Grundfos UPE 2000 Series, UPE 100-120 FZ, UPED 80-120 FZ, UPE 80-120 FZ, UPED 100-120 FZ Installation And Operating Instructions Manual
GRUNDFOS INSTRUCTIONS
UPE Series 2000
UPE(D) 80-120 FZ, UPE 100-120 FZ
Installation and operating instructions
UPE Series 2000
Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
English (GB)
Installation and operating instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Deutsch (DE)
Montage- und Betriebsanleitung. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Appendix 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Table of contents
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Declaration of conformity
Declaration of Conformity
GB: EC declaration of conformity
We, Grundfos, declare under our sole responsibility that the products
UPE(D) Series 2000, to which this declaration relates, are in conformity
with these Council directives on the approximation of the laws of the EC
member states:
– Machinery Directive (2006/42/EC).
Standard used: EN 809: 2009.
– Low Voltage Directive (2006/95/EC).
Standards used: EN 60335-1: 2002 and EN 60335-2-51: 2003.
– EMC Directive (2004/108/EC).
Standard used: EN 61800-3.
DE: EG-Konformitätserklärung
Wir, Grundfos, erklären in alleiniger Verantwortung, dass die Produkte
UPE(D) Series 2000, auf die sich diese Erklärung bezieht, mit den
folgenden Richtlinien des Rates zur Angleichung der Rechtsvorschriften
der EU-Mitgliedsstaaten übereinstimmen:
– Maschinenrichtlinie (2006/42/EG).
Norm, die verwendet wurde: EN 809: 2009.
– Niederspannungsrichtlinie (2006/95/EG).
Normen, die verwendet wurden: EN 60335-1: 2002 und
EN 60335-2-51: 2003.
– EMV-Richtlinie (2004/108/EG).
Norm, die verwendet wurde: EN 61800-3.
Bjerringbro, 15th March 2011
Svend Aage Kaae
Technical Director
Grundfos Holding A/S
Poul Due Jensens Vej 7
8850 Bjerringbro, Denmark
Person authorised to compile technical file and
empowered to sign the EC declaration of conformity.
4
English (GB) Installation and operating instructions
Caution
Note
Original installation and operating instructions.
CONTENTS
Page
1. Symbols used in this document
2. General description
3. Applications
3.1 Pumped liquids
4. Installation
4.1 Positioning the pump
4.2 Mounting the pressure sensor
4.3 Control box positions
4.4 Twin-head pumps
4.5 Non-return valve
4.6 Insulation
4.7 Frost protection
5. Electrical connection
5.1 Ferrite core
5.2 Wiring diagram
6. Start-up
6.1 Venting the pump
7. Functions
7.1 Control modes
7.2 Control of twin-head pumps
7.3 Selection of control mode
7.4 Max. or min. curve duty
7.5 Constant-curve duty
7.6 Temperature influence
7.7 Indicator lights
7.8 External fault indication
7.9 External analog 0-10 V controller
7.10 External forced control
7.11 Deactivating the control panel
7.12 Bus communication
7.13 Remote control
8. Setting the pump
8.1 Factory settings
8.2 Control panel
8.3 R100
8.4 Menu OPERATION
8.5 Menu STATUS
8.6 Menu INSTALLATION
8.7 Priority of settings
9. Fault finding
10. Megging
10.1 Megging of UPE pumps
10.2 High-voltage test
11. Service kits
12. Technical data
13. Disposal
Warning
Prior to installation, read these
installation and operating instructions.
Installation and operation must comply
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1. Symbols used in this document
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2. General description
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The Grundfos UPE(D) FZ is a range of circulator
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pumps with differential-pressure control enabling
adjustment of the pump performance to the actual
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system requirements. In many systems, this will
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reduce the power consumption considerably, reduce
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noise from thermostatic valves and similar fittings,
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and improve the control of the system.
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The desired head can be set on the pump control
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panel.
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These instructions apply to the pump types
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UPE(D) 80-120 FZ and UPE 100-120 FZ.
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The pump offers the following functions:
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• Proportional-pressure control (factory setting).
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• Constant-pressure control.
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• Constant-curve duty.
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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.
Warning
If these safety instructions are not
observed, it may result in personal
injury!
If these safety instructions are not
observed, it may result in malfunction
or damage to the equipment!
Notes or instructions that make the job
easier and ensure safe operation.
The pump head is changed in accordance with
the flow demand. The desired head can be set on
the pump control panel.
A constant head is maintained, irrespective of the
flow demand. The desired head can be set on the
pump control panel.
The pump runs at a constant speed on or
between the max. and min. curves.
English (GB)
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• Temperature influence.
Note
Note
English (GB)
The pump head varies depending on the liquid
temperature.
• External fault signal via a potential-free output.
• External analog control of head or speed from
an external 0-10 V signal transmitter.
• External forced control via inputs for
– start/stop
– min. curve.
• Bus communication.
