valves with the nuts & bolts provided (at & lock washers also provided). Install the required bolts for the tting connections (elbow, wye strainer,and buttery valve)-to-pipe connection and tighten bolts to a snug t.

7. Tighten and torque all pipe connection bolts as required.

8. Install and/or tighten loose pipe support brackets as required. Remove any temporary supports.

9. Refer to specic installation documents or

drawings for the package system.

10. Familiarity with the parts requirements and any referenced documents or drawings will aid in the piping assembly. All hardware and

gaskets required for re-assembly are supplied. Final package system connections hardware by others.

11. Ensure alignment of pipe end connections between sections. Connections must be square.

Install the required bolts for each of the tting connections- (elbow, separator, valve, etc.) -to pipe connections and tighten bolts to a snug t.

Gasket may be required.

12. Working from the middle of base sections to the outside. Snug all base connection bolts

making sure the base channel anges are ush

top, bottom and side. Torque base connection bolts to approx. 75 ft/lb

13. Ensure pipe connections are aligned. Tighten and torque all the pipe connection bolts as required.

14. Install and/or tighten loose pipe support brackets and bolts as required.

Other packaged system requirements:

1. Required electrical wiring can now be

connected. A qualied electrician should do

the electrical wiring. Power/control/sensing runs may be disconnected for package splits or remote/future use, and tagged with color-coded tape or with a numbering system.

2. Mount the gauge & switch wing panel. Required sensing lines can now be connected. Sensing lines may be disconnected for package splits or for remote/future use, and tagged with color-coded tape or with a numbering system.

3. Complete the package system installation per individual parts provider or manufacturer, customer, or maintenance instructions requirements.

Installation

3. PACOpaQ Installation

3.1 General instructions

Important notice:

Carefully inspect this equipment for damage, and missing pieces. If the shipment has been damaged or there are missing pieces, have the carrier note the condition on the receipt. Also, check as soon as possible for any concealed damage. It is the customer’s

responsibility to le a claim for damage or

missing pieces with the carrier. Failure to follow this procedure may result in refusal by the carrier to honor any claims with a consequent loss to the customer.

3.2 Lifting and rigging instructions:

Avoid twisting or uneven lifting of unit. Lifting lugs are provided on the sides, or as part of the internal structure of the system base. Lifting with a single hook will require cables. Cables are to be connected to the lugs by use of shackles. Required cable lengths may vary due to lifting lugs not being symmetrical to the center of gravity of system, or to avoid system internals.

Fig. 1 Side view of lifting points

Fig. 2 Plan view of lifting points

3.3 Storage:

Unit should be stored in a dry and dust free and temperature controlled environment. It is not recommended the unit be stored outside. If the unit must be stored outside it is required that the entire unit must be covered with a watertight seal. Electronic equipment is delicate and will not withstand variations in humidity and temperature.

3.4 Bolt check instructions:

System bolts may become loose during shipment due to vibration. Bolts must be checked for tightness and for required torque. This must be done before system is pressurized.

3.5 Field connections:

Piping isolation is recommended on all package

system eld connections. It is the installer’s responsibility to suppor

piping.

Request for assistance:

If there are questions concerning the installation of this package system contact:

Service Department Grundfos Commercial Building Services 902 Koomey Road Brookshire, TX. 77423

t and anchor eld

1-800-955-5847

3.6 Assembly of packaged sections

Installation

(if applicable):

gaskets required for re-assembly are supplied. Final package system connections hardware by others.

1. Refer to specic installation documents or

drawings for the package system.

3. Check pipe/pump/ttings/valves end

connections. Any loose scale, paint or dirt must be removed.

4. Ensure alignment of end connections

between pump/pipe/ttings/valves

Connections must be square.

6. Use proper gasket (if required) and install

the individual pump suction & discharge pipe/

7. Tighten and torque all pipe connection bolts as required.

8. Install and/or tighten loose pipe support brackets as required. Remove any temporary supports.

11. Ensure alignment of pipe end connections between sections. Connections must be square.

Install the required bolts for each of the tting connections- (elbow, separator, valve, etc.) -to pipe connections and tighten bolts to a snug t.

Gasket may be required.

12. Working from the middle of base sections to the outside. Snug all base connection bolts

making sure the base channel anges are ush

top, bottom and side. Torque base connection bolts to approx. 75 ft/lb

13. Ensure pipe connections are aligned. Tighten and torque all the pipe connection bolts as required.

14. Install and/or tighten loose pipe support brackets and bolts as required.

3.7 Other packaged system requirements:

1. Required electrical wiring can now be

connected. A qualied electrician should do

the electrical wiring. Power/control/sensing runs may be disconnected for package splits or remote/future use, and tagged with color-coded tape or with a numbering system.

3. Complete the package system installation per individual parts provider or manufacturer, customer, or maintenance instructions requirements.

PACOpaQ System Installation

9. Refer to specic installation documents or

drawings for the package system.

10. Familiarity with the parts requirements and any referenced documents or drawings will aid in the piping assembly. All hardware and

English (US)

2.14 law and arbitration

3.2 Receiving

• Check pumping unit for shortage and damage immediately upon arrival. Pump accessories when required are packaged in a separate container and shipped with the unit.

• If equipment is damaged in transit, promptly report this to the carrier's agent. Make complete notations on the freight bill to speed satisfactory adjustment by the carrier.

• Unload and handle the unit with a sling. Do not lift unit by eye bolts on the motor!

3.3 Temporary storage

• If pump is not to be installed and operated soon after arrival, store it in a clean, dry area of moderate ambient temperature.

• Rotate the shaft by hand periodically to coat bearing with lubricant to retard oxidation and corrosion.

• Follow motor manufacturer's storage recommendations where applicable.

3.4 Location

• Locate the pump as close to the suction supply as possible. Use the shortest and most direct suction piping practical. Refer to 3.9 Suction (inlet) piping.

• Locate the pump below system level wherever possible. This will facilitate priming, assure a steady liquid flow, and provide a positive suction head.

• Always allow sufficient accessibility for maintenance and inspection. Provide a clear space with ample head room for use of a hoist strong enough to lift the unit.

• Make sure a suitable power source is available for the pump motor. Electrical characteristics should match those specified on the motor data plate, within the limits covered in

4. Installation-electrical and 5. Operation.

• Avoid pump exposure to sub-zero temperatures to prevent pump liquid from freezing. If freezing conditions exist during shutdown periods, see Sections 5.6 Pump shutdownand

5.7 Short duration shutdown for specific recommendations.

3.5 Horizontal pump foundation

Horizontal pumps should be permanently installed on a firm, concrete foundation mounting pad of sufficient size to dampen any vibration and prevent any deflection or misalignment. The pad may float on springs or be a raised part of the equipment room floor. The foundation should be poured without interruption to 3/4 to 1 - 1/2 inches below the final pump elevation. The top surface should be well scored or grooved before the concrete sets to provide a suitable bonding surface for the grout. Anchor bolts should be set in pipe sleeves for positioning allowance, as shown in Fig. 2. Allow enough bolt length for grout, lower base plate flange, nuts and washers. Allow the foundation to cure several days before proceeding with pump installation.

Warning

Prior to installation, read these installation and

operating instructions. Installation and operation

must comply with local regulations and accepted

codes of good practice.

Warning

The use of this product requires experience with

and knowledge of the product. Persons with reduced physical, sensory or mental

capabilities must not use this product, unless

they are under supervision or have been

instructed in the use of the product by a person

responsible for their safety. Children must not use or play with this product.

PACO Pumps

Paco Pumps Installation and Opereating Procedures

3.4 Installation - Mechanical

Read these instructions thoroughly before installing and operating your PACO Type L Centrifugal Pump. Successful operation depends on careful attention to the procedures described in Sections 1, 2, 3 and 4 of this manual. Keep this instruction manual handy for future use.

4.1 Pump identification

All PACO Pumps are identified by Catalog and Serial Numbers. These numbers are stamped on the pump nameplate (Fig. 1) affixed to each pump volute casing, and should be referred to in all correspondence with the Company.

Fig. 1 Nameplate

4.2 Receiving

• Check pumping unit for shortage and damage immediately upon arrival. Pump accessories when required are packaged in a separate container and shipped with the unit.

• If equipment is damaged in transit, promptly report this to the carrier's agent. Make complete notations on the freight bill to speed satisfactory adjustment by the carrier.

• Unload and handle the unit with a sling. Do not lift unit by eye bolts on the motor!

4.3 Temporary storage

• If pump is not to be installed and operated soon after arrival, store it in a clean, dry area of moderate ambient temperature.

• Rotate the shaft by hand periodically to coat bearing with lubricant to retard oxidation and corrosion.

• Follow motor manufacturer's storage recommendations where applicable.

4.4 Location

• Locate the pump as close to the suction supply as possible.

TM 05 8912 3712

Use the shortest and most direct suction piping practical. Refer to 3.9 Suction (inlet) piping.

• Locate the pump below system level wherever possible. This will facilitate priming, assure a steady liquid flow, and provide a positive suction head.

• Always allow sufficient accessibility for maintenance and inspection. Provide a clear space with ample head room for use of a hoist strong enough to lift the unit.

• Make sure a suitable power source is available for the pump motor. Electrical characteristics should match those specified on the motor data plate, within the limits covered in

4. Installation-electrical and 5. Operation.

• Avoid pump exposure to sub-zero temperatures to prevent pump liquid from freezing. If freezing conditions exist during shutdown periods, see Sections 5.6 Pump shutdownand

5.7 Short duration shutdown for specific recommendations.

4.5 Horizontal pump foundation

Finished

Wedges or shims

grouting

.75 to 1.25

allowance for grout

Base plate

Grout

left in place

4.9 Suction (inlet) piping

The sizing and installation of suction piping is particularly important. It must be selected and installed in a manner that minimizes pressure loss and permits sufficient liquid flow into the pump during starting and operation. Many NPSH problems can be traced directly to improper design of suction piping systems. Observe the following precautions when installing suction piping:

PACO Pumps

Dam

Pipe sleeve

Washer

Fig. 2 Anchor bolt installation

ecuring base plate

4.6 S

• After the concrete pad has been poured and set, lower the pump base plate over the anchor bolts and rest it on loose adjustment wedges or shims placed near each anchor bolt and at intervals not to exceed 24" along each side. Shims or wedges must be placed to raise the bottom of the base 3/4" to 1 - 1/4" above the pad, allowing clearance for grout. Level the pump shaft, flanges, and base plate using a spirit level, adjusting the wedges or shims, as required.

• Check to make sure that the piping can be aligned to the pump flanges without placing any strain on either flange.

• After pump alignment has been established (LF), put nuts on foundation bolts and tighten them just enough to keep the unit base plate from moving. Construct a form or dam around the concrete pad and pour grout in and around the pump base, as shown in Fig. 2. Grout compensates for uneven foundation, distributes the weight of the unit, and prevents shifting. Use an approved, non shrinking grout (such as Embeco 636 by Master Builders, Cleveland, Ohio or equivalent). Allow at least 24 hours for this grout to set before proceeding with piping connections.

• After the grout has thoroughly hardened, check the foundation bolts and tighten if necessary. Recheck the pump alignment after the foundation bolts are secured.

• No alignment or grouting required for LCS pump.

4.7 Vertical mount

The PACO LCV Vertical Close Coupled pump need not be grouted to its foundation, but should be anchored with 4 anchor bolts set in concrete similar to the horizontal anchoring arrangement Fig. 2.

4.8 P

iping-general

• Do not use pump as a support for piping! Use pipe hangers or other supports at proper intervals to provide complete piping support near the pump.

• Both suction and discharge piping should be independently supported and properly aligned so that no strain is transmitted to the pump when flange bolts are tightened.

• Make sure piping is as straight as possible, avoiding unnecessary bends and fittings. Where necessary, use 45 ° or long-sweep 90 ° pipe fittings to decrease friction loss.

• Where flanged joints are used, make sure that inside diameters properly match and mounting holes are aligned.

• Do not spring or force piping when making any connections!

ing instructions

Top foundation

leave rough clean

& wet down

LUG

TM 05 4775 2512

TM05 4791 2613

Fig. 3 Inlet piping

• Suction piping should be as direct as possible, and ideally the length should be at least ten times the pipe diameter. Short suction piping can be the same diameter as the suction opening. Longer piping should be one or two sizes larger (depending on length), reducing to the diameter of the pump suction opening.

• Use an eccentric reducer, with the eccentric side down Fig. 3 when reducing the pipe diameter to the diameter of suction opening.

• At no point should suction piping be smaller in diameter than the pump suction opening.

• Horizontal suction lines should follow an even gradient, if possible. A gradual upward slope to the pump is recommended for suction lift conditions, and a gradual downward slope for positive suction head.

• Avoid any high points, such as pipe loops Fig. 4, that may create air pockets and throttle the system or produce erratic pumping.

• Install a valve in the suction line to isolate the pump during shutdown and maintenance, and facilitate pump removal. Where two or more pumps are connected to the same suction line, install duplicate gate valves to isolate each pump from the line.

• Gate valves should always be installed in positions that avoid air pockets. Globe valves should not be used, particularly when NPSH is critical.

• During pumping operation, valves on suction line must always be at FULL OPEN.

• Properly sized pressure gauges can be installed in gauge taps on pump suction and discharge nozzles. Gauges enable the operator to monitor pump performance and determine that the pump conforms to the parameters of the performance curve. If cavitation, vapor binding, or other unstable operation occurs, pressure gauges will indicate wide fluctuation in suction and discharge pressures.

English (US)

PACO Pumps

Fig. 4 Air pocket prevention

4.10 Discharge (outlet) piping

• Short discharge piping can be the same diameter as the pump discharge opening. Longer piping should be one or two sizes larger depending on length.

• An even gradient is best for long horizontal runs of discharge piping.

• Install a valve near the discharge opening to prime and start the pump. The discharge gate valve is also used to isolate the pump during shutdown, maintenance, and facilitate pump removal.

• Any high points in discharge piping may entrap air or gas and thus retard pump operation.

• If the possibility of liquid hammer exists, (i.e. check valves are used) close the discharge gate valve before pump shutdown.

4.11 Shaft sealing-general comments

• PACO offers both mechanical seals and packed stuffing boxes as a means to seal the shaft. Pumps with stuffing boxes are normally packed before shipment. If the pump is installed within 60 days after shipment, the packing material will be in good condition for operation with a sufficient supply of lubrication. If the pump is stored for a longer period, it may be necessary to repack the stuffing boxes.

• The stuffing box must be supplied at all times with a source of clean, clear liquid to flush and lubricate the packing. When pumps are equipped with mechanical seals, no maintenance or adjustment is required. Mechanical seals are preferred to packing on most applications because they require less maintenance.

4.13 Mechanical seals

All PACO Type L pumps that are equipped with mechanical seals are matched to conditions for which the pump was sold. Observe the following precautions to avoid seal damage and obtain maximum seal life:

• Do not exceed temperature or pressure limitations for the mechanical seal used.

• DO NOT RUN THE PUMP DRY OR AGAINST A CLOSED VALVE! Dry operation will cause seal failure within minutes.

• Clean and purge suction piping in new installations before installing and operating pump. Pipe scale, welding slag and

TM05 4792 2613

other abrasives can cause rapid seal failure.

Fig. 5 Checking parallel alignment

TM05 4795 2613TM05 4794 2613

4.12 Packing gland adjustment

With the pump running, the packing gland should be adjusted to permit 40 to 60 drops per minute leakage. This is required for shaft lubrication. After initial start up, additional packing and adjustment may be required. Pumps with mechanical seals require no adjustment.

Fig. 6 Checking alignment

4.14 Coupling alignment (LF)

• The following anchoring and alignment procedure is typical and, if performed with care, should result in a smooth running, trouble-free installation.

• If the pump and motor were shipped mounted on the pump base as an assembly, remove the coupling guard.

• The pump and motor were accurately aligned at the factory, but handling during shipment usually alters this pre-alignment. Using a small straight edge and feeler gauges or a dial indicator, check for horizontal, vertical, and angular misalignment of the coupling hubs Fig. 5 and Fig. 6.

• Coupling alignment is correct when the dial indicator reads no more than .005" run out in any direction (or when the straight edge contacts both hubs evenly in both horizontal and vertical positions). If misalignment is detected, loosen the motor and shift or shim as necessary to re-align, then re-tighten bolts. Always align the motor to the pump as piping strain will occur if the pump is shifted. Never reposition pump on base!

• After final piping connections to the pump have been made, motor wiring compared, correct rotation has been established, and piping filled with liquid, check shaft alignment once again.

• Leave the coupling guards off until the pump priming procedure is completed for a final shaft alignment check.

• To protect personnel from rotating machinery, Always install coupling guards after installation is complete; before starting pump!

4.15 Coupling alignment (LCS)

• No alignment of the pump and motor is required.

Installation-electrical

Warning

Use only qualified electricians for electrical installation and maintenance.

Refer to manuals provided with electrical accessory components and disconnect power supply as recommended for servicing.

Warning

Never do maintenance work when the unit is connected to power.

5.1 Motors general

the motor control circuit must have the following components in order to comply with the National Electrical Code.

• Motor Disconnecting Device: A motor disconnecting device must be installed that is capable of disconnecting both the controller (motor starter) and the motor from their source of power.

• The disconnecting device must be located so that the controller (motor starter) can be seen from the disconnecting means. In all cases, the distance from the disconnecting device to the controller must be less than 50'.

• In most installations the disconnecting device will be a circuit breaker or fusible disconnect switch.

Motor short circuit and ground fault protection:

• Short circuit and ground fault protection are usually provided by means of a circuit breaker or fusible disconnect switch.

• The selection of the size of the circuit breaker or fuse must be in accordance with Section 430-52 and Table 430-152 of the National Electrical Code.

Motor controller with running over current protection (magnetic starter):

• These components must be installed in accordance with applicable local and state electrical codes in addition to the National Electrical Code.

PACO Pumps

Warning

Whenever powered equipment is being used in explosive surroundings, the rules and regulations generally or specifically imposed by the relevant responsible authorities or trade organizations must be observed.

5.2 Installation wiring

• Mount the control panel or motor starter(s) in close proximity to the pump to provide convenient control and ease of installation.

• Wire panel or starter(s) to motor(s) and pilot device(s): Wires to each motor must be sized for at least 125 % of the motor nameplate full load amps. AWG #16 Type THW stranded wire is recommended for wiring of pilot devices (float switches).

• Check incoming power source to ensure that it is the same as the voltage and phase of the motors.

• Verify that the starters are suitable to operate the pump motors on voltage and phase that is available.

English (US)

Caution

PACO Pumps

Operation

5.1 Priming

• The PACO Type L pump is not self-priming, and must be completely primed (filled with liquid) before starting.

• If the pump will operate with a positive suction head, prime by opening the suction valve and allowing liquid to enter pump casing. Open air vents at this time, and make sure all air is forced from pump by liquid before closing.

• Rotate the shaft by hand to free entrapped air from impeller passageways.

• If pump has a suction lift, priming must be accomplished by other methods. The use of foot valves or ejectors, or manual filling of the pump casing and suction line with liquid are possible methods suggested for this purpose.

• CAUTION: Never run the pump dry in the hope that it will prime itself! Serious damage to the mechanical seal will result.

Never run the pump dry in the hope that it will prime itself! Serious damage to the shaft seals, pump wear rings and shaft sleeves will result.

6.2 Pre-start checklist

Warning

In the interest of operator safety, the unit must not be operated above the nameplate conditions. Such operation could result in unit failure causing injury to operating personnel. Consult instruction book for proper operation and maintenance of the pump and its supporting components.

Make the following inspections before starting your PACO Type L pump:

1. Make sure the suction and discharge piping has been cleaned

and flushed to remove dirt and debris before operating pump.

2. Double check rotation must be clockwise operating in reverse

will destroy the impeller and shaft.

3. Make sure all wiring connections to the motor (and starting

device) match the wiring diagram and produce clockwise rotation as viewed from the back of the motor.

4. If the motor has been in storage for an extended length of

time, either before or after installation, refer to motor instructions before starting.

5. Check the voltage, phase, and line circuit frequency with the

motor nameplate. Turn rotating element by hand to make sure it rotates freely.

6. Tighten plugs in gauge and drain taps. If the pump is fitted

with pressure gauges, keep gauge clocks closed when not in use.

7. Check suction and discharge piping for leaks, and make sure

all flange bolts are securely tightened.

6.3 Motor rotation

Never check driver rotation unless pump and driver couplings are disconnected and physically separated. Failure to follow this instruction can result in serious damage to pump and driver if rotation is wrong.

After the unit has been wired and checked to insure that all components in the system (disconnect device, magnetic starters, pilot devices and motors) are properly connected, check motor rotation as follows:

• For 3 phase units only—momentarily energize the motors to ensure that the rotation is correct as indicated by the arrow cast into the pump volute. If rotation is incorrect, interchange two wires at the motor starter terminals T1 and T2.

• IMPORTANT: The pumps must not be operated while dry. Use extreme caution that motors are energized only momentarily to determine proper rotation.

6.4 Starting the pump

Warning

The pump must not be operated without an approved coupling guard in place. Failure to observe this warning could result in injury to operating personnel.

1. Install coupling guard on coupled units.

2. Fully open gate valve (if any) in suction line, and close gate

valve in discharge line.

3. Fill suction line with liquid and completely prime pump.

4. Start the motor (pump).

5. Immediately make a visual check of pump and suction piping

for pressure leaks.

6. Immediately after pump reaches full operating speed, slowly

open the discharge gate valve until complete system flow is achieved.

7. Check discharge piping for pressure leaks.

8. If pump is fitted with pressure gauges, open gauge cocks and

record pressure reading for future reference. Verify that the pump is performing in accordance with parameters specified on performance curve.

9. Check and record voltage, amperage per phase, and

kilowatts, if a wattmeter is available.

6.5 Voltage regulation

The motor will operate satisfactorily under the following conditions for voltage and frequency variation, but not necessarily in accordance with the standards established for operation under rated conditions:

• The voltage variation may not exceed 10 % above or below rating specified on the motor data plate.

• The frequency variation may not exceed 5 % above or below motor rating.

• The sum of the voltage and frequency variations may not exceed 10 % above or below motor rating, provided the frequency variation does not exceed 5 %.

6.6 Pump shutdown

The following shutdown procedures will apply in most normal shutdowns for the PACO Type L pumps. If the pump will be inoperative for an extended length of time, follow storage procedures in Extended Period Shutdown.

• Always close the discharge valve before stopping the pump. Close the valve slowly to prevent hydraulic shock.

• Cut and lock off power to the motor.

6.7 Short duration shutdown

• For overnight or temporary shutdown periods under nonfreezing conditions, the pump may remain filled with liquid. Make sure the pump is fully primed before restarting.

• For short or frequent shutdown periods under freezing conditions, keep fluid moving within the pump casing and insulate or heat the pump exterior to pre vent freezing.

6.8 Extended period shutdown

• For long shutdown periods, or to isolate the pump for maintenance, close suction gate valve. If no suction valve is used and the pump has positive suction head, drain all liquid from suction line to terminate liquid flow into pump suction nozzle. Remove plugs in pump drain and vent taps, as required, and drain all liquid from the pump volute casing.

• If freezing conditions will exist during long shutdown periods, completely drain the pump and blow out all liquid passages and pockets with compressed air. Freezing of pump liquid can also be prevented by filling the pump with antifreeze solution.

7. Maintenance

Warning

Do not attempt any maintenance, inspection, repair or cleaning in the vicinity of rotating equipment. Such action could result in personal injury to operating personnel.

Before attempting any inspection or repair on the pump, the driver controls must be in the "OFF" position, locked and tagged to prevent injury to personnel performing service on the pump.

7.1 Motor lubrication

Always follow motor manufacturer's lubrication instructions if available, and periodically check grease fittings and drain plugs for leaks. If lubricating instructions do not accompany motor, refer to for recommended lubrication periods.

• To lubricate the motor while running or at rest, remove grease drain plug (if any) and filler plug on grease fitting. Grease with clean lubricant until grease appears at drain hole or along motor shaft.

Recommended Lubrication Periods

Motor RPM Motor HP Operating conditions

Standard Severe Extreme

0.33 - 7.50p 3 yrs 1 yr 6 mo

1750 and

below

above 1750 all hp 6 mo 3 mo 3 mo

Standard conditions:

8 Hours per day operation, normal or light loading, clean air, 100 °F, maximum ambient temperature.

Severe conditions:

Continuous 24-hour operation, shock loading or vibration, poor ventilation, 100-150 °F, ambient temperature.

Extreme conditions:

Continuous operation, heavy shock or vibration, dirt or dust in air, extreme ambient temperature.

• One-half to one cubic inch of grease is sufficient for motors 5 HP and under, with proportionately more grease for greater HP motors.

• Most fractional and some integral frame motors have "sealedfor-life" bearings, and do not require further lubrication throughout motor life.

• Always follow motor manufacturer's lubrication instructions, and periodically check grease fittings and drain plugs for leaks.

• If lubricating instructions do not accompany motor, refer to Table , “Recommended Lubrication Periods,” on page 10 for recommended lubrication periods.

• Table , “Approved lubricants,” on page 11 lists recommended types of grease for both pump and motor lubrication. These types have all been thoroughly tested and should be used whenever possible.

10-40 1-3 yrs 6 mo - 1 yr 3 mo

50-150 1 yr 6 mo 3 mo

200 and up 1 yr 6 mo 3 mo

PACO Pumps

English (US)

PACO Pumps

7.2 Pump lubrication

• PACO Type LF pumps on horizontal bearing frames have bearing that may be sealed for life (requiring no lubrication), regreasable or oil lubricated.

Approved lubricants

MANUFACTURER LUBRICANT

SHELL DOLIUM

EXXON POLYREX

CHEVRON

PHILIPS POLYTAC™

TEXACO POLYSTAR RB

• To lubricate regreasable bearings, remove grease drain plug (if any) and filler plug. Add clean ball bearing lubricant until grease appears at drain hole or along shaft. On units with drain hole, all old grease can be purged out ahead of new. In such cases, the drain should be left unplugged for several minutes during pump operation to allow excess grease to be forced out.

• Lubricate bearing frame bearings at intervals of one to three months, depending on severity of environment. Pumps in a clean, dry, moderate temperature (100 °F maximum) environment should be regreased at three month intervals. Too much grease can cause premature bearing failure-do not overgrease.

On those PACO Type LF Centrifugal End Suction pumps

• ordered with oil lubricated bearings, Fig. 7. A regular oil maintenance program must be enforced.

After the first 200 hours of operation the oil should be

• changed. To change the oil, remove the drain plug at the bottom of the bearing cover and the filler plug (that also acts as a vent plug) at the top of the housing. After draining oil, replace the fittings and refill with an acceptable oil selected from Table , “List of acceptable Lube oils,” on page 11. After the first oil change, the oil should be changed again at 2000 hours and then at intervals of 8000 hours or once yearly, thereafter.

SRI GREASE NLGI 2

BLACK PEARL - NLGI 2

List of acceptable Lube oils

Lubricant Manufacturer Bearing oil brand name

Aral Refining Co.

British Petroleum Co.

Calypsol Oil Co.

Standard Oil Co.

Esso Corp

Fina Oil Co.

Gulf Refining Co.

Socony Mobil Oil Co.

Shell Oil Co. Shell Tellus oil 29

Sundco Oil Co. Sunvis 821

The Texas Co.

Wisura Refining Co.

Aral Oil CMU

Aral Oil TU 518

BP Energol

TH 100-HB

Calypsol Bison Oil

SR 25 or SR 36

Chevron

Hydraulic Oil 11

Circulating oil 45

Esso-Mar 25

Teresso 47

Esstic 50

Fina hydran 34

Fina Cirkan 32

Gulf Harmony 47

Gulf Paramount 45

Vac hlp 25

Mobulix D.T.E. 25

Texaco ursa oil P 20

Dea viscobil sera 4

Wisura norma 25 (36)

Wisura tempo 25 (36)

7.3 Disassembly of pumps

Caution

Note

Caution

Warning

Depending on the product being pumped, the pump should be washed down before any work is done on it.

Warning

Observe extreme caution when venting and/or draining hazardous liquids. Wear protective clothing in the presence of caustic, corrosive, volatile, flammable, or hot liquids. DO NOT breathe toxic vapors. DO NOT allow sparking, flames, or hot surfaces in vicinity of the equipment.

1. Complete disassembly instructions are outlined below. Proceed only as far as required to perform the maintenance work needed.

2. Turn of power.

3. Drain System. Flush, if necessary.

4. Closed coupled units. Remove motor hold down bolts.

7.3.1 Disassembly of liquid end

1. Remove casing bolts (8B).

2. Remove back pull-out bearing frame assembly (20Y) from

casing (1A).

3. Unscrew impeller nut (8A).

Do not screwdriver between impeller vanes to prevent rotation. It may be necessary to use a strap wrench around the impeller or shaft to prevent rotation.

4. Use appropriate size gear puller aligned behind impeller

vanes to remove impeller (3A) from shaft (6A).

5. Remove impeller key (12A).

6. Remove back plate bolts (8D). Remove back plate (2K) and

seal housing (26P).

7. Place seal housing on flat surface and press out seal seat

(14A).

8. If shaft sleeve (5A) requires replacement, it must be evenly

heated to approximately 350 °F to loosen locktite. Twist sleeve off shaft (6A).

7.3.2 Disassembly of bearing frame (LF)

1. Remove slinger (13G).

2. Remove grease seal(s), (14S) if any.

3. Remove bearing house retaining ring (61K).

4. Press or tap on the pump end of the bearing-shaft assembly

until one bearing is out.

5. When one bearing is out, remove second retaining ring (61F),

then remove complete assembly from bearing housing.

6. Remove shaft retaining ring (61C) and press off bearings.

7. press on new bearings, remember to press only on inner race

of bearing while pressing them on.

8. Assemble frame in the reverse procedure used for

disassembly.

9. Observe the following when reassembling the bearing frame.

10. Replace lip seals (14S) if worn or damaged.

11. Replace bearings (18A), (18B) if loose, rough or noisy when

rotated.

12. Check shaft (6A) for runout at the sleeve (5A) area. Maximum

permissible is .002" T.I.R.

7.4 Seal replacement (LCS)

1. Complete preparations noted.

2. Remove coupling guard (34F).

3. Remove coupling bolts (8E). Pry apart the coupling halves (23D), remove keys (12B) and set aside.

Mark or measure the original position of the pump coupling on the motor side.

4. Unscrew tubing connector from pipe tee of air vent assembly. Pipe dope is applied to threads during factory assembly, and resulting bond may retard but will not prevent manual disassembly.

5. Remove seal cap bolts and slide seal cap (2N) up shaft to remove.

6. Remove seal head assembly manually from shaft (6A). Water-soluble lubricant may be applied to shaft to ease removal of shaft seal (14A). Pull seal head assembly manually from shaft, using slight twisting motion (as necessary) to loosen bellows from shaft.

7. Remove and discard seal spring and retainer.

8. remove and discard seal seat from seal cap (2N) and thoroughly clean the inside cavity of seal cap.

9. Interior surface of bellows on new seal head is coated with bonding agent that adheres to motor shaft. When old seal head is removed, bonding agent no longer exists and bellows may crack or split during removal. Installation of new mechanical seal is always recommended if it becomes necessary to remove existing seal from shaft.

10. Clean and lubricate shaft (6A) with water-soluble lubricant and make sure no sharp edges exist to cut or scratch bellows of new seal.

11. Press new seal seat firmly into seal cap. Avoid direct contact of seal face with metallic or abrasive objects and wipe clean after installation to ensure abrasive free sealing surface.

12. Slide new seal head assembly onto shaft by applying even pressure to base of assembly.

13. Install seal cap (2N) down shaft.

14. See reassembly instructions.

7.5 Wear ring replacement

1. Complete preparations.

2. Back-pull rotating assembly.

3. It may be necessary to remove volute (1A) from piping, to facilitate easy access to interior of volute. If necessary, remove flange bolts at piping.