The UPE(D) FZ circulator pumps incorporate an
input for bus communication. The pump can be
controlled and monitored by a building
management system.
• Remote control.
The pump can be operated with the Grundfos
R100 remote control.
3. Applications
The UPE(D) FZ circulator pumps are designed for
circulating liquids in heating systems.
The UPE(D) FZ range is suitable for
• systems with a constant flow where it is
desirable to optimise the setting of the pump duty
point.
• systems with variable flow-pipe temperatures.
3.1 Pumped liquids
Thin, clean, non-aggressive and non-explosive
liquids, not containing solid particles, fibres or
mineral oil.
In heating systems, the water should meet the
requirements of accepted standards on water quality
in heating systems, for example the German
standard VDI 2035.
Warning
The pump must not be used for the
transfer of flammable liquids, such as
diesel oil, petrol or similar liquids.
4.2 Mounting the pressure sensor
Mount the pressure sensor only after
the pump has been installed in the
system.
See fig. 1.
1. Place the O-ring in the seat of the pump housing.
2. Place the sensor housing without damaging the
O-ring.
3. Fit and tighten the two screws.
Fig. 1 Mounting the pressure sensor
4.3 Control box positions
The control box must only be turned to
the positions shown on page 310.
The arrows show the allowed/possible flow
directions.
4.3.1 Changing the control box position
Warning
Before any dismantling of the pump,
the system must be drained, or the
isolating valves on either side of the
pump must be closed, as the pumped
liquid may be scalding hot and under
high pressure.
TM04 4631 1809
4. Installation
4.1 Positioning the pump
The arrow on the pump housing indicates the liquid
flow direction through the pump.
Warning
Make sure that persons cannot
accidentally come into contact with
the hot surfaces of the pump.
The pump must be installed with the motor shaft
horizontal.
See mounting dimensions at the end of these
instructions.
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Fig. 2 Correct control box position
Change the control box position as follows:
1. Slacken the cable clamp of the pressure sensor.
2. Remove the four screws holding the pump head.
3. Turn the pump head to the desired position.
4. Refit the four screws and tighten securely.
5. Adapt the pressure sensor cable, and tighten the
cable clamp.
Warning
Make sure that the pressure sensor
cable cannot come into contact with
the pump head.
TM04 4633 1809
4.4 Twin-head pumps
Twin-head pumps offer these operating modes:
• alternating operation
• standby operation
• synchronous operation
• single-pump operation.
4.4.1 Master pump and slave pump
The master pump will always be the pump to the
right when seen from the control box end and the
pump is pumping upwards. See fig. 3, pos. 1.
Fig. 3 Master pump (1) and slave pump (2)
4.5 Non-return valve
If a non-return valve is fitted in the pipe system
(fig. 4), it must be ensured that the minimum
discharge pressure is always higher than the closing
pressure of the valve. This is especially important in
proportional-pressure control mode (reduced head
at low flows).
Fig. 4 Non-return valve
4.6 Insulation
If the pump is insulated without using Grundfos
insulating kits, it must be ensured that the
differential-pressure and temperature sensor in the
pump housing is not covered.
4.7 Frost protection
If the pump is not being used during periods of frost,
the necessary steps must be taken to prevent frost
bursts.
5. Electrical connection
The electrical connection and protection must be
carried out according to local regulations.
Warning
Never make any connections in the
pump control box unless the power
supply has been switched off for at
least 5 minutes. The indicator light
must be off. See fig. 6, pos. 21.
The earth terminal of t he pump m ust be
earthed.
The pump must be connected to an
external mains switch with a minimum
contact gap of 3 mm in all poles.
Earthing or neutralisation can be used
for protection against indirect contact.
Megging must be carried out as
described in section 10. Megging.
If the pump is connected to an electric
TM04 4629 1809TM02 0640 0301
• The pump requires no external motor protection.
• Check that the supply voltage and frequency
5.1 Ferrite core
Install the ferrite core as shown below.
installation where an earth leakage
circuit breaker (ELCB) is used as an
additional protection, this circuit
breaker must trip out when earth fault
currents with DC content (pulsating
DC) and smooth DC earth fault currents
occur.
The earth leakage circuit breaker must
be marked with these symbols:
correspond to the values stated on the pump
nameplate.
English (GB)
Fig. 5 Ferrite core installed
TM04 9584 4610
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5.2 Wiring diagram
English (GB)
Fig. 6 Internal view of the control box
TM04 4634 4709
Pos. Description
A, Y, B Terminal block for GENIbus
T Terminal block for twin-head pump
D Terminal block for pressure and temperature sensor on the pump (standard)
1, 2 (START/STOP)
3, 4 (MIN.)
5, 6 (0-10 V)
7, 8 (ALARM) Terminal block for remote alarm contact. Maximum load: 250 VAC, 5 A.