4. To remove worn Case Wear Ring (4A), drill two holes slightly smaller than width of ring into exposed edge of ring. Once holes are drilled, a chisel may be used to completely sever ring at holes and break ring into two halves for easy removal.

5. Clean the ring cavity in the volute prior to installing wear ring to ensure a properly aligned fit.

6. To reassemble, press fit new wear ring squarely into volute casing cavity. Ring may be tapped into place to make sure it is completely impressed into cavity.

Do not use metal tooling against wear ring surfaces. Use only rubber, rawhide, wood or other soft material to prevent damage to ring.

PACO Pumps

English (US)

PACO Pumps

7.6 Reassembly of pumps

1. All parts should be cleaned before reassembly.

2. Refer to parts list to identify required replacement items Specify pump serial or catalog number when ordering parts.

3. Reassembly is the reverse of disassembly.

4. Observe the following when reassembling the liquid end:

• All mechanical seal components must be in good condition or

leakage may result. Replacement of complete seal assembly is recommended.

• New shaft sleeves are installed by bonding to shaft with

hydraulic setting locktite.

5. Re-install coupling guards on coupled pumps.

7.7 Ordering parts

Grundfos Pumps has over 90 years of experience in the design, manufacture, and application of centrifugal pumps and pumping systems. Grundfos's commitment to state-of-the-art pump design and quality manufacturing assures maximum user benefits with optimum equipment life at lower cost.

Grundfos's commitment to their customers continues through an extensive service organization. Highly trained technicians can assist customers with initial startup, troubleshooting, repair, and system analysis.

PACO maintains an extensive stock of replacement parts and parts kits for our most popular model pumps. Shipment of these parts is normally made within three days after receipt of an order. On larger pumps, where it is impractical for our factory to inventory low usage parts, replacement parts are normally manufactured and shipped within 15 working days of receipt of an order. In order to reduce pump repair time and shorten inconvenient pump service interruptions, it is suggested that the pump user stock spare parts. For suggested spare parts see Replacement Parts Guide A1b.2, attached, and contact your local PACO Sales Representative (see back cover for the number of your nearest PACO Sales office). Since spare parts requirements and quantities vary for specific pump constructions, allow your PACO Representative to help in defining your spare part requirements. To ensure that the proper replacement parts are ordered for your particular pump model, when you call:

• Identify all pertinent data from the pump name plate (see

Pump Identification ). This should always include the pump Catalog or Model Number, and the pump Serial Number.

• For replacement impellers, also include from the nameplate

the operating conditions (GPM and TDH) and the impeller diameter.

• Identify all parts by item number and description as indicated

by the appropriate assembly drawing in this manual, for your particular pump model.

Warning

Coupling guard must be reinstalled and in place prior to operation.

7.8 Type LF, cross section and parts list

PACO Pumps

ITEM NO PART NAME ITEM NO PART NAME ITEM NO PART NAME

1A Casing *10A Washer, Packing 16L Plug, Seal Chamber

2K Backplate 10A Washer, Impeller 18A Bearing, Inboard

3A Enclosed Impeller 11A Gasket, Casing 18B Bearing, Outboard

4A Case Wear Ring 11F Gasket, Backplate 20Y Bearing Frame

**4F Balance Ring 12A Key, Impeller *22A

5A Shaft Sleeve 12B Key, Coupling 26P Seal Housing

*5L Lantern Ring *13A Packing *26U Packing Box

6A Shaft 13G Slinger *35F Nut, Packing Gland

*7A Packing Gland 14A Shaft Seal 61C Snap Ring

8A Cap Screw, Impeller 14S Lip Seal *61J Snap Ring

8B Cap Screw, Casing 16A Plug, Drain

8D Cap Screw, Brg. Frame 16D Plug, Grease/Oil Filter

* Packed Pumps Only

** If Applicable

Stud, Packing

Gland

TM05 4796 3712

English (US)

PACO Pumps

7.9 Type LC, cross section and parts list

ITEM NO PART NAME ITEM NO PART NAME

*1A Casing 11F Gasket, backplate

2K Backplate 12A Key

3A Impeller *13A Packing

4A Front case wear ring 13G Slinger

4F Rear case wear ring 14A Mechanical seal

5A Shaft sleeve 16A Plug, drain

*5L Lantern ring 16J Plug, stuffing box

*7A Packing gland 21A Bracket

8A Impeller capscrew *22A Stud, packing gland

8B Capscrew, casing 34B Nameplate

8D Capscrew, bracket *35F Nut, packing gland

8N Capscrew, motor 61B Snap ring

10A Washer, impeller *61L Retaining ring

*10K Washer, packing 65A Motor

11A Gasket, casing 84R Set screws

* Packed pumps only

TM05 8911 2913

7.10 Type LCV, cross section and parts list

PACO Pumps

ITEM NO PART NAME ITEM NO PART NAME

1A Volute 10A Impeller washer 2H Hand hole cover (not shown) 12A Key 2K Backplate 13G Slinger 3A Impeller 14A Single mechanical seal assembly

4Q Suction cover wear ring 20H Stand

4S Impeller wear ring 21F Pedestal bracket 5A Sleeve 32C Elbow with clean out port 8A Impeller screw

TM05 8910 2913

English (US)

PACO Pumps

7.11 Type LCS, cross section and parts

ITEM NO PART NAME ITEM NO PART NAME

1A VOLUTE 17E SEAL CAP O-RING

2N SEAL CAP 20B BASE RAIL

3A IMPELLER 20C MOTOR DECK

4A CASE WEAR RING 20J CAST IRON STAND

4F BALANCE RING 20D PUMP SUPPORT

6A PUMP SHAFT 21A MOTOR BRACKET

8B VOLUTE SCREW 22A SEAL CAP STUDS

8C PUMP SHAFT SCREW 23D COUPLING HALVES

8E COUPLING SCREW 24H BUSHING

8F COUPLING GUARD SCREW 34B IMPELLER WASHER

8G LOCATING RING SCREW 34C PUMP SHAFT WASHER

8N MOTOR SCREW 34D COUPLING WASHER

11A VOLUTE GASKET 35E COUPLING NUT

12B COUPLING KEY 34F COUPLING GUARD

14A SEAL ASSEMBLY 35F SEAL CAP NUT

15A LOCATING RING 65A MOTOR

16A PIPE PLUG

TM06 1700 2614

Trouble Shooting

8.1 Symptom

Symptoms Cause Code

Pump does not deliver any liquid at start-up.

Pump stops delivering liquid after start-up.

Pump overheats and/or ceases to deliver liquid.

Shaft seal leaks appreciably, or the packing leaks excessively.

Shaft seal or packing fails prematurely.

Bearings overheat and/or fail prematurely.

Insufficient flow rate.

Excessive flow rate.

Discharge pressure is too high.

Pump uses too much power.

Pump runs rough and noisily.

8.2 Possible Causes

1*2*3*4*5*6*7*8*9*10*11*14*16*17*22*23*24*34

2*3*4*5*6*7*8*9*10*11*12*13*22*23*24*34

1*3*9*10*11*21*22*27*29*30*31*33*34*40*41

2*3*4*5*6*7*8*9*10*11*14*16*17*20*21*22*23*24*25*26*34

15*18*20*34

4*14*16*18*20*22*23*24*25*26*34

27*28*29*30*33*34*35*36*39*41

12*13*27*28*29*30*33*34*35*36*37*38*39*41

15*16*18*19*20*23*25*27*28*31*33*34*35*37*38*44

2*3*4*5*6*7*8*9*10*11*15*17*18*21*23*24*27*28*29*30*

31*32*33*34*40*41*42*45*46*

27*28*29*30*31*32*33*34*40*41*42*43*44*45*46

PACO Pumps

1. The pump has not been properly bled of air.

2. The pump suction line have not been completely primed.

3. The suction head (NPSHR) required by the pump is too high, or the net positive suction head available (NPSHA) at your facility is too low.

4. The fluid pumped contains too much entrained air or gas.

5. There are air pockets in the suction line.

6. An entry of air has suddenly occurred in thesuction line.

7. An entry of air past the shaft seal into the pump has occurred.

8. The inlet of the suction line is insufficiently submerged.

9. The suction valve is closed or only partially open.

10. The suction strainer is clogged with dirt or debris.

11. The foot valve is clogged or undersized.

12. Little or no cooling fluid supplied to the shaft seals.

13. The lantern ring is not positioned opposite the flushing inlet thereby restricting fluid flow.

14. Pump drive rotational speed too low.

15. Pump drive rotational speed too high.

16. Pump rotation wrong or impeller installed backwards.

17. Total head of installation (back Pressure) higher than rated total head of the pump.

18. Total head of installation (back Pressure) lower than rated total head of the pump.

19. Density of fluid pumped differs from that specified when the pump was purchased.

20. Viscosity of fluid pumped differs from that specified when the pump was purchased.

21. The pump is operating at too low a rate of flow (The discharge valve may be throttled too much).

22. If pumps are operating in parallel, the pump characteristics may not be suitable for parallel operation.

23. The impeller may be clogged with debris.

24. The impeller may be damaged.

25. The casing and impeller wear rings may be excessively worn.

26. There may be internal leakage from the discharge to the suction compartments as the result of internal gasket failure.

27. There may be a misalignment of the pump shaft.

28. The shaft may chatter because it is bent.

29. The pump may run rough due to improper balancing of the impeller.

30. The shaft may not be running due to worn bearings.

31. The impeller may be rubbing against the inside of the case.

32. The concrete pad might not be of sufficient size to provide pump stability.

33. The pump may have become misaligned during Installation.

34. The operating conditions of the installation do not agree with the data specified when the pump was purchased.

35. The shaft seal may be incorrectly installed, or the stuffing box has not been packed correctly.

36. The shaft sleeve may be scored or pitted in the region of the packing due to dirt or abrasive matter in the flushing fluid.

37. Excessive tightening of the packing gland may block the flushing port thereby diminishing the sealing fluid flow.

38. Packing material may have become wedged or extruded between the shaft and the bottom of the stuffing housing due to excessive clearance on the packing backup washer.

39. The mechanical seal may have been damaged by running dry.

40. There may be excessive axial thrust (side loading) due to improper impeller central alignment.

41. The bearings may be worn.

42. The bearings may have been damaged during installation and/ or dirt or other foreign matter may have entered the bearings during greasing or oiling.

43. Excessive greasing may cause the bearings to overheat.

44. Inadequate lubrication may be causing bearing failure.

45. Dirt may have entered the bearings past the O-Rings.

46. Moisture may have entered the bearing housing causing the bearings to rust.

16. Technical data 42

16.1 Enclosure 42

16.2 Main dimensions and w eig ht 43

16.3 Surroundings 43

16.4 Terminal tightening tor qu es 43

16.5 Cable length 44

16.6 Fuses and cable gauge size 44

16.7 Inputs and outputs 46

16.8 Sound pressure level 46

17. Disposal 46

Caution

Note

Grundfos CUE

9. Grundfos CUE

Variable Frequency Drive

Installation and Operating Instructions

Warning Prior to installation, read these installation and

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

Symbols used in this document

Warning If these safety inst ructi ons ar e not obser ved,

it may result in pe rsonal injury!

If these safety inst ructi ons ar e not obser ved, it may result in malfunction or damage to the equipment!

Notes or instructions that make the job easier and ensure safe operation.

Introduction

9.1

This manual introdu ce s all as pects of your Grundf os C UE variable frequency dri ve in the o utpu t curre nt ra nge of 1.8 to 177 A.

Always keep this manu al clos e to the CUE.

9.2 General description

The CUE is a series of ext erna l varia ble frequen cy drive s especially designe d for pumps.

Thanks to the start-up guide in the CU E, the install er can quick ly set central parameter s and put the CUE int o ope rati on.

Connected to a sen so r or an external control signa l, the CUE will quickly adapt th e pump speed to t he actu al dem and .

9.3 Applications

The CUE series an d Grundfos standard pumps are a supplement to the Grundfos E- pumps r ange w ith int egr ated variab le frequency drive .

A CUE solution offers t he same E-pu mp fu ncti onali ty

• in the su pply v oltage o r powe r ra nges not c overe d by the E-pump range.

• in applications where an integrated variable frequency drive is not desirable or permiss ible.

9.4 References

Techn ical do cum entation f or G rund fos C UE:

• The ma nu al contains all info rma tion r equir ed for put ting t he CUE into oper ation.

• The data boo klet contains a ll technic al infor mation abo ut the construction and applic atio ns of the C UE.

• Service in str uction s contain a ll requir ed ins truct ions fo r dismantling and r epairing the variable frequency d riv e.

Techn ical do cum entation is avail able on www.grundfos .com > International webs ite > WebCAP S.

If you have any ques tion s, pl ease c ontact th e ne arest Gr un dfos company or servic e work shop .

Safety and warnings

10.

10.1 Warning

Warning Any installation, maintenance and inspection

must be carried out by trained personnel.

Warning Touching the electrical p arts m ay be fatal, ev en

after the CUE has been switched off. Before making any work o n th e CUE , the m ains

supply and other input voltages must be switched off at least for as long as stated below.

Voltage Min. waiting time

4 minutes 15 minut es 20 m inutes 200-240 V 1 - 5 hp 7.5 - 60 hp 380-500 V 0.75 - 10 hp 15 - 125 hp 525-600 V 1 - 10 hp 525-690 V 15 - 125 hp

Wait only for shorter time if stated s o on the n amep late o f the CUE in question.

10.2 Safety regulations

• The On/Off button of the control panel does not disconnect the CUE from the p ower su ppl y a nd mu st t her ef or e n ot be us ed as a safety switch.

• The CUE mus t be gro unded c orre ctly an d protec ted aga inst indirect contact a ccor ding t o nat ional re gu lation s.

• The leak age c urre nt to gr ound ex ceed s 3. 5 mA.

• Enclos ure c lass N EMA 1 mus t no t be install ed freely accessible, but only in a panel.

• Enc losur e clas s NE MA 12 mu st n ot be in stalled outdoor s without additional pro tect ion agai nst wat er an d the sun .

• Alwa ys ob serv e nat ional an d local r egu lations as t o cable gauge size, short-circuit protection and overcurrent protection.

10.3 Installation requirements

The general safe ty ne cess itates s pe cial co nside rations as t o these aspects:

• fuses and sw itch es for o ve rcur rent and sh ort- circ uit p rotect ion

• selection of cables (mains current, motor, load distribution and relay)

• net configur atio n (IT, TN, grounding)

• safety on c onnec ting inputs a nd out puts (PELV).

10.3.1 IT mains

Warning Do not connect 380-500 V CUE variable frequency

drives to mains supplies with a voltage between phase and ground of more than 440 V.

In connection with IT mains and grounded delta mains, the supply voltage may exceed 440 V between phase and ground.

10.3.2 Aggressive environment

The CUE should not be installed in an

Caution

The CUE contains a l arge n umber of mec hanic al and el ec tronic components. They ar e all vuln erab le to en vi ronm ental effects.

environment where the air contains liquids, particles or gases wh ich may affec t and dama ge the electronic components.

10.4 Reduced performance under certain conditions

The CUE

• low air pre ssure ( at hig h altitu de)

• long mot or ca ble s.

The required measures are described in the next two sections.

10.4.1

PELV = Protective Extra Low Voltage. At low air pressure, the cooling capacity of air is reduced, and the

CUE automatic ally redu ce s the perfo rma nce t o prev ent overl oad . It may be necessa ry to se lect a CU E w ith a h igher perform anc e.

10.4.2 Reduction in connection with long motor cables

The maximum cable length for the CUE is 1000 ft for unscreened and 500 ft for screen ed c ables . In case of long er cables , co ntact Grundfos.

The CUE is designe d for a motor ca ble with a ma ximu m gaug e size as stated in se ctio n 16. 6 Fuses and cable gau ge s ize .

will reduce its performance under these conditions:

Reduction at low air pressure

Warning At altitudes above 6600 ft, PELV cannot be met.

Grundfos CUE

Identification

11.

11.1 Nameplate

The CUE can be iden tified b y mea ns of the n An example is s hown b elow.

T/C: CUE202P1M2T5E20H1BXCXXXSXXXXAXBXCXXXXDX

Prod. no: 12345678

1.5 kW (400V) IN: 3x380-500 V 50/60Hz 3.7A OUT: 3x0-Vin 0-100Hz 4.1 A 2.8 kV CHASSIS/IP20 Tamb. 45C/122F

S/N: 123456G234

IIIIIIIIIIIBAR CODEIIIIIIIIIII

Listed 76X1 E134261 Ind. Contr. Eq. See manual for prefuse

CAUTION:

SEE MANUAL / VOIR MANUEL

WARNING:

STORED CHARGE DO NOT TOUCH UNTIL 4 MIN AFTER DISCONNECTION

CHARGE RESIDUELLE, ATTENDRE 4 MIN APRES DECONNEXION

Fig. 1 Example of nam eplate

Text Description

T/C: Prod. no: Produc t nu mber : 123 45678

S/N:

1.5 kW Typical shaft power on the mot or IN:

OUT:

CHASSIS/ IP20

Tamb. Max imum amb ient temp erat ure

CUE (product n am e) 202P1M2... (inter nal co de)

Serial number: 12345 6G2 34 The last three digits indic ate the prod uc tion dat e: 23 is the week, and 4 is the ye ar 2004.

Supply voltage, freq uency and m axim um inp ut current

Motor voltage, freque ncy a nd max imum o utput current. The maximum out put frequ ency usuall y depends on the pum p type.

Enclosure class

ameplate.

MADE IN DENMARK

12.2 Transportation and unpacking

The CUE must only be unpacked at the installation site to prevent damage during the tran spor t to the si te.

The packaging co ntains acces sor y bag (s) , docum e ntation and the unit itself. See fig. 2.

Documentation

Accessory bag(s)

TM04 3272 3808

Fig. 2 CUE packaging

12.3 Space requirements and air circulation

CUE units can be mou nted side by side, bu t as a sufficien t air circulation is requir ed fo r cooli ng the se re qui reme nts must be met:

• Sufficient free s pace abov e and b elow t he CUE . See table below.

• Ambient temper ature u p to 12 2 °F.

• Hang the CU E d irect ly on the wa ll, or fit it wi th a ba ck pla te. See fig. 3.

TM03 8857 2607TM03 8859 2607

11.2 Packaging label

e CUE can also be identi fied by mean s of the lab el on the

Th packaging.

Mechanical installation

12.

The individual CUE cabine t siz es ar e charac ter ised by the ir enclosures. The table in se ction 16.1 shows the re lation sh ip o f enclosure class and enclosure t y pe.

12.1 Reception and storage

Check on receipt that the pac kagin g is intac t, and the un it is complete. In case of d amag e du ring tra nsport , contact th e transport company to com pla in.

Note that the CUE is delivered in a packaging which is not suitable for outdoor storag e.

Fig. 3 CUE hung directl y on the wall or fi tted w ith a back

plate

Required free space above and below the CUE

Enclosure Space [in]

A2, A3, A5 3.9 B1, B2, B3, B4, C1, C3 7.9 C2, C4 8.9

12.4 Mounting

Caution

1. Mark and drill holes. See the dim ens ions in sec tion 16.2.

2. Fit the screws, but leave loose. M ount the CUE , and tighte n the four screws.

The user is responsible for mounting the CUE securely on a firm su rfac e.

Instructions ac cord ing to EN IEC 61800 -5-1 :

• The CUE m ust be stationar y, installed permanently and connected perma nen tly to the m ain s supp ly.

• The groun d co nnec tion mus t be carri ed out with dupl ica te protective conduc tors or with a single rei nforce d protec tiv e conductor with a g aug e size of m inimum 8 AWG.

13.1.2 Protection against short-circuit, fuses

The CUE and t h e s upply system mus t be protected against s hor t circuit.

Grundfos demand s tha t the ba ck- up fus es men tione d in sec tion

16.6 are used for pro tect ion aga inst short- circ uit.

The CUE offers com ple te sh ort-c ircuit prot ectio n in c ase o f a short-circuit on the moto r output .

13.1.3 Additional protection

Grundfos CUE

Fig. 4 Drilling of hole s

13.

Electrical connection

Warning The owner or installer is responsible for ensuring

correct grounding and protection according to national and local standards.

Warning Before making any work o n th e CUE , the m ains

supply and other voltage inputs must be switched off for at leas t as long as stat ed in section 3. Safety and warnings.

ELCB

Fig. 5 Example of th ree- phase mains conn ect ion of the CU E

with mains switch, back -up f uses an d ad dition al protection

13.1 Electrical protection

13.1.1 Protection against electric shock, indirect contact

Warning The CUE must be grounded correctly and

protected against indirect contact according to national regulations.

The leakage curren t to gro und e xce eds 3.5 mA, and a reinforced ground connection is required.

Protective cond ucto rs mus t alwa ys ha ve a yello w/green (PE ) or yellow/green/b lue (PEN ) colo r m ark ing.

Caution

If the CUE is conne cte d to an electri cal ins tallation w here a n earth leakage circuit breaker (ELCB) is used as additional protection, the circuit break er mus t be of a t ype m ark ed wit h the following symbols :

TM03 8860 2607

The circuit brea ker is type B. The total leakage curre nt of all the electr ical equ ipme nt in the

installation must be taken i nto accou nt. The leakage curre nt of the CU E in norm al opera tion can be se en

in section 16. 7.1 Mains supp ly (L 1, L2, L 3). During start and in asy mme trical s upply sys tems, t he leak age

current can be higher than norm al and m ay c ause the EL CB to trip.

13.1.4 Motor protection

The motor requi res no ex tern al moto r pr ote ctio n. The C UE protects the motor a gains t therm al ov erload ing and block ing .

13.1.5 Protection against overcurrent

The CUE has an int ernal overcur rent protec tion for o verlo ad protection on the m oto r output .

6.1.6 Protection against supply voltage transients

The CUE is protected against supply voltage transients according

TM03 8525 1807

to EN 61800-3, sec ond env iron ment .

The leakage curren t to gro und e xce eds 3 .5 mA.

ELCB

13.2 Mains and motor connection

The supply voltage and freq uency are m arke d on the C UE nameplate. Make sur e tha t the CU E is suitab le for the p owe r supply of the installatio n site.

The maximum output voltage of the CUE is equal

Note

13.2.1 Mains switch

A mains switch can be installed before the CUE according to local regulations. Se e fig. 5.

to the input voltage. Example: If the sup ply vo ltage is 208 V, choose a 208 V rated m otor.

Caution

Grundfos CUE

13.2.2 Wiring diagram

The wires in th e termi nal b ox mu st b e as sh or t as p ossib le. Excepted from thi s is t he prote ctive c on ductor which must be so long that it is the last one to be dis conn ected in case the cable is inadvertently p ulled ou t of the cabl e en try.

Fig. 6 Wiring dia gram , thre e-pha se ma ins co nnec tion

Terminal Function

91 (L1)

Three-phase suppl y92 (L2) 93 (L3) 95/99 (PE) Ground connectio n 96 (U) 97 (V) 98 (W)

Note

13.2.3 Mains connection, enclosures A2 and A3

For information a bout enclos ure, s ee table in sect ion 16.1.

1. Fit the mounting pla te with two s crew s.

Three-phase motor co nnect ion, 0-100 % of

supply voltage

For single-phase connection, use L1 and L2. Cable si z in g: To determine the conductor gauge size for

single-phase mains input cable, multiply the CUE's max. current output by 2, and choose the gauge size based on that amperage.

For three-phase input, use the same conductor gauge size as selected for the motor.

For CUE to motor, use standard published threephase wiring charts based on motor size.

Check that mains volta ge a nd fre quency correspond to the values on the nameplate of the CUE and the motor.

2. Connect the ground cond uc tor to termin al 95 (PE ) and the mains conductors t o the t ermin als 91 (L1), 92 (L2 ), 93 (L 3) of the mains plug. Put the main s pl ug int o the soc ket m arked MAINS.

TM03 8799 2507

Fig. 8 Connecting th e groun d cond uctor and ma ins

3. Fix the mains cable to the mo unti ng plate.

Fig. 9 Fixing the main s c able

Note

conductors

For single-phase connection, use L1 and L2.

TM03 9011 2807

TM03 9014 2807

Fig. 7 Fitting the mou ntin g plate

TM03 9010 2807

13.2.4 Motor connection, enclosures A2 and A3

Note

clamp.

For information a bout enclos ure, s ee table in sect ion 16.1.

Caution

1. Connect the ground c onduc tor to term inal 99 (PE ) on the mounting plate. Connect the motor conductors to the terminals 96 (U), 97 (V), 98 (W) of the m otor pl ug.

Fig. 10 Connecting t he gr ound c onduc tor and mo tor

2. Put the motor plug in to the s ock et mark ed MOTOR. F ix the screened cable to the m ount ing plate with a c able c lamp.

The motor cable must be screened for the CUE to meet EMC requ irements.

conductors

13.2.5 Enclosure A5

For information a bou t enclos ure, see table in sect ion 16.1.

Mains connection

Check that mains volta ge and freq uency

Caution

1. Connect the ground conductor to terminal 95 (PE). See fig. 12.

2. Connect the mains c ond uctors to t he te rmin als 91 ( L1 ), 92 (L2), 93 (L3) of the mains pl ug.

3. Put the mains plug into the socket m arke d MAIN S.

4. Fix the mains cable with a cable clam p.

TM03 9013 2807TM03 9012 2807

Fig. 12 Mains con necti on, A5

Note

Motor connection

Caution

1. Connect the ground conductor to terminal 99 (PE). See fig. 13.

2. Connect the motor conductors to the terminals 96 (U), 97 (V), 98 (W) of the motor plu g.

3. Put the motor plug in to the s ock et ma rked MO TOR.

4. Fix the screened cable w ith a c able c lamp.

correspond to the values on the nameplate of the CUE and the mo to r.

For single-phase connection, use L1 and L2.

The motor cable must be screened for the CUE to meet EMC requ irements.

Grundfos CUE

TM03 9017 2807

Fig. 11 Connecting t he m otor plu g an d fixi ng the scre ened

Note

cable

Cable screens must be grounded at both ends.

The cable screen must be exposed and in physical contact with the mounting plate and clamp.

TM03 9018 2807

Fig. 13 Motor connec tion, A 5

The cable screen must be exposed and in physical contact with the mounting plate and

Note

Grundfos CUE

13.2.6 Enclosures B1 and B2

For information a bout enclos ure, s ee table in sect ion 16.1.

Mains connection

Check that mains volta ge a nd fre quency

Caution

1. Connect the ground conductor to terminal 95 (PE). See fig. 14.

2. Connect the mains c onduc tors t o the te rmin als 91 ( L1), 92 (L2), 93 (L3).

3. Fix the mains cable wi th a c able cla m p.

correspond to the values on the nameplate of the CUE and the motor.

13.2.7 Enclosures B3 and B4

For information a bou t enclos ure, see table in sect ion 16.1.

Mains connection

Check that mains volta ge and freq uency

Caution

1. Connect the ground conductor to terminal 95 (PE). See figs 16 and 17.

2. Connect the mains c ond uctors to t he te rmin als 91 ( L1 ), 92 (L2), 93 (L3).

3. Fix the mains cable with a cable clam p.

Motor connection

Caution

1. Connect the ground conductor to terminal 99 (PE). See figs 16 and 17.

2. Connect the motor conductors to the terminals 96 (U), 97 (V), 98 (W).

3. Fix the screened cable w ith a c able c lamp.

correspond to the values on the nameplate of the CUE and the mo to r.

The motor cable must be screened for the CUE to meet EMC requ irements.

Fig. 14 Mains conne ction, B1 and B2

Note

Motor connection

Caution

1. Connect the ground conductor to terminal 99 (PE). See fig. 15.

2. Connect the mot or co ndu cto rs to t he term ina ls 96 (U), 97 (V ), 98 (W).

3. Fix the screened ca ble with a cab le clam p.

For single-phase connection, use L1 and L2.

The motor cable must be screened for the CUE to meet EMC requ irements.

TM03 9019 2807

Fig. 16 Mains and m oto r con nect ion, B3

The cable screen must be exposed and in

Note

physical contact with the mounting plate and clamp.

TM03 9446 4007

Fig. 15 Motor conn ection , B1 a nd B2

The cable screen must be exposed and in physical contact with the mounting plate and clamp.

TM03 9020 2807

TM03 9449 4007

Fig. 17 Mains and m oto r con nect ion, B4

The cable screen must be exposed and in

Caution

Note

13.2.8 Enclosures C1 and C2

For information a bout enclos ure, s ee table in sect ion 16.1.

Mains connection

1. Connect the ground conductor to terminal 95 (PE). See fig. 18.

2. Connect the mains c onduc tors t o the te rmin als 91 ( L1), 92 (L2), 93 (L3).

Motor connection

1. Connect the ground conductor to terminal 99 (PE). See fig. 18.

2. Connect the mot or co ndu cto rs to t he term ina ls 96 (U), 97 (V ), 98 (W).

3. Fix the screened ca ble with a cab le clam p.

physical contact with the mounting plate and clamp.

Check that mains volta ge a nd fre quency correspond to the values on the nameplate of the CUE and the motor.

The motor cable must be screened for the CUE to meet EMC requ irements.

13.2.9 Enclosures C3 and C4

For information a bou t enclos ure, see table in sect ion 16.1.

Mains connection

Check that mains volta ge and freq uency

Caution

1. Connect the ground conductor to terminal 95 (PE). See figs 19 and 20.

2. Connect the mains cond uct ors t o the termi nals 91 (L1 ), 92 (L2), 93 (L3).

Motor connection

Caution

1. Connect the ground conductor to terminal 99 (PE). See figs 19 and 20.

2. Connect the motor conductors to the terminals 96 (U), 97 (V), 98 (W).

3. Fix the screened cable w ith a c able c lamp.

correspond to the values on the nameplate of the CUE and the mo to r.

The motor cable must be screened for the CUE to meet EMC requ irements.

Grundfos CUE

Fig. 18 Mains and mo tor c onnec tion , C1 a nd C2

The cable screen must be exposed and in

Note

physical contact with the mounting plate and clamp.

TM03 9016 2807

Fig. 19 Mains and m oto r con nect ion, C3

The cable screen must be exposed and in

Note

Fig. 20 Mains and m oto r con nect ion, C4

physical contact with the mounting plate and clamp.

The cable screen must be exposed and in physical contact with the mounting plate and clamp.

TM03 9448 4007

TM03 9447 4007

Caution

Note

Grundfos CUE

13.3 Connecting the signal terminals

As a precaution, signal cables must be separat ed from other groups by reinforced insulation in their entire lengths.

If no external on/o ff switch is conn ect ed, sho rtcircuit terminals 18 and 20 usi ng a sho rt wi re.

Connect the signal cables according to the guidelines for good practice to ensure EMC-correct installation.

• Use sc reene d si gnal ca ble s with a c onduc tor gauge s ize of min. 22 AWG and max. 16 AWG.

• Use a 3-c ondu ctor sc reen ed bus cable in new sys tem s.

13.3.1 Wiring diagram, signal terminals 0/4-20 mA

0/4-20 mA

Terminals 53 and 54:

0-10 V0-10 V

1 K

See section

6.3.5

0-20 mA

GND

AO 1

RS-485 A

RS-485 B

RS-485 GND Y

+10 V out

GND

Sensor 1

Ext. setpo int

Terminal Type Function

12 +24 V out Supply to sensor 13 +24 V out Additional supply 18 DI 1 Digital input, start/stop 19 DI 2 Digital input, programma ble 20 GND Groun d for dig ital inputs 32 DI 3 Digital input, programma ble 33 DI 4 Digital input, programma ble 39 GND Groun d for ana log out put 42 AO 1 Analog output, 0-20 mA 50 +10 V out Supply to potentiometer 53 AI 1 External setpo int, 0- 10 V/0/ 4-20 mA 54 AI 2 Sensor input , se nsor 1, 0/4- 20 mA 55 GND Groun d for ana log inpu ts 61 RS-485 GND Y GENIbus, GND 68 RS-485 A GENIbus, signal A (+) 69 RS-485 B GENIbus, signal B (-)

Termina ls 2 7, 29 a nd 37 ar e not used.