9, 10, 11
12, 13, 14
15 Motor earthing screw
16, 17 Terminals for connection of motor protector, white lead (T1, T2)
18 Terminal for control panel
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Terminals for external start/stop
(connect only contacts with no voltage)
Terminals for min. curve input
(connect only contacts with no voltage)
Terminals for external analog input 0-10 VDC
Terminal 5 = +10 V
Terminal 6 = 0 V
Terminals for supply voltage, 1 x 230 V, 50-60 Hz
Terminal 9 = Line (L)
Terminal 10 = Earth ( )
Terminal 11 = Neutral (N)
Terminals for connection of motor cables
Terminal 12 = brown lead
Terminal 13 = grey lead
Terminal 14 = black lead
19 Control panel retaining screws
Note
Vent screw
20 Terminal for fan
21 High-voltage indicator
22 Terminal for screened motor cable
23 Fan
Note:
• All cables used must be heat-resistant up to
at least +85 °C.
• All cables used must be installed in accordance
with EN 60204-1.
Warning
Wires connected to
• outputs 7 and 8,
• inputs 1 to 6,
• supply terminals and
• differential-pressure and
temperature sensor
must be separated from each other and
from the supply by reinforced
insulation.
All wires connected to a terminal block
must be tied up at the terminals.
Concerning demands on signal wires and signal
transmitters, see section 12. Technical data.
6. Start-up
Do not start the pump until the system has been filled
with liquid and vented. Furthermore, the required
minimum inlet pressure must be available at the
pump inlet. See section 12. Technical data.
The system cannot be vented through
the pump.
6.1 Venting the pump
Vent the pump before start-up. See fig. 7.
Warning
When the vent screw is slackened,
scalding hot liquid under high pressure
may escape. Care must be taken to
ensure that the escaping liquid does
not cause personal injury or damage to
other components.
English (GB)
Fig. 7 Venting the pump
The pump may be noisy, when first switched on,
due to air remaining in the pump. This noise should
cease after a few minutes running.
After start-up, set the desired operating mode and
possibly pump head.
TM04 4635 1809 - TM04 4636 180 9
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7. Functions
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H
Q
H
Q
H
set
H
set
H
set
Proportional
pressure
Constant
pressure
Slave pump Master pump
English (GB)
Some functions can only be selected with the
Grundfos R100 remote control. Where and how the
various settings are made appear from
section 8. Setting the pump.
7.1 Control modes
The UPE(D) FZ pumps can be set to the control
mode which is most suitable for the individual
system.
Two control modes are available:
• proportional pressure (factory setting)
• constant pressure.
Proportional-pressure control
To be set on the control panel or with the R100.
The pump head is reduced at falling water demand
and increased at rising water demand. See fig. 8.
This is the factory setting as, in most cases, this is
the optimum control mode, and at the same time
it consumes the least energy.
Constant-pressure control
To be set on the control panel or with the R100.
The pump maintains a constant pressure,
irrespective of water demand. See fig. 8.
Fig. 8 Pressure control
7.2 Control of twin-head pumps
The factory setting can be changed with the R100.
Fig. 9 Master and slave pumps
Four operating modes are available. The selection of
operating mode depends on whether reliability,
lifetime or performance has top priority.
• Alternating operation (factory setting).
Pump operation alternates every 24 hours.
If the power supply to the pump has been
switched off, any of the pumps may start when
the power supply is switched on again.
Reaction in case of fault: In case of fault in one
pump, the duty pump will operate continuously as
a single-head pump.
• Standby operation.
The master pump is operating continuously.
Every 25 hours the slave pump will start and run
for approx. 10 seconds to prevent it from seizing
up.
Reaction in case of fault: If the master pump
stops due to a fault, the slave pump will operate
continuously as a single-head pump.
• Synchronous operation.
The pumps are operating at the same motor
frequency. This operating mode is suitable if the
flow demand exceeds the flow of one pump.
Reaction in case of fault: In case of fault in one
pump, the duty pump will operate continuously as
a single-head pump.
• Single-pump operation.
The pumps are operating completely
independently of each other without internal
communication, but the twin-head cable must
be connected. All functions of each pump are
identical to those of a single-head pump.
All the other functions mentioned in sections
7.1 Control modes to 7.13 Remote control are
possible in the four operating modes.
7.2.1 Why select single-pump operation
Select single-pump operation
• when the twin-head pump is to be controlled or
TM00 5546 4596TM04 4629 1809
monitored by a Grundfos pump management
system.
• in all other situations where the master and slave
pumps are to operate independently of each
other as two single-head pumps.
7.2.2 R100 remote control
Single-pump operation is to be selected with the
R100. See section 8.6.6 Twin-head pump.
7.2.3 Operation in parallel
In single-head operation mode, the pumps must
never run at the same time, unless the pump is
controlled by a Grundfos pump management system.
7.2.4 Setting the slave pump
When single-pump operation mode has been
selected, the slave pump settings will correspond to
the settings of the last working pump.
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