Note

The RS-485 screen must be connected to ground.

13.3.2 Minimum connection, signal terminals

Operation is only po ssible wh en the te rmin als 18 and 2 0 are connected, for in stance by mean s of a n exter nal on/ off switc h or a short wire.

+24 V out

DI 2

Start/stop

DI 3

DI 4

Fig. 21 Wiring diagram, signal t e rm ina l s

GND

TM03 8800 2507

Start/stop

GND

Fig. 22 Required m inimu m con nect ion, signal term inals

TM03 9057 3207

13.3.3 Access to signal terminals

Bus Ter = ON

All signal terminals a re beh ind th e termi nal cov er of the C UE front. Remove the termi nal c over a s sho wn i n figs 23 a nd 24.

Fig. 23 Access to si gnal t ermin als, A2 and A3

13.3.4 Fitting the conductor

1. Remove the insulatio n at a le ngth of 0.34 - 0.3 9 in (9-10 m m).

2. Insert a screwdriver with a tip of max imum 0.01 5 x 0.1 in (0.4 x 2.5 mm) into the square hole.

3. Insert the conductor in to the c orre spon ding round hole. Remove the screwdr iver. The conduct or is n ow fix ed in the terminal.

Fig. 26 Fitting the con ductor into the signa l termin al

13.3.5 Setting the analog inputs, terminals 53 and 54

TM03 9003 2807

The contacts A53 and A54 are posit ioned behind the c ontrol panel and used for sett ing t he sign al type o f the two a nalog inputs.

The factory setting of t he inputs is voltage signa l "U".

If a 0/4-20 mA sensor is connected to terminal 54,

Note

Remove the co ntrol pa nel to set th e contac t. Se e fig. 27.

the input must be set to current signal "I". Switch off the power supply before setting the

A54.

Grundfos CUE

TM03 9026 2807

Fig. 24 Access to signal terminals, A5, B1, B2, B3, B4, C1,

C2, C3 and C4

Fig. 25 Signal term inals ( all enc losur es)

A53 UI

TM03 9004 2807

Fig. 27 Setting contact A54 to c urre nt si gnal "I "

6.3.6 RS-485 GENIbus network connection

One or more CUE units can be co nnect ed to a c on trol unit via GENIbus. See the exam ple in fig. 28 .

TM03 9025 2807

Fig. 28 Example of an RS-485 GENIbus network

A54 UI

TM03 9104 3407TM03 9005 2807

TM03 9007 2807TM03 9008 2807TM03 9009 2807

Grundfos CUE

The reference poten tial , GN D, for R S-48 5 (Y) co mmu nicat ion must be connecte d to ter minal 61.

If more than one CU E unit is co nnecte d to a GE NIb us netw ork, the termination contact of the las t CUE m ust be s et to "ON " (termination of the RS-4 85 por t).

The factory setting of t he term inat ion con tact is "OF F" (not terminated).

Remove the contr ol pane l to se t the co ntact. See f ig. 2 9.

BUS TER

OFF ON

Fig. 29 Setting the ter mina tion c ontact to "ON "

13.4 Connecting the signal relays

Access to signal relays

The relay outputs are po sitio ned as sh own in figs 31 to 36.

Fig. 31 Terminals for relay connection, A2 an d A3

TM03 9006 2807

As a precaution, signal cables must be separat ed

Caution

Fig. 30 Terminals for signal relays in normal s tate

Terminal Function

C 1 C 2 Common NO 1 NO 2 Normally open contact NC 1 NC 2 Normally closed contact

from other groups by reinforced insulation in their entire lengths.

NC 1

NO 1

(not activated)

C 1

NC 2

NO 2

Fig. 32 Terminals for relay connection, A5, B1 and B2

TM03 8801 2507

Fig. 33 Terminals for relay conne ction, C1 and C 2

Fig. 34 Terminals for relay connectio n, B3

13.5 Connecting the MCB 114 sensor input module

The MCB 114 is an option offering additional analog inputs for the CUE.

13.5.1 Configuration of the MCB 114

The MCB 114 is equipped with three anal og inputs for these sensors:

• One addit ional s ensor 0/4-20 mA. See section 10.7.13 Sen sor 2 (3. 16).

• Two Pt100/Pt1000 te mper ature s enso rs for m e asure ment o f motor bearin g temp eratu re or an al tern ativ e temp erat ure, such as liquid temperat ure. Se e sec tions 10.7.18 Temperature sensor 1 (3.21) an d 10.7.19 Temperature sensor 2 (3.22).

When the MCB 114 has been installed, the CUE will automatically

TM03 9442 4007TM03 9441 4007TM03 9440 4007

detect if the sensor is Pt10 0 or P t1000 wh en it is swit ched on.

13.5.2 Wiring diagram, MCB 114

Grundfos CUE

Fig. 35 Terminals for relay connectio n, B4

Fig. 36 Terminals for relay connection, C3 and C4, in th e

upper right corner of the CUE

GND

WIRE

TEMP

GND

WIRE

TEMP

GND

I IN

VDO

1 98765432

Fig. 37 Wiring diagram , MCB 114

Terminal Type Function

1 (VDO) +24 V out Supply t o sen sor 2 (I IN) AI 3 Sensor 2, 0/4-20 mA 3 (GND) GND Ground for analog input 4 (TEMP)

5 (WIRE) 6 (GND) GND Ground for temperature senso r 1 7 (TEMP)

8 (WIRE) 9 (GND) GND Ground for temperature senso r 2

Termina ls 1 0, 11 and 12 are not used.

AI 4 Tem peratur e sen sor 1, P t100/ Pt100 0

AI 5 Tem peratur e sen sor 2, P t100/ Pt100 0

12111

TM04 3273 3908

Grundfos CUE

13.6 EMC-correct installation

This section gives guidelines for good practice when installing the CUE. Follow these guideli nes to meet EN 6 1800- 3, firs t environment.

• Use o nly mo tor a nd sig nal cab les wit h a br aided m etal sc reen in applications without output filter.

• There are no spe cial re quirem e nts to supply cabl es, a part from local require ments.

• Leav e the screen a s clos e to the co nnec ting ter mina ls a s possible. See fig. 38.

• Avoid terminating the screen by twis t ing the ends. See fig. 39 . Use cable clamps or EMC sc rewe d cable entr ies ins tead.

• Connect the screen to ground at both ends for both motor and signal cables. See fig. 40. If the c ontrolle r h as no c able clamps, connect only the s cree n to the CUE. See fig . 41.

• Avoid unsc reen ed m otor an d s ignal c ables in electr ica l cabinets with variable frequ ency dri ves.

• Make t he mot or cab le as shor t as pos sible in applic ations without output filter to limit the noise level an d minimis e leakage currents.

• Screw s for groun d conn ect ions m ust alway s be ti ghtene d whether a cable is co nn ected or not.

• Keep main cab les , mot or cab les an d signa l ca bles s eparated in the installation, if possible.

Other installation methods m ay give s imilar EM C re sults if the above guidelines for good practice are followed.

CUEController

TM03 8731 2407

Fig. 41 Example of connection of a 3-conductor bus cable with

screen connected at t h e C UE (controller with no c ab le clamps)

13.7 RFI filters

To meet the EMC requirements, the CUE comes with the following types o f built- in radio freq uenc y inte rferen ce f ilter (RF I):

Voltage Typical shaft power P2 RFI filter type

1 x 200-240 V* 1.5 - 10 hp C1 3 x 200-240 V 1 - 60 hp C1 3 x 380-500 V 0.75 - 125 hp C1 3 x 525-600 V 1 - 10 hp C3 3 x 525-690 V 15 - 125 hp C3

* Single-phase input - three- pha se outp ut.

Description of RFI filter types

Fig. 38 Example of str ipped cab le with scre en

Fig. 39 Do not twist the screen ends

CUEController

Fig. 40 Example of connection of a 3-conductor bus cable with

screen connected a t both e nds

C1: For use in domes tic are as

For use in industrial a re as with ow n lo w-vo ltage

C3:

transformer

RFI filter types ar e acco rdin g to EN 61 80 0-3.

13.7.1 Equipment of category C3

• This type of powe r driv e syst em (P DS) is not inte nde d to be

TM02 1325 0901TM03 8812 2507TM03 8732 2407

used on a low-voltage public network which supplies domestic premises.

• Radio freq uen cy inte rfer ence is exp ecte d if used on suc h a network.

13.8 Output filters

Output filters are us ed fo r redu cing the voltage stres s on t he motor windings and t he stre ss on th e moto r ins ulat ion sy ste m as well as for decreas ing ac oust ic no ise from the varia blefrequency-driv en mot or.

Two types of output filter are ava ilable as acc es sorie s for t he CUE:

• dU/dt filters

• sine-wave filt ers.

Use of output filters

Pump type

SP, BM, BMB with 380 V motor and up

Other pumps, noise reduction

Other pumps, higher noise reduction

Pumps with 690 V motor

The lengths stated app ly to t he m otor ca ble .

Typical shaft

power P2

Up to 10 hp

15 hp and up 0-500 500 -1000

Up to 10 hp

15 hp and up 0-500 500 -1000

Up to 10 hp

15 hp and up

All

dU/dt

filter [ft]

– 0-1000

– 0-1000 – 0-1000

– 0-1000

Sine-wave

filter [ft]

Figures 42 and 43 show installa tions wi th and witho ut filter and

CUE and filter close to well

Screened

connection box mus t be conn ect ed to gro und.

Screened

Unscreened

where to use scr eened a nd u nscree ned cable .

Unscreened cable

CUE

Screened motor cable

Fig. 42 Example of ins tallation w ithout filter

Screened motor

Unscreened cable

CUE Filter

cable

Example: Max. curve operation can for ins tance be used in connection with vent ing the pu mp dur ing ins tallation .

Example: Min. curve operation can for instance be used in periods with a v ery s mall f low re quir eme nt.

Control modes

15.

The control mode is set on the control panel in menu

TM03 8802 2507TM03 8803 2507TM04 3579 4608TM04 3580 4608

INSTALLATION, display 3.1. See section 17.7.1. There are two basic cont rol m odes:

• Uncontro lled ope ra tion (op en lo op)

• Contro lled ope ra tion ( clos ed lo op) wit h a se ns or co nnect ed. See sections 15.1 and 15.2.

15.1 Uncontroll

ed operation (open

Grundfos CUE

Fig. 43 Example of installat ion wit h filter. The cable be tween

the CUE and filter mus t be shor t.

Unscreened

cable

CUE

Screened

cable

Filter

Unscreened drop cable

Fig. 44 Submersib le pu mp with out c onnec tion box. Variable

frequency drive and filter installed close to the well.

Unscreened

cable

CUE

Filter

cable

Connection box*

drop cable

* Both ends of the sc reen ed cab le be twee n filter and

Fig. 45 Submersib le pu mp with conne ctio n bo x and s cree ned

cable. Variable frequency drive an d filter installed close to the well.

14.

Operating modes

The following oper atin g mode s are set o n the con trol panel in menu OPERATION, display 1. 2. See se ctio n 10.5.2.

loop)

Constant curve. The speed is kept at a set va lue in the range between the min. and max. curve. The setpoint is set in % corresponding t o t he required speed.

TM03 8479 1607

Example: Operation on constant curve c an fo r instance be u sed for pumps with no se nsor co nnect ed.

Example: Typically used in connection with an overall control system such as the MPC or another external controller.

Operating mode Description

Normal

Stop

The pump is running in the c ontrol m ode selected.

The pump has been stopped (green indicator light is flashing) .

Min. The pump is ru nn ing at min imu m sp eed. Max. The pump is ru nning a t ma ximu m s peed.

Max.

Min. and max. cu rves . The pump spee d is kep t at a given

Min.

set value for minimum and maximum speed, respectively.

TM03 8813 2507

Grundfos CUE

5.2 Controlled operation (closed loop)

CUE

TM03 8475 1607

TM03 8476 1607

TM03 8477 1607

Δp

CUE

Δp

CUE

Δp

CUE

Proportional differential pressure. The differential pressure is reduced at falling flow rate and increased at rising flow rate.

TM03 8804 2507

Constant differential pressure, pump. The differential pressure is kep t constant, independently of the flow rate.

TM03 8804 2507

Constant differential pressure, system. The differential pressure is kep t constant, independently of the flow rate.

TM03 8806 2507

Constant pressure. The pressure is kept constant, independently of the flow rate.

TM03 8805 2507

Constant pressure with stop function. The outlet pressure is kept constant at high flow rate. On/off operation at low flow rate.

TM03 8807 2507

Constant

CUE

temperature. The liquid temperature is kept constant,

independently of

TM03 8482 1607

the flow rate.

TM03 8811 2507

CUE

TM03 8482 1607

CUE

TM03 8482 1607

CUE

TM03 8478 1607

Constant level. The liquid level is kept constant, independently of the flow rate.

TM03 8808 2607

Constant level with stop function. The liquid level is kept constant at high flow rate. On/off operation at low flow rate.

TM03 8809 2607

Constant flow rate. The flow rate is kept constant, independently of the head.

TM03 8810 2507

16.

Automatic or m anual

Menu overview

START-UP GUIDE 0. GENERAL 1. OPERATION

0.1 1.1

1/16 0.2 1.2

2/16 0.24 1.3

3/16 8/16 1.4

Grundfos CUE

4/16 9/16 1.5-1.9

5/16 10/16-14/16

setting of the direct ion of rotation

6/16 15/16 1.10-1.14

7/16 16/16

Fig. 46 Menu overv iew

Menu structure

The CUE has a start-up guid e, whic h is start ed at th e first startup. After the start-up guide, the CU E has a men u str uctur e divided into four m ain m enus:

1. GENERAL gives access to the start-up g uide f or the gen eral setting of the CUE.

2. OPERATION enables the s etting of setp oin t, select ion of operating mode and r esett ing of ala rms . It is als o poss ible t o see the latest five war nin gs and alarm s.

3. STAT U S shows the status of the CUE an d the p ump. It is not possible to chan ge or s et va lue s.

4. INSTALLATION gives access to all parameter s. Her e a detailed setting of the CU E can be m ade.

Grundfos CUE

2. STATUS 3. INSTALLATION

2.1 2.10 3.1 3.12

2.2 2.11 3.2 3.13

2.3 2.12 3.3 3.15

2.4 2.13 3.3A 3.16

2.5 2.14 3.4 3.17

2.6 2.15 3.5 3.18

2.7 2.16 3.6 3.19

2.8 2.17 3.7 3.20

2.9 3.8 3.21

3.9 3.22

3.10 3.23

3.11 3.24

Grundfos CUE

Setting by means of the control panel

17.

17.1 Control panel

Warning The On/Off button on the control panel does not

disconnect the CUE from the power supply and must therefore no t be u sed as a safe ty sw itch .

On/ Off

The control panel is used f or local s etting of the C UE. T he functions available dep end on the pu mp f amily co nne cte d to the CUE.

The On/Off button has the highest priority. In "off" condition, pump operation is not possible.

CUE

On/ Off

The editing button s of th e cont rol pane l can be set to t hes e values:

• Active

• Not active. When set to Not active (loc ke d), the editi ng but tons do not

function. It is only pos sible to navig ate in the menu s and read values.

Activate or deact ivate the bu ttons by pr essin g the arrow up and arrow down bu ttons simu ltaneou sly f or 3 se co nds.

Adjusting the display contrast

Press OK and + for darker display. Press OK and – for brigh ter disp lay.

Indicator lights

The operating co nditi on of the pump is indic ated by the in dicat or lights on the front of the c ont rol panel. See fig . 47.

The table show the fun ction of the indica tor li ghts.

Indicator light

On (green)

Off (orange) Alarm (red) In dicat es an alarm or a warni ng.

Function

The pump is runnin g or ha s been stop ped by a stop function.

If flashing, the pump h as bee n sto pped b y the user (CUE menu) , exte rnal s tart/stop o r bus .

The pump has been stop pe d with th e On /Off button.

Off

Fig. 47 Control panel of t he CUE

Editing buttons

Button Function

On/ Off

Navigating buttons

Button Function

Makes the pump re ady for opera tion/ starts and stops the pump.

Saves changed valu es, res ets ala rms and expands the value field.

Changes values in the value field.

Navigates from one m enu t o anot her. When the

menu is changed, the d isp lay s hown wi ll alw ays be the top display of the ne w m enu.

Navigates up and dow n in th e ind ividua l menu .

Alarm

Displays, general terms

Figures 48 and 49 s hows t he ge neral t erms o f the dis play.

Display name

Value field

TM03 8719 2507

Fig. 48 Example of display in the s tart-up g uide

Fig. 49 Example of display in the user menu

Current display / tota l numb er

Display name

Value field

Display number, menu n am e

17.2 Back to factory setting

Follow this procedure to get back to the

1. Switch off the power supply to the CUE.

2. Press On/Off, OK and + while swit ching on the pow er su pply. The CUE will reset all para me ter s to fa cto ry setti ngs . The dis pla y

will turn on when the reset is co mplete d.

factory setting:

17.3 Start-up guide

Check that equipment connected is ready for start-up, and that the CUE has been connected to

Note

Use the start-up guide f or the g ene ral se tting o f the CUE including the se tti ng of the co rrec t direc tion o f rotatio n.

The start-up guide is sta rted th e first time wh en the CUE is connected to supp ly vol tage. It can be restarted in menu GENERAL. Pleas e not e that in this case all pr eviou s setti ngs wil l be erased.

Bulleted lists show pos sible set tings. Fact ory set ting s are sho wn

in bold.

17.3.1 Welcoming display

• Press OK . You will now be guided through the start-up gu ide.

17.3.2 Language (1/16)

power supply. Have nameplate data for motor, pump and CUE

at hand.

17.3.4 Pump family (3/16)

Select pump family ac cor ding to the p um p nam eplate:

• CR, CRI, CRN, CRT

• SP, SP-G, SP-NE

• ...

Select "Other" if the pump family is not on the list.

17.3.5 Rated motor power (4/16)

Set the rated motor po wer, P2, according to the motor namepla t e:

• 0.75 - 125 H P (0.55 - 90 kW). The setting ran ge is s ize -rela ted, an d the fact ory se tting corresponds to the rated power of the CUE.

17.3.6

Supply voltage (5/16)

Grundfos CUE

Select the language to be u sed in t he dis play:

• English UK

• English US

• German

• French

• Italian

• Spanish

• Portuguese

10.3.3 Units (2/16)

Select the units to be used in the display :

• SI: m, kW, bar...

• US: ft, HP, psi...

• Greek

• Dutch

• Swedish

• Finnish

• Danish

• Polish

• Russian

• Hungarian

• Czech

• Chinese

• Japanese

• Korean.

Select supply voltage according to the rated supply voltage of the installation site.

Unit 1 x 200-240 V:*

• 1 x 200 V

• 1 x 208 V

• 1 x 220 V

• 1 x 230 V

• 1 x 240 V.

Unit 3 x 525-600 V:

• 3 x 575 V.

* Single-phase input - three- pha se outp ut. The setting range dep ends o n the C UE typ e, an d the fac tory

setting correspo nds to t he rate d supp ly vol tage of the CU E.

Unit 3 x 200-240 V:

• 3 x 200 V

• 3 x 208 V

• 3 x 220 V

• 3 x 230 V

• 3 x 240 V.

Unit 3 x 525-690 V:

• 3 x 575 V

• 3 x 690 V.

Unit 3 x 380-500 V:

• 3 x 380 V

• 3 x 400 V

• 3 x 415 V

• 3 x 440 V

• 3 x 460 V

• 3 x 500 V.

Grundfos CUE

17.3.7 Max. motor current (6/16)

Set the maximum motor current according to the motor nameplate:

• 0-99 9 A. The setting range dep ends o n the C UE t ype, an d the fa ctor y

setting correspon ds t o a t y pic al motor current at t he mo tor power selected.

17.3.8 Speed (7/16)

Set the rated spe ed acc ordin g to the pump n am eplate:

• 0-9999 r pm. The factory setting depends on previous selections. Based on the

set rated speed, the CUE will automatic ally set the moto r frequency to 50 or 6 0 Hz .

17.3.9 Frequency (7A/16)

The CUE will give an a larm if the contro l mode select ed req uires a sensor and no s ensor ha s be en ins talled. To continue the setting without a sensor, select "Open loop", and proceed. When a sensor has been connected, set the sensor and control mode in menu INSTALLATION.

17.3.11 Rated flow rate (8A/16)

This display appea rs on ly if the co ntrol m ode selec ted is proportional differential pr ess ure.

Set the rated flow ra te ac cord ing to the pu m p name pla te:

• 1-28840 gpm (1 -6 550 m

17.3.12 Rated head (8B/16)

This display only a ppear s if the co ntro l mode selec ted is proportional differential pr ess ure.

Set the rated head accor ding t o the pump name plate :

• 1-3277 ft (1 -9 99 m).

17.3.13 Sensor connected to terminal 54 (9/16)

/h).

This display appe ars on ly if m anua l ente ring of the fr equen cy is required.

Set the frequency a ccor din g to the motor n am eplat e:

• 40-200 H z. The factory setting depends on previous selections.

17.3.10 Control mode (8/16)

Select the desired control mode. See section 17.7.1.

• Open lo op

• Const . pressur e

• Const. diff. pressure

• Prop. diff. pr essu re

• Const. flow rate

• Cons t. te mp eratur e

• Cons tant le vel

• Cons t. other value.

The possible settings and the factory setting depend on the pump family.

Set the measuring range of th e conn ected s enso r wit h a sign al range of 4-20 mA. T he m easur ing ra nge dep en ds on t he co ntro l mode selected :

Proportional differentia l pressure:

• 0-20 ft

• 0-33 ft

• 0-54 ft

• 0-84 ft

• 0-200 ft

• 0-334 ft

• Other.

Constant pressure:

• 0-58 psi

• 0-87 psi

• 0-120 ps i

• 0-145 ps i

• 0-232 ps i

• 0-362 ps i

• 0-580 ps i

• 0-870 ps i

• Other.

Constant temperature :

• Other.

Constant differential press ure:

• 0-20 ft

• 0-33 ft

• 0-54 ft

• 0-84 ft

• 0-200 ft

• 0-334 ft

• Other.

Constant flow rate:

• Other.

Constant level:

• Other.

If the control mode selected is "Const. other value", or if the measuring range sele cte d is "Ot her", th e sensor mus t be set according to the nex t se ctio n, displ ay 9A /16.

17.3.14 Another sensor connected to terminal 54 (9A/16)

This display only appear s w hen the c ont rol mo de "C onst. ot her value" or the measur ing ran ge "Oth er" has been s elected in display 9/16.

• Sensor output signa l:

0-20 mA

4-20 mA.

• Unit of meas urem ent of se nsor:

bar, mbar, m, kPa, psi, ft, m gal/h, gal/m, gal/s, ft

• Sensor meas uring range . The measuring ra nge de pen ds on th e sens or conne cte d and t he measuring unit selected.

17.3.15

Priming and venting (10/16)

/h, m3/min, m3/s, l/h, l/min, l/s,

/h, ft3/min, ft3/s,°C, °F, %.

Grundfos CUE

Information displays.

• Press OK to continue.

The pump starts after 10 sec onds . It is possible to int errupt the te st and re tur n to the p revio us

display.

See the installation an d op erating inst ruct ions of the pu mp. The general settin g of the CUE is now com plete d, and t he start-

up guide is read y fo r sett ing the dire ction of ro tation :

• Press OK to go o n to au tom atic or manua l se tting o f the direction of rotation.

17.3.16 Automatic setting of the direction of rotation (11/16)

Warning During the test, the pump will run for a short

time. Ensure no personnel or equipment is in danger!

Before setting the direction of rotation, the CUE

Note

The CUE automa tically tests an d sets th e corr ect dir ect ion of rotation without chang ing the cable co nnect ions .

This test is not suitable for certain pump ty pes an d will in certain cases not be able to d eter mine for cer tainty the c orre ct di rection of rotation. In these ca ses, t he CU E cha nges o ver to m an ual setting where the d irect ion of r otatio n is dete rmine d on the basi s of the installer’s observations.

will make an automatic motor adaptation of certain pump types. This will take a few minutes. The adaptation is carried out during standstill.

The pump runs with b oth d ire ctio ns of rota tion a nd st ops automatically.

It is possible to interrupt the test, stop the pump and go to manual setting of the directio n of rotatio n.

The correct direction of rotation has now been set.

• Pres s OK to set the setpoint. See Setpoint (15/16) on page 26.

17.3.17 Setpoint (15/16)

Set the setpoin t acco rd ing to th e co ntro l mod e and se ns or selected.

The automatic setti ng of th e direction of rotati on ha s fai led.

• Pres s OK to go to manu al setting of the dire ction of rotation.

Grundfos CUE

17.3.18 General settings are completed (16/16)

• Press O K to make the p ump r eady for opera tion or start the pump in the operating mode Normal. Then display 1.1 of menu OPERATION will appear.

17.3.19 Manual setting when the direction of rotation is

visible (13/16)

It must be possibl e to o bserve the m otor f an or shaft.

Information displays.

• Press OK to continue.

17.3.20 Manual setting when the direction of rotation is not visible (13/16)

It must be possible to o bserv e the he ad o r flow rate .

Information displays.

• Press OK to continue.

The pump starts after 10 sec onds . It is possible to int errupt the te st and re tur n to the p revio us

display.

The pump starts after 10 seconds . It is possible to int erru pt the test an d retur n to the previo us

display.

The pressure will be shown during the test if a pressure sensor is connected. The moto r curre nt is a lwa ys show n durin g the te st.

State if the direction of rotation is corr ect.

• Yes • No

The pressure will be shown during the test if a pressure sensor is connected. The m oto r cur rent is a lways shown dur ing the t est.

The first test is completed.

• Write down t he pre ssur e a nd/o r flow rate , and press OK t o

continue the manu al test with th e oppos ite d irect ion of rotation.

The pump starts after 10 sec onds .

The correct direction of rotation has now been s et.

• Pres s OK to set the setpoint. See Setpoint (15/

16) on page 26.

The direction of rotati on is n ot correct.

• Pres s OK to repe at the t est with the opposite dir ecti on of rotation.

It is possible to int erru pt the test an d retur n to the previo us display.

17.4.2 Type code change (0.2)

The pressure will be shown during the test if a pressure sensor is connected. The moto r curre nt is a lwa ys show n durin g the te st.

The second test is com plet ed. Write down the pressure an d/or flow rate, and s tate which t est

gave the highest pum p p erform anc e:

• First test

• Second tes t

• Make ne w test .

The correct direct ion of ro tation has now been s et.

• Press OK to set the setpoint. See Setpoint (15/16) on page 26.

17.4 Menu GENERAL

This display is for service use only.

17.4.3

Copy of settings

It is possible to co py the s etting s of a CUE an d re use the m i n another one.

Options:

• No co py.

• to CUE (c opies th e settings of the CUE) .

• to contr ol panel (c op ies the s ett ings t o anot her CUE ). The CUE units must have the same firmware version. See section

10.6.16 Firmware versio n (2. 16) .

17.5 Menu OPERATION

17.5.1 Setpoint (1.1)

Grundfos CUE

Note

The menu makes it pos si ble to return to the start-up guide, which is usually only used dur ing t he first s tart-up of the CU E.

17.4.1 Return to start-up guide (0.1)

State your choice:

• Yes

• No.

If Yes is se lected, al l settings will be er ased, and the entire startup guide must be co mplete d.

If the start-up guide is started, all previous settings will be erased!

The start-up guide must be carried out on a cold motor!

Repeating the start-up guide may lead to a heating of the motor.

Setpoint set Actual setpoin t

Actual value Set the setpoin t in un its of th e feed back sens or. In control mode Open loop, the s etpoint i s set in % of the

maximum performa nce. T he settin g range will lie be twee n the min. and max. curves. See fig. 56.

In all other control modes ex cep t pro portion al differen tial pressure, the sett ing ra ng e is equ al to the se nsor me as uring range. See fig. 57.

In control mode Proportional differential pressure, the set ting range is equal to 25 % to 90 % of max . head . Se e fig. 58 .

If the pump is connec ted to a n exter nal setp oint si gnal, the val ue in this display will be the maximum value of the external setpoint signal. See section 20.1.2 External setpoint.

The tolerances are stated as a guide in % of the maximum value s

Grundfos CUE

17.5.2 Operating mode (1.2)

Set one of the follo wing op erat ing mo de s:

• Normal (duty)

• Stop

• Min.

• Max. The operating mode s can be s et with out cha ngin g the setpoin t

setting.

17.5.3 Fault indications

Faults may result in tw o types of in dication : Ala rm or warni ng. An "alarm" will activate an alarm in dication in CUE and ca use

the pump to chan ge oper atin g mode , typi cally t o stop . How ev er, for some faults resultin g in alar m, the pu mp i s set to c ontinue operating even if th ere is an alar m.

A "warning" will activate a warning indication in CUE, but the pump will not change opera ting or control m ode.

Alarm (1.3)

Warning log (1.10-1.14)

In case of a "warning", the last fiv e war ning i ndica tions wi ll appear in the warnin g log. "Warning log 1" s hows the late st fau lt, "Warning log 2" shows the latest fau lt but on e, etc .

The display shows thr ee piec es of inf orm atio n:

• the warnin g ind ication

• the warnin g co de

• the number of minutes the pump has been connected to the power supply after the warnin g occ urred.

17.6 Menu STATUS

The displays appea ring in this menu are status d isplays only. It is not possible to chan ge or set value s.

The tolerance of the displayed value is stated under each display.

of the parameters.

10.6.1 Actual setpoint (2.1)

In case of an alar m, the caus e will app ear in the displa y. See section 15.1 Warning and alarm list.

Warning (1.4)

In case of warning, the cause will a ppe ar in the dis play. See section 15.1 Warning and alarm list.

17.5.4 Fault log

For both fault type s, a larm a nd wa rning , the CU E has a log function.

Alarm log (1.5-1.9)

In case of an "alarm", the last five alarm indications will appear in the alarm log. "Ala rm log 1" shows the la t es t alarm, "Alarm log 2" shows the latest alar m but on e, etc .

The display shows thr ee piec es of inf orm atio n:

• the a lar m indication

• the a larm code

• the n umbe r of mi nut es the p um p has b een conne cte d to t he power supply after the ala rm oc curr ed.

This display show s th e actual setp oint a nd the ex ter nal setp oint. The actual setpoint is shown in u nits of fe edbac k se nsor. The external setpoint is shown in a rang e of 0-10 0 %. If the

external setpoi nt influ ence is disac tivat ed, th e value 100 % is shown. See section 13 .2 External se tpoi nt.

10.6.2 Operating mode (2.2)

This display shows the actual operating mode (Normal, Stop, Min. or Max.). Furthermor e, it sh ow s w here th is op erat ing mo de was selected (CUE menu, Bus, External or On/off button).

17.6.3 Actual value (2.3)

This display show s the ac tual value c ontr olled. If no sensor is conn ected to the CU E, "– " will appe ar in t he

display.

17.6.4 Measured value, sensor 1 (2.4)

17.6.9 Lubrication status of motor bearings (2.9)

This display show s the ac tual value m easu red by sens or 1 connected to ter minal 5 4.

If no sensor is connected to the CUE , "–" will appe ar in the display.

17.6.5 Measured value, sensor 2 (2.5)

This display is onl y show n if an MCB 114 sensor input module has been installed.

This display show s the ac tual value m easu red by sens or 2 connected to an MCB 114.

If no sensor is connected to the CUE , "–" will appe ar in the display.

17.6.6 Speed (2.6)

Tolera nc e: ± 5 % This display shows the actual pump speed.

17.6.7

Input power and motor current (2.7)

This display s hows how many times the user has given the lubricated informa tion and whe n to r eplace the m otor be ar ings.

When the motor bear ings have bee n relub ricate d, co nfirm th is action in the INSTALLATION menu. See section

17.7.17 Confirming relubrication/replacement of motor bearings (3.20). When relubrica tion i s conf irmed , the figur e in the ab ove

display will be increa se d by one.

17.6.10 Time until relubrication of motor bearings (2.10)

This display is only s hown if dis pl ay 2.11 is not shown. This display show s whe n to re lubric ate the mot or bea rings .

The controller monitors the opera ting pat tern of the pum p and calculates the per iod bet ween b earing re lubric atio ns. If the operating pattern ch ang es, th e calc ulated t ime till relu brica tion may change a s well.

The estimated time un til rel ubricat ion takes into acc ount if the pump has bee n runni ng w ith re duce d sp ee d.

See section 17.7.17 Confirming relubrication/replacement of motor bearings (3.20).

17.6.11 Time until replacement of motor bearings (2.11)

Grundfos CUE

Tolera nce: ± 10 % This display show s the ac tual pump in put p ower in W or kW and

the actual motor cur rent in Am pere [A].

17.6.8 Operating hours and power consumption (2.8)

Tolera nc e: ± 2 % This display shows the number of operating hours and the power

consumption. T he valu e of op erating hou rs is an ac cum ul ated value and cannot be reset. The value of power consumption is an accumulated va lue cal culat ed from the unit’s birth, and it canno t be reset.

This display is only show n if dis play 2.10 is no t shown . This display show s whe n to re place the m otor be ari ngs.

The controller monitors the opera ting pat tern of the pump and calculates the per iod bet ween b earing re place ments.

The estimated time until replacement of motor bearings takes into account if the p ump ha s been ru nning with reduc ed sp eed .

See section 17.7.17 Confirming relubrication/replacement of motor bearings (3.20).

17.6.12 Temperature sensor 1 (2.12)

This display is only s hown if an MC B 114 sensor input mo dule has been installed.

This display show s the m easur ing poi nt and the ac tua l value measured by Pt100 /Pt1 000 tem peratu re sen sor 1 conne cted to the MCB 114. The measuring point is selec ted i n displa y 3.21.

If no sensor is connected to the CUE, "–" will appear in the display.

Note

Grundfos CUE

10.6.13 Temperature sensor 2 (2.13)

This display is onl y show n if an MCB 114 sensor input mo dule has been installed.

This display show s the m easur ing poi nt and the a ctual va lue measured by Pt100 /Pt1 000 t empe rature senso r 2 co nnect ed to the MCB 114. The measuring point is selec ted in dis play 3.22.

If no sensor is connected to the CUE, "–" will appear in the display.

17.6.14 Flow rate (2.14)

This display is onl y show n if a flo wm eter ha s be en co nfigu red. This display show s the ac tual value m easu red by a flow meter

connected to the d igital pulse in pu t (termi nal 3 3) or the ana log input (terminal 5 4).

17.6.15 Accumulated flow (2.15)

17.7 Menu INSTALLATION

17.7.1 Control mode (3.1)

Select one of th e following control m od es:

• Open loop

• Const. press ure

• Const. diff. pressure

• Prop. diff . press ure

• Const. flow rate

• Const. temp erat ure

• Constant le ve l

• Const. other value.

If the pump is connected to a bus, the control mode cannot be selected via the CUE. See section 20.3 GENIbus signal.

17.7.2 Controller (3.2)

This display is onl y show n if a flo wm eter ha s be en co nfigu red. This display show s the va lue of the a ccum ulat ed flo w and t he

specific energy fo r the trans fer of the pump ed li quid. The flow measurement can be connected to the digital pulse input

(terminal 33) or th e analog inp ut (ter mina l 54).

17.6.16 Firmware version (2.16)

This display shows the version of the s

Configuration file (2.17)

7.6.17

This display s hows the config ur at ion file.

oftware.

The CUE has a factor y set ting of gain (K However, if the factory setting is not the optimum setting, the gain and the integral ti me can b e ch anged in the display.

• The gain (K

• The integral time (T 3600 s. If 3600 s is selected, the controller wil l function as a P controller.

• Furtherm ore, it is pos sibl e to set t he con trol ler to i nver se control, meaning th at if t he setpo int is incre ased , the sp eed will be reduced. In the case of inv erse cont rol, th e gain ( K must be set within the ran ge from – 0.1 to –20.

) can be set within the r ange fr om 0.1 t o 20.

) can be set within the ra nge fr om 0.1 to

) and integral time (Ti).

)

The table below sh ows t he su gge ste d cont rolle r se tting s:

System/application

CUE

Heating

system

Cooling

system

0.2 0.5

SP, SP-G, SP-NE: 0.5 0.5

CUE

0.2 0.5

SP, SP-G, SP-NE: 0.5 0.5

CUE

0.2 0.5

–2.5 100

0.5 –0.5 10 + 5L

1. Heating systems are sy stem s in w hich an inc reas e in pum p performance will result in a rise in tem peratur e at th e se nsor.

2. Cooling systems are sy stem s in w hich a n incr ease in pump

performance will result in a drop in tempera ture at t he sen sor.

= Distance in [m] between pump and s en sor.

= Distance in [m] between heat excha nge r and s ensor.

How to set the PI controller

For most applicat ions , the fac tory s etting of th e contr oller constants K

and Ti will ensure optimum pum p oper ation.

Grundfos CUE

However, in some applications an a dju stmen t of the cont rolle r may be needed.

Proceed as follows :

1. Increase the gain (K

) until the motor be com es uns table.

Instability can be seen by obser ving if the meas ured valu e starts to fluctuate. Furthermore, instability is audible as the motor starts hunting up an d down . As some systems, such as temperature controls, are slowreacting, it may be difficult to obser ve that the motor is unstable.

2. Set the gain (K

) to half the value of the value which made the

motor unstable. This is the c orrect s etting of the ga in.

3. Reduce the integral tim e (T

) until the motor become s

unstable.

4. Set the integral time (T

) to twice the value which made the

motor unstable. This is the c orrect s etting of the in tegral t ime.

General rules of thumb:

• If the contr oller is too s low-r eact ing, inc reas e K

• If the contr oller is hun ting or uns table, dampe n the syste m by reducing K

or increasing Ti.

17.7.3 External setpoint (3.3)

CUE

Δt

CUE

Δp

CUE

Δp

* T

= 100 seconds (factory setting).

0.5 10 + 5L

0.5 –0.5 30 + 5L2*

0.5 0.5*

< 5 m: 0. 5*

0.5

> 5 m: 3*

> 10 m: 5*

The input for extern al set point sign al (te rmin al 53) c an be s et to the following types:

• Active

• Not act ive.

If Active is selected, the actual setpoint is influenced by the signal connected to the external setpoint input. See section

20.2 External setpoint.

Grundfos CUE

17.7.4 Signal relays 1 and 2 (3.4 and 3.5)

The CUE has two signal r elays . In the d isplay be low, select in which operating s ituatio ns the s ignal re lay sh ould be acti vate d.

Signal relay 1 Signal relay 2

ady

• Ready

• Alarm

• Operation

• Pump r unning

• No t a ctive

• Warning

• Relubricate

Note

17.7.5 Buttons on the CUE (3.6)

For distinction between alarm and warning, see section 17.5.3 Fault indications.

• Re

• Alarm

• Operation

• P ump r unning

• No t a ctive

• Warning

• Relubricate.

17.7.7 Pump number (3.8)

This display show s the G ENIbu s n umbe r. A number betw een 1 and 199 can be alloc ated to the p ump. I n the case of bus communication, a number must be allocated to each pump.

The factory setting is "–".

17.7.8 Digital inputs 2, 3 and 4 (3.9 to 3.11)

The editing buttons (+, –, On/Off, OK) on the control panel can be set to these value s:

• Active

• Not active.

When set to Not active (locked), the editing buttons do not function. Set the buttons to Not active if the pump should be controlled via an external control system.

Activate the butt ons b y pres sing the arro w up and arr ow dow n buttons simultaneo usly fo r 3 sec onds .

17.7.6 Protocol (3.7)

This display show s the pr otoc ol sel ection f or the R S-48 5 po rt of the CUE. The protoc ol can be set to the se va lues:

• GENIbus

• FC

• FC MC .

If GENIbus is selected, the communication is set according to the Grundfos GENIb us standa rd. FC and FC MC is for s ervi ce purpose only.

The digital inputs of the CUE ( termin al 19, 32 a nd 3 3) can individually be se t to differe nt func tion s.

Select one of the following functions:

• Min. (min. curve)

• Max. (max. curve)

• Ext. fault (external fault)

• Flow sw it ch

• Alarm res et

• Dry run ning (f rom extern al sen sor)

• Accumulated flow (pul se flow, only terminal 3 3)

• Not active.

The selected function is active when the digital input is activated (closed contact). S

Min.

When the input is activated, the pump w ill oper ate accor ding to the min. curve.

Max.

When the input is activated, the pump w ill oper ate accor ding to the max. curve.

Ext. fault

When the input is act ivated, a timer will be s tarted. If the input is activated for more than 5 se conds, an e xtern al fault will be indicated. If the input is deactivate d, the fau lt con ditio n will c ea se and the pump ca n on ly be re start ed m anually by re se tting t he fault indication.

Flow switch

When this function is select ed, the pu mp will be stopp ed whe n a connected flow swi tch d etects lo w flow.

It is only possible to use this fun ctio n if the p ump is co nnec ted to a pressure sensor or a level sensor, and the stop function is activated. See sections 17.7.10 and 17.7.11.

Alarm reset

When the input has been activated, the alarm is reset if the cause of the alarm no longer exists.

ee also section 20.1 Digital inputs.

Dry running

When this function is sele cted , lac k of inlet press ure or wate r shortage can be detected. This req u ir es th e us e of an accessory, such as:

• a Grun dfos Liq tec

• a press ure s witch ins talled on t he suct ion sid e of a p ump

• a float swit ch ins talled on the suc tion s ide of a pu m p. When lack of inlet pr essur e or wat er s hortage ( D ry runn ing) is

detected, the pump will be s topped. Th e pu mp canno t restart as long as the input is activa ted.

Restarts may be delaye d by up to 30 mi nutes , dep ending on the pump family.

Accumulated flow

When this function is set for digital input 4 and a pu lse s ensor is connected to ter minal 3 3, the a ccum ulat ed flo w can be measured.

17.7.9 Digital flow input (3.12)

This display ap pears only if a flo wme te r has b een co nfigu re d in display 3.11.

The display is use d for settin g the volum e for ev ery p uls e for the function Accu mulate d flow with a pulse s enso r conn ected to terminal 33.

Setting range:

• 0-26 5 gal/puls e (0- 1000 lit re/pu ls e). The volume can be set in the unit selected in the start-up guide.

17.7.10

Constant pressure with stop function (3.13)

Settings

The stop function can b e set to these v alues :

• Active

• No t ac tive. The on/off band can be set to thes e valu es:

• Δ H is factory-set to 10 % of actual setpoint.

• Δ H can be set within th e range from 5 % to 30 % of the act ual setpoint.

Operating conditions for the stop function

It is only possible t o use th e sto p funct ion if the sys tem incorporates a pr essur e se nsor, a check valve and a dia ph ragm tank.

Descriptions

The stop function is used f or c hangin g be tween on /off oper atio n at low flow and contin uous ope ratio n at hi gh flow.

dry-running swit ch

On/off operation

Continuous ope ration

Stop pressure

Start pressure

Fig. 50 Constant pressur e wi th sto p funct ion. Difference

Low flow can be detec ted in two differen t ways:

1. A built-in "low-flow detection function " which f unc tions if th e digital input is not set up fo r flo w swit ch.

2. A flow switch connected to th e digital inpu t.

1. Low-flow detection function

The pump will chec k the flow r egular ly by reduc ing th e spee d for a short time. If there is no or only a small change in pressure, this means that there is low flow.

The speed will be incr ease d un til the s top pre ssur e (ac tual setpoint + 0.5 x ΔH) is reached and the pump will stop after a few seconds. The pum p will re start at the la test whe n the pressur e has fallen to the start pressur e (ac tual set point – 0.5 x Δ H).

If the flow in the off period is high er th an the l ow-flow lim it, th e pump will restart before the press ure ha s fallen to the start pressure.

When restarting, the pump will react in the followin g way:

1. If the flow is higher than the low-flow limit, the pump will return to continuous operat ion at cons tant pre ssure.

2. If the flow is lower than the low-flow limit, the pump will continue in start/sto p oper ation . It will co ntinu e in start/stop operation until the flow is higher than the low-flow limit. When the flow is higher than the low-flow limit, the pump will return to continuous operat ion.

2. Low-flow detection with flow switch

When the digital input is ac tivated becau se ther e is low- flow, the speed will be increased until the stop pres sure (actua l setpoin t + 0.5 x ΔH) is reached, and the pump will stop. When the pressure has fallen to start pressu re, the pu mp will s tart again. If the re is still no flo w, the pump will reach the sto p pres sure and stop. If there is flow, the pump wi ll contin ue o peratin g ac cord ing to the setpo i nt.

Caution

ΔH

between start and stop pre ssures (ΔH)

The check valve mus t alwa ys be inst alled b efore the pressure sensor. See figs 51 and 52 .

If a flow switch is used to detect low flow, the switch must be inst all ed o n t h e sy stem side after the diaphragm tank.

Grundfos CUE

TM03 8477 1607

Check valve

Diaphragm tank

Grundfos CUE

Diaphragm tank

Pressure sens or

Pump

Fig. 51 Position of the c heck va lve an d pres su re se nsor in

Fig. 52 Position of the c heck va lve an d pres su re se nsor in

Diaphragm tank

The stop function requires a diaphragm tank of a certain minimum size. The tank must b e installed a s clos e as po ssib le after t he pump and the prec harge pressu re mus t be 0.7 x actu al set point .

Recommended diaphr agm ta nk size:

If a diaphragm tank of t he abo ve size is ins talled in the s ystem , the factory setting of ΔH is the corre ct setting. If the tank installed is too small, the pump w ill start and stop too often. This can be rem edied b y in crea sing Δ H.

17.7.11 Constant level with stop function (3.13)

system with suction lift operation

Pressure sensor

Pump Check valve

system with positiv e inlet pressu re

Rated flow rate of pump

[gpm]

0-26 2

27-105 4.4 106-176 14 177-308 34 309-440 62

Typical diaphragm tank size

[gallons]

A built-in low-flow de tection fun ction wi ll auto matica lly me asur e and store the power consu mption at ap prox. 5 0 % and 8 5 % of the rated speed.

If Active is selected, proceed as follows:

1. Close the isolating val ve to cr eate a no-f low co ndit ion.

2. Press OK to start the auto-t uning.

Operating conditions for the stop function

It is only possible to us e the cons tant leve l sto p func tion if the system incorporates a level sensor, and all valves can be closed.

TM03 8582 1907TM03 8583 1907

Description

The stop function is used f or c hangin g be tween on /off oper atio n at low flow and contin uou s oper atio n at hi gh flow.

Start level

Stop level

Fig. 53 Constant leve l with st op func tion . Differe nce be twee n

Low flow can be detec ted in two differen t ways:

1. With the built-in low-fl ow det ectio n fun ctio n.

2. With a flow switch connected to a dig ital input.

1. Low-flow detection function

The built-in low-flo w de tecti on is ba sed on the m easu reme nt of speed and power.

When low flow is detected, the pump will stop. When the level has reached the start level, the pump will start again. If there is still no flow, the pump will reach the stop level and stop. If there is flow, the pump will continue ope rating a ccor ding to the setpoin t.

2. Low-flow detection with flow switch

When the digital input is activated because of low flow, the speed will be increased until the stop level (actual setpoint – 0.5 x ΔH) is reached, and th e pu m p will stop. When the lev el has reached the start level, the pump will start again. If there is still no flow, the pump will reach the s top lev el and stop. If there is flow, the pump will continue operating acc ording to the s etpoint.

17.7.12 Sensor 1 (3.15)

ΔH

start and stop levels (ΔH)

TM03 9099 3307

Settings

The stop function can b e set to these v alues :

• Active

• No t ac tive. The on/off band can be set to thes e valu es:

• Δ H is factory-set to 10 % of actual setpoint.

• Δ H can be set within the range from 5 % to 30 % of actual setpoint.

Setting of sensor 1 connected to terminal 54. This is the feedback sensor.

Select among the foll owing v alues :

• Sensor ou tput signa l:

0-20 mA 4-20 mA.

• Unit o f measurement of sensor:

bar, mbar, m, kPa, psi, ft, m

• Sensor m easur ing ra nge .

/h, m3/s, l/s, gpm, °C, °F, %.

17.7.13 Sensor 2 (3.16)

Setting of sensor 2 con nect ed to an M CB 114 sensor input module.

Select among the foll owing v alues :

• Sensor output signa l:

0-20 mA 4-20 mA.

• Unit of meas urem ent of se nsor:

bar, mbar, m, k Pa, psi, ft, m

• Sensor meas uring range : 0-100 %.

17.7.14 Duty/standby (3.17)

Settings

The duty/standby func tion can be se t to th ese value s:

• Active

• No t ac tive.

Activate the duty/ standby fun ctio n as f ollo ws:

1. Connect one of the pu mps to the m ains s upply. Set the duty/standby fun ctio n to No t a ctive. Make the necessary s etting s in me nu OPER ATION and INSTALLATION.

2. Set the operating mode to Stop in menu OPERATION.

3. Connect the other pu mp t o the mains su ppl y. Make the necessary s etting s in me nu OPER ATION and INSTALLATION. Set the duty/standby fun ctio n to Active.

The running pump will s earch for the other p ump an d automatically set the duty/standby function of this pump to Active. If it cannot find the other pump, a fault will b e indicated.

/h, m3/s, l/s, gpm, °C, °F, %.

Grundfos CUE

The two pumps must be connected electrically

Note

The duty/standby func tion applies to tw o pum ps con nected in parallel and controlle d vi a GENIbu s. E ach p ump must be connected to its own CUE an d sens or.

The primary targets of the fun ctio n is the f ollowin g:

• To start the standby pump if the duty pum p is st oppe d du e to an alarm.

• To alternate the pumps at least eve ry 24 h ours.

via the GENIbus, and nothing else must be connected on the GENIbus.

Nominal speed Max. s peed

Min. speed

Grundfos CUE

17.7.15 Operating range (3.18)

How to set the operating range:

• Set the m in . speed w ithin the ra nge f rom a pump -depe ndent min. speed to the adju sted m ax. speed . The f actor y set ting depends on the pump fam ily.

• Set the max. speed within the range from adjusted min. speed to the pump-depen dent m axim um sp eed . The fac tor y sett ing will be equal to 100 %, i.e. the sp eed stated on the p ump nameplate.

Pump-depende nt spee d ra nge

Min.

Actual speed ra nge

Min. speed, adjuste d

The area between the min. and m ax. speed is th e actual operating range of the pump.

The operating ra nge ca n be chang ed by the us er within the pump-depende nt sp eed range .

For some pump families, oversynchronous operation (max. speed above 100 %) will be possible. This requires an oversize motor to deliver the shaft power r equir ed by the pump during oversynchrono us opera tion.

Speed [%]

Max.

100 %

Max. speed, adjus ted

Fig. 54 Setting of the min. and max. curves in % of maximum performance

10.7.16 Motor bearing monitoring (3.19)

The motor bearing monitoring function can be set to these values:

• Active

• No t a ctive.

When the function is set to Active, the CUE will give a warn ing when the motor bearings are due to be relubricated or replaced.

Description

The motor bearing m onit oring func tion is used to give a n indication when it is tim e to rel ubri cate or replac e the motor bearings. See dis play 2 .10 an d 2.11.

The warning indication and the estimated time take into account if the pump has been running with reduced speed. Furthermore, the bearing temperature is included in the calculation if temperature sensors are installed a nd con ne cted to an MC B 114 sensor input module.

The counter will continue counting even if the

Note

function is switched to Not active, but a warning will not be given when it is time for relubrication.

10.7.17 Confirming relubrication/replacement of motor bearings (3.20)

This function can be s et to the se va lues:

• Relubricated

• Replaced

• Nothing done.

When the motor be arings have bee n relub ricat ed or replac ed, confirm this action in the a bove d isp lay by pres sing "OK ".

Note

Relubricated

When the warning Relubric ate mot or be arings ha s been confirmed,

• the counter is set to 0.

• the numbe r of relu bri cati ons is inc reas ed b y 1.

When the number of relub ricatio ns has re ache d the per miss ible number, the warning Replac e motor bearin gs app ears in the display.

Relubricated cannot be selected for a period of time after confirming relubrication.

TM04 3581 4608

Replaced

Time

When the warning Replace m oto r bear ing s ha s b een co nfir med,

• the cou nter is set to 0 .

• the num be r of relu brica tions is se t to 0.

• the num be r of bear ing ch ang es is in crea sed by 1.

17.7.18 Temperature sensor 1 (3.21)

17.7.21 Ramps (3.24)

This display is onl y show n if an MCB 114 sensor input mo dule has been installed.

Select the functio n of a P t100/ Pt100 0 tem peratu re sensor 1 connected to an MCB 114:

• D-en d bear ing

• ND-e nd bear ing

• Other liq. temp. 1

• Other liq. temp. 2

• Motor windin g

• Pumpe d liq. tem p.

• Ambien t temp.

• Not active.

17.7.19 Temperature sensor 2 (3.22)

This display is onl y show n if an MCB 114 sensor input mo dule has been installed.

Select the functio n of a P t100/ Pt100 0 tem peratu re sensor 2 connected to an MCB 114:

• D-en d bear ing

• ND-e nd bear ing

• Other liq. temp. 1

• Other liq. temp. 2

• Motor windin g

• Pumpe d liq. tem p.

• Ambien t temp.

• Not active.

17.7.20 Standstill heating (3.23)

Set the time for e ac h of the two r amps, ramp -u p and ra m p-dow n:

• Factory s etting : Depending on power size.

• The ran ge of the ramp parameter: 1-3600 s.

The ramp-up time is the acceleration time from 0 rpm to the rated motor speed. Choose a ramp-up time such that the output current does not exceed t he ma xi mu m cu rrent lim it f or the C UE .

The ramp-down tim e is the d ecele ratio n time f rom rate d mot or speed to 0 rpm. Choo se a ram p-dow n tim e such t hat no overvoltage arises an d suc h that t he gen erat ed cu rrent does not exceed the maximum current limit for the CUE.

Speed

Rated

Maximum

Minimum

Initial ramp Final ramp

Ramp-up Ramp-down

Fig. 55 Ramp-up and r amp- down, disp lay 3.24

Setting by means of PC Tool E-products

18.

Special setup requirements differing from t he se ttings availa ble via the CUE require the use of Grundfos PC Tool E-products. This again requires th e as sistance of a Grundfo s se rv ice technician or engineer. Contact your local Grundfos com pany f or more information.

Grundfos CUE

TM03 9439 0908

The standstill heat ing func tion c an be s et to t hese val ues :

• Active

• No t ac tive. When the function is set to Active and the p um p is sto ppe d by a

stop command, a c urre nt wil l be appli ed to th e m otor win ding s. The standstill heat ing func tion p re-he ats the m otor t o avoid

condensation.

Grundfos CUE

Priority of settings

19.

The On/Off button has the highest priority. In "off"

On/ Off

condition, pump operation is not possible.

The CUE can be cont rolled in vari ous ways at the s ame time . If t wo or m ore o per ating m od es are active at the s ame t ime, the operating mode with the high est pri ori ty will be in forc e.

19.1 Control without bus signal, local operating mode

Priority CUE menu External signal

1Stop 2Max. 3 Stop 4 5 Min. Min. 6 Normal Normal

Example: If an external signal has acti vated the op erating m ode Max., it will only be possible to stop the pump.

Max.

19.2 Control with bus signal, remote-controlled operating mode

Priority CUE menu External signal Bus signal

1 Stop 2 Max. 3 Stop Stop 4 5 6

Example: If the bus signal has activated t he ope ra ting mod e Max., it will only be possible to stop the pump.

External control signals

20.

Max. Min. Normal

20.1 Digital inputs

The overview sho ws funct ions in co nnectio n with cl os ed con tact.

Terminal Type Function

18 DI 1 • Start/stop of pump

• Min. (min. curve)

• Max. (max. curve)

• Ext. fault (external fault)

19 DI 2

32 DI 3

• Flow switch

• Alarm res et

• Dry runn ing (fro m exte rnal s ensor )

• Not activ e.

• Min. (min. curve)

• Max. (max. curve)

• Ext. fault (external fault)

• Flow switch

• Alarm res et

• Dry runn ing (fro m exte rnal s ensor )

• Not activ e.

Terminal Type Function

• Min. (min. curve)

• Max. (max. curve)

• Ext. fault (external fault)

33 DI 4

The same function m us t not be s ele cted fo r more t han on e inp ut. See fig. 21.

• Flow switch

• Alarm reset

• Dr y running (f rom external s ens or )

• Acc umula ted flo w (p ulse flo w)

• Not activ e.

20.2 External setpoint

Terminal Type Function

53 AI 1 • External setpoint (0-10 V)

The setpoint can b e remo te- set by c onnec ting an anal og s ignal transmitter to the s etpo int in put (te rmin al 53).

Open loop

In control mode O pen loop (c onsta nt cu rve) , the actual setpoint can be set externa lly w ithin the rang e fro m the m in. cu rve to th e setpoint set via the CUE m enu. See fi g. 56.

Setpoint

Max. curve

Setpoint, CUE menu

Actual

Actual setpoint

Min. curve

0 10 V

Ext. setpoint signal

Fig. 56 Relation bet ween t he ac tual set point and the ex ternal

setpoint signal in control m o de Open lo op

setpoint range

TM03 8856 2607

Closed loop

In all other contro l modes , ex cept pr opor tiona l differentia l pressure, the actu al setpo int c an b e set ex ternal ly wi th in the range from the lowe r value of the s en sor mea surin g rang e (sensor min.) to the set point se t via the CU E me nu. Se e fig. 57.

Setpoint

Sensor max.

Setpoint, CUE menu

Actual

Actual setpoint

Sensor min.

0 10 V

Ext. setpoint signal

Fig. 57 Relation bet ween t he ac tual set point and the ex ternal

Example: At a sensor min. value of 0 bar, a setpoint set v ia the

CUE menu of 3 bar a nd an ex ter nal setp oin t of 80 % , the ac tual setpoint will be as follows:

Actual setpoin t =

setpoint signal in con trol mo de C ontrolle d

(setpoint set via the C UE m enu – s ensor min. )

x % external setpoint sign al + sens or m in. = (3 – 0) x 80 % + 0 = 2.4 bar.

setpoint range

20.3 GENIbus signal

The CUE suppo rts se rial co m munic atio n via an RS -485 in pu t. The communica tion is c arried out a ccor ding to t he G rundfos GENIbus protocol and ena bles c onnec tion to a buildin g management sy ste m or an othe r ext erna l co ntrol sy st em.

Operating parame ters , su ch as set point and ope ra ting mod e c an be remote-set v ia the bus signal. At the same time, the pump can provide status infor mat ion ab out im po rtant param ete rs, such as actual value of co ntrol para met er, input power and fault indications.

Contact Grundfos for furthe r details .

Note

If a bus signal is used, the number of settings available via the CUE will be reduced.

20.4 Other bus standards

Grundfos offers variou s b us sol ution s wit h com munic atio n according to other standa rds.

Contact Grundfos for furthe r details .

Maintenance and service

21.

TM03 8856 2607

21.1 Cleaning the CUE

Keep the cooling f ins and fan b lades clean t o ens ure su fficient cooling of the CUE.

21.2 Service parts and service kits

For further info rmat ion on se rvic e parts and serv ice ki ts, visit www.grundfos.com > In t ernational website > WebCAPS.

Grundfos CUE

Proportional differential pressure

In control mode Proportiona l diff erentia l pres sure , th e actual setpoint can be set exter nally w ithin the ra ng e from 2 5 % of maximum head to the setpoint set via the CUE m enu. See fig. 58.

Setpoint

90 % of max . head

Setpoint, CUE menu

Actual

Actual setpoint

25 % of max. head

0 10 V

Ext. setpoint signal

Fig. 58 Relation bet ween t he ac tual set point and the ex ternal

setpoint signal in control mode Proportional differential pressure

Example: At a maximum head of 12 metres, a setpoint of 6 metres set via the CUE me nu an d an external setpoint of 40 %, the actual setpoint will be as follows :

Actual setpoin t =

(setpoint, CUE men u – 25 % o f maxim um

head) x % external se tpoint signa l + 25 % of

maximum head

= (6 – 12 x 25 %) x 40 % + 12/4 = 4.2 m.

setpoint range

TM03 8856 2607

Grundfos CUE

Troubleshooting

22.

22.1 Warning and alarm list

Status

Code and display text

Warning

Too high le akage

current 2 Mains phase failure 3 External fault

16 Othe r fault 30 Replace motor bearings z

32 Overvoltage

40 Undervoltage

48 Overload 49 Overload

55 Overload

57 Dry runn ing

Too high C UE 64

temperature

Too high m oto r 70

temperature

Communication faul t, 77

duty/standby 89 Sensor 1 outside r ange

Temperat ure sen sor 1 91

outside range 93 Sensor 2 outside r ange z

Setpoint signal outside 96

range

Too high b earing 148

temperature

Too high b earing 149

temperature 155 Inrush fault

Temperat ure sen sor 2 175

outside range

Relubricate motor 240

bearings 241 Motor phase failure

242 AMA

In case of an alarm, the CUE wi ll chang e the opera ting m ode depending on the pum p type.

AMA, Automatic Motor Adaptation. Not active in the present software.

Warning is reset in display 3.20.

did not succeed z – Man.

z Stop Aut. z Stop Man. z Stop Aut.

z Stop Aut.

z Stop Aut. z Stop Aut.

z Stop Aut.

z Stop Aut. z Stop Aut.

z Stop Aut.

z Stop Aut. z Stop Aut.

z Stop Aut.

Operat-

ing mode

Alarm

Locked alarm

z Stop Man.

– Man. – Aut.

– Aut.

z Stop Man.

– Aut.

– Aut. – Aut.

– Aut.

– Man. – Aut.

Reset-

ting

Aut.

22.2 Resetting of alarms

In case of fault or ma lfun ctio n of the CUE, ch ec k the ala rm lis t in menu OPERATION. The latest five alarms and latest five warnings can be found in the log men us.

Contact a Grundfo s tec hni cian if an ala rm oc curs re peat edly.

22.2.1 Warning

The CUE will continue the oper ation as long as the w arning is active. The warni ng rem ains a ctive u ntil t he cau se no longer exists. Some warni ngs m ay sw itch to alarm condi tion.

22.2.2 Alarm

In case of an alarm, the CUE wi ll sto p the p ump or c han ge the operating mode de pendin g on the ala rm t ype a nd pum p type. See section 15.1 Warning and alarm list.

Pump operation will be resumed when the cause of the alarm has been remedied an d the alarm has be en re set.

Resetting an alarm manually

• Press OK in the al arm di splay.

• Press On/Off twice.

• Activate a digital input DI 2-DI 4 s et to Alarm reset or the digital input DI 1 (Start/stop).

If it is not possibl e to rese t an a larm, the rea son may be that the fault has not been re m edied, or that t he alar m has been lo cke d.

15.2.3 Locked alarm

In case of a locked al arm, the CUE wi ll stop t he pum p and become locked. Pump opera tion c anno t be re sum ed until t he cause of the locked alarm has be en rem edied and the al arm h as been reset.

Resetting a locked alarm

• Switch off the powe r supply to the C UE for a pprox . 30 seconds. Switch on the po wer su pply, and press OK in the alarm display to reset the alarm.

22.3 Indicator lights

The table show the functio n of the ind icator li ghts.

Indicator light

On (green)

Off (orange) Alarm (red) In dicat es an alarm or a warni ng.

Function

The pump is runnin g or ha s be en stop ped by a stop function.

If flashing, the pump h as bee n sto pped b y the user (CUE menu) , exte rnal s tart/stop o r bus .

The pump has been stop pe d with th e On /Off button.

22.4 Signal relays

The table show the functio n of the sig nal relay s.

Type Function

Relay 1

Relay 2

Grundfos PACOpaQ Installation And Operating Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual