17554 2 Grundfos 96734489 Instructions User Manual

User Manual: Pump 17554 2 Grundfos 96734489 Instructions

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GRUNDFOS MAGNA

Series 2000

MAGNA 40-120, 65-120, 65-60

GRUNDFOS INSTRUCTIONS

Installation and operating instructions

LIMITED WARRANTY

Products manufactured by GRUNDFOS PUMPS CORPORATION (Grundfos) are

warranted to the original user only to be free of defects in material and workmanship

for a period of 24 months from date of installation, but not more than 30 months from

date of manufacture. Grundfos' liability under this warranty shall be limited to

repairing or replacing at Grundfos' option, without charge, F.O.B. Grundfos' factory

or authorized service station, any product of Grundfos' manufacture. Grundfos will

not be liable for any costs of removal, installation, transportation, or any other

charges which may arise in connection with a warranty claim. Products which are

sold but not manufactured by Grundfos are subject to the warranty provided by the

manufacturer of said products and not by Grundfos' warranty. Grundfos will not be

liable for damage or wear to products caused by abnormal operating conditions,

accident, abuse, misuse, unauthorized alteration or repair, or if the product was not

installed in accordance with Grundfos' printed installation and operating

instructions.

To obtain service under this warranty, the defective product must be returned to the

distributor or dealer of Grundfos' products from which it was purchased together

with proof of purchase and installation date, failure date, and supporting installation

data. Unless otherwise provided, the distributor or dealer will contact Grundfos or

an authorized service station for instructions. Any defective product to be returned

to Grundfos or a service station must be sent freight prepaid; documentation

supporting the warranty claim and/or a Return Material Authorization must be

included if so instructed.

GRUNDFOS WILL NOT BE LIABLE FOR ANY INCIDENTAL OR

CONSEQUENTIAL DAMAGES, LOSSES, OR EXPENSES ARISING FROM

INSTALLATION, USE, OR ANY OTHER CAUSES. THERE ARE NO EXPRESS OR

IMPLIED WARRANTIES, INCLUDING MERCHANTABILITY OR FITNESS FOR A

PARTICULAR PURPOSE, WHICH EXTEND BEYOND THOSE WARRANTIES

DESCRIBED OR REFERRED TO ABOVE.

Some jurisdictions do not allow the exclusion or limitation of incidental or

consequential damages and some jurisdictions do not allow limit actions on how

long implied warranties may last. Therefore, the above limitations or exclusions may

not apply to you. This warranty gives you specific legal rights and you may also

have other rights which vary from jurisdiction to jurisdiction.

GRUNDFOS MAGNA

Series 2000

MAGNA 40-120, 65-120, 65-60

Installation and operating instructions 4

Notice d’installation et d’entretien 25

CONTENTS

Page

1. Symbols used in this document 4

2. General description 4

3. Applications 4

3.1 Pumped liquids 4

4. Installation 5

4.1 Changing the control box position 5

4.2 Two pumps in parallel 5

4.3 Check valve 5

4.4 Frost protection 5

5. Electrical connection 6

5.1 Supply voltage 6

5.2 Connection diagram 7

6. Start-up 8

7. Functions 9

7.1 Control modes 10

7.2 Selection of control mode 11

7.3 Automatic night-time duty 12

7.4 Constant-curve duty 12

7.5 Max. or min. curve duty 12

7.6 Temperature influence 12

7.7 External start/stop 13

7.8 Signal relay 13

7.9 Indicator lights 13

7.10 Expansion modules 14

7.11 GENI module 14

7.12 LON module 14

8. Setting the pump 14

8.1 Factory setting 14

8.2 Control panel 15

8.3 R100 remote control 16

8.4 R100 display overview 17

8.5 Menu OPERATION 18

8.6 Menu STATUS 19

8.7 Menu INSTALLATION 20

8.8 Priority of settings 21

9. Fault finding chart 22

10. Megging 23

11. Technical data 24

12. Disposal 24

1. Symbols used in this document

2. General description

The GRUNDFOS MAGNA Series 2000 is a complete

range of circulator pumps with integrated differential

pressure control enabling adjustment of pump

performance to the actual system requirements.

In many systems, this will reduce the power

consumption considerably, reduce noise from

thermostatic valves and similar fittings, and improve

the control of the system.

The desired head can be set on the pump control

panel.

3. Applications

The GRUNDFOS MAGNA is designed for circulating

liquids in heating systems. The pump can also be

used in domestic hot-water systems.

The pump range is primarily used in

• systems with a variable flow.

The pump range can also be used in

• systems with a constant flow where it is

desirable to optimize the setting of the pump duty

point,

• systems with variable supply-pipe temperature.

GRUNDFOS MAGNA pumps can be used in snow-

melting applications. To avoid condensation in the

control box, the pump should not be installed on the

return side.

3.1 Pumped liquids

Thin, clean, non-aggressive and non-explosive liquids,

not containing solid particles, fibers or mineral oil.

In heating systems, the water should meet the

requirements of accepted standards on water quality

in heating systems.

In domestic hot-water systems, it is advisable to

use GRUNDFOS MAGNA pumps only for water with

a degree of hardness lower than approx. 17 grains/

gallon (14 °dH).

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!

If these safety instructions are not

observed, it may result in personal

injury!

Caution If these safety instructions are not

observed, it may result in malfunction

or damage to the equipment!

Note Notes or instructions that make the job

easier and ensure safe operation.

WARNING!

The pump must not be used for the

transfer of inflammable liquids such as

diesel oil, petrol or similar liquids.

4. Installation

Arrows on the pump housing indicate the liquid flow

direction through the pump.

4.1 Changing the control box position

Change the control box position as follows:

1. Remove the inspection screw (1) and the four

Allen screws (6 mm) (2) in the stator housing, see

fig. 1.

2. Lift off the stator housing (3). Keep the rotor (4) in

place using a suitable tool, e.g. a T-key (M8) (5),

see fig. 2.

3. Check that the O-ring (6) is intact.

A defective O-ring must be replaced.

4. Hold the stator housing/control box (3) in the

desired position.

5. Lower the stator housing over the rotor.

Keep the rotor in place as described in point 2.

6. Fit and tighten the four screws, torque

14-17.5 Nm, and the inspection screw, torque

8-10 Nm.

Fig. 1 Removing the control box

Fig. 2 Changing the control box position

4.2 Two pumps in parallel

Two pumps in parallel can be controlled via the

optional GENI module. Both pumps should have a

GENI module installed in the control box. The

modules are connected with a wire. The modules

determine the pump operating mode, see section

7.11 GENI module.

4.3 Check valve

If a check valve is fitted in the pipe system, see fig.

3, it must be ensured that the set minimum discharge

pressure of the pump 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. 3 Check valve

4.4 Frost protection

If the pump is not used during periods of frost,

necessary steps must be taken to prevent frost

bursts.

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.

TM03 8910 2707

TM03 8911 2707

Pos. Description

1 Inspection screw

2Screw

3 Stator housing/control box

4 Rotor

5 T-key (not provided with the pump)

6 O-ring

TM02 0640 0301

Note

Additives with a density and/or

kinematic viscosity higher than those/

that of water will reduce the hydraulic

performance.

5. Electrical connection

The electrical connection and protection should be

carried out in accordance with local regulations.

• The pump requires no external motor protection.

• The operating voltage and frequency are marked

on the pump nameplate. Please make sure that

the motor is suitable for the electricity supply on

which it will be used.

Open the control box cover as shown in fig. 4.

Fig. 4 Opening the control box

If the control box cover cannot be lifted sufficiently, it

can be removed as shown in fig. 5.

Fig. 5 Removing the control box cover

5.1 Supply voltage

1 x 230 V ± 10 %, 50/60 Hz.

WARNING!

Never make any connections in the

pump control box unless the electricity

supply has been switched off for at

least 5 minutes.

The ground terminal of the pump must

be earthed.

The pump must be connected to an

external mains switch with a contact

separation of at least 1/8 inch (3 mm) in

each pole.

Grounding or neutralization can be

used for protection against indirect

contact.

Megging must be carried out as

described in section 10. Megging.

If the pump is connected to an electric

installation where an earth leakage

circuit breaker (ELCB) is used as

additional protection, this circuit

breaker must trip out when earth fault

currents with DC content (pulsating

DC) occur.

The earth leakage circuit breaker must

be marked with the symbol shown:

Step Action

TM02 0456 3503

TM02 0457 3503

Step Action

TM02 7441 3503

TM02 7442 3503

5.2 Connection diagram

Fig. 6 Wiring diagram

Concerning demands on signal wires and signal

transmitters, see section 11. Technical data.

A connection example can be found on page 49.

Note:

• If no external on/off switch is connected, the

connection across terminals STOP and should

be maintained.

• All cables used must be heat-resistant up to

+185 °F (+85 °C).

• All cables used must be installed in accordance

with NEC or applicable local codes and

regulations.

• If a GENI module is fitted, the screen must be

connected to . See page 50.

TM02 0235 1007

NC NO C

213

Supply connection Signal output Start/stop input

NC NO C

WARNING!

•Wires connected to

– supply terminals,

– outputs NC, NO, C and

– start/stop input

must be separated from each other

and from the supply by reinforced

insulation.

•All wires connected to a terminal

block must be tied up at the

terminals.

6. Start-up

Do not start the pump until the system has been

filled with liquid and vented. Furthermore, the

required minimum inlet pressure must be available at

the pump inlet, see section 11. Technical data.

The system cannot be vented through the pump.

The pump can be vented by slackening the

inspection screw.

Fig. 7 Venting the pump

WARNING!

If the inspection screw is to be

loosened, see fig. 7, care should be

taken to ensure that the escaping,

scalding hot liquid does not cause

personal injury or damage to

components.

TM03 8912 2707

Inspection screw

7. Functions

Most functions can be selected on the pump control panel. However, some functions can only be selected with

the R100 or via expansion modules.

On the pump control panel, see fig. 13, page 15:

•AUTOADAPT (factory setting)

Recommended for most heating installations.

During operation, the pump automatically makes the necessary adjustment to the actual system

characteristic. This setting ensures minimum energy consumption and noise level which reduces operating

costs and increases comfort.

•Proportional-pressure control

The pump head is changed continuously in accordance with the water demand in the system. The desired

setpoint can be set on the pump control panel.

•Constant-pressure control

A constant head is maintained, irrespective of water demand. The desired setpoint can be set on the pump

control panel.

•Automatic night-time duty

The pump changes automatically between normal duty and night-time duty depending on the supply-pipe

temperature. Automatic night-time duty can be combined with the above-mentioned control modes.

Further functions:

Via the digital input:

•External start/stop

The pump can be started or stopped via the digital input.

With the R100 remote control:

•Constant-curve duty

The pump runs at a constant speed, on or between the max. and min. curves.

•Temperature influence

The head varies depending on the liquid temperature.

•External fault and operating signal

The pump controls an external fault or operating signal device via a potential-free output.

Via expansion modules:

GENI module

•External analog control of head or speed via a signal from an external 0-10 V signal transmitter.

•External forced control via inputs for:

- Max. curve,

- Min. curve.

•Bus communication via GENIbus

The pump can be controlled and monitored by a GRUNDFOS Pump Management System 2000,

a building management system or another type of external control system.

•Control of two pumps in parallel

The control of two pumps in parallel is described in section 7.11.

LON module

•Bus communication via LON

This module enables connection to a network based on LonWorks® technology and to other units which

are based on this communication standard.

7.1 Control modes

A GRUNDFOS MAGNA pump can be set to the

control mode which is most suitable for the individual

system.

Possible control modes:

•AUTO

ADAPT (factory setting)

• Proportional pressure

• Constant pressure.

Each of the control modes can be combined with

automatic night-time duty, see section 7.3 Automatic

night-time duty.

AUTOADAPT

To be set on the control panel or with the R100, see

section 8. Setting the pump.

The control mode AUTOADAPT continuously adapts

the pump performance.

The setpoint (Hset1) of the pump has been factory-

set as follows and cannot be changed manually:

• MAGNA 40-120, 65-120 to 21 feet (6.5 m).

• MAGNA 65-60 to 11.5 feet (3.5 m).

When the pump registers a lower pressure on the

max. curve, A2, the AUTOADAPT function

automatically selects a correspondingly lower control

curve, Hset2, thus reducing the energy consumption.

Fig. 8 AUTOADAPT

A1: Original duty point.

A2: Lower registered pressure on the max. curve.

A3: New duty point after AUTOADAPT control.

Hset1: Original setpoint.

Hset2: New setpoint after AUTOADAPT control.

Hfac.: Factory-set setpoint.

The AUTOADAPT function can be reset by pressing

the button for approx. 10 seconds until the control

mode is back to the starting point (AUTOADAPT or

AUTOADAPT with automatic night-time duty).

Proportional-pressure control

To be set on the control panel or with the R100, see

section 8. Setting the pump.

The pump head is reduced as the water demand

declines and increased as the water demand rises,

see fig. 9.

Constant-pressure control

To be set on the control panel or with the R100, see

section 8. Setting the pump.

The pump maintains a constant pressure,

irrespective of water demand, see fig. 9.

Fig. 9 Pressure control

TM02 0251 4800

Hmax.

Hfac.

A3A2

Hset2

Hset1

TM00 5546 4596

Proportional

pressure Constant

pressure

Hset Hset

Hset

7.2 Selection of control mode

7.2.1 Setpoint setting

If AUTOADAPT is selected, the setpoint cannot be set.

The setpoint can be set by pressing or when

the pump is in control mode:

• proportional pressure

• constant pressure

• constant-curve duty.

Set the setpoint so that it matches the system.

A too high setting may result in noise in the system

whereas a too low setting may result in insufficient

heating or cooling in the system.

System type Description Select this

control mode

Typical heating

systems

Grundfos recommends to let the pump remain in AUTOADAPT mode.

This ensures optimum performance at the lowest possible energy

consumption. AUTOADAPT

Relatively great

head losses in

the distribution

pipes

1. Heating

systems with

thermostatic

valves and:

• with a dimensioned pump head higher than 13 feet

(4 m),

Proportional

pressure

• very long distribution pipes,

• strongly throttled pipe balancing valves,

• differential pressure regulators,

• great head losses in those parts of the system

through which the total quantity of water flows

(e.g. boiler, heat exchanger and distribution pipe up

to the first branching).

2. Primary circuit pumps in systems with great head losses in the primary

circuit.

Relatively small

head losses in

the distribution

pipes

1. Heating

systems with

thermostatic

valves and:

• with a pump head lower than 6.5 feet ( 2 m),

Constant

pressure

• designed for natural circulation,

• with small head losses in those parts of the system

through which the total quantity of water flows

(e.g. boiler, heat exchanger and distribution pipe up

to the first branching) or

• designed for a high differential temperature

between supply pipe and return pipe (e.g. district

heating).

2. Radiant floor heating systems with thermostatic valves.

3. One-pipe heating systems with thermostatic valves or pipe balancing

valves.

4. Primary circuit pumps in systems with small head losses in the primary

circuit.

7.3 Automatic night-time duty

To be set on the control panel or with the R100, see

section 8. Setting the pump.

Once automatic night-time duty has been activated,

the pump automatically changes between normal

duty and night-time duty (duty at low performance).

Changeover between normal duty and night-time

duty is dependent on the supply-pipe temperature.

The pump automatically changes over to night-time

duty when the built-in sensor registers a supply-pipe

temperature drop of more than 18-27 °F (10-15 °C)

within approx. 2 hours. The temperature drop must

be at least 0.18 °F/min. (0.1 °C/min.).

Changeover to normal duty takes place without a

time lag when the temperature has increased by

approx. 18 °F (10 °C).

7.4 Constant-curve duty

To be set with the R100, see section 8. Setting the

pump.

The pump can be set to operate according to a

constant curve, like an uncontrolled pump, see

fig. 10.

Fig. 10 Operating curves

7.5 Max. or min. curve duty

To be set on the control panel, with the R100 or via

GENI module, see section 8. Setting the pump.

The pump can be set to operate according to the

max. or min. curve, like an uncontrolled pump, see

fig. 11.

This operating mode is available, irrespective of the

control mode.

Fig. 11 Max. and min. curves

The max. curve mode can be selected if an

uncontrolled pump is required.

The min. curve mode can be used in periods in

which a minimum flow is required. This operating

mode is for instance suitable for manual night-time

duty if automatic night-time duty is not desired.

7.6 Temperature influence

The temperature influence function is available with

proportional- or constant-pressure control mode.

To be set with the R100, see section 8. Setting the

pump.

When the temperature influence function is

activated, the setpoint for head will be reduced

according to the liquid temperature.

The temperature influence limits can be set to 122 °F

(50 °C) or 176 °F (80 °C). The temperature limits are

not adjustable.

These temperature limits are called Tmax.. The

setpoint is reduced in relation to the head set

(= 100 %) according to the characteristics below.

Fig. 12 Temperature influence

In the above example, Tmax. = 176 °F (80 °C) has

been selected. The actual liquid temperature Tactual

causes the setpoint for head to be reduced from

100 % to Hactual.

The temperature influence function requires:

• Proportional- or constant-pressure control mode.

• The pump must be installed in the supply-side

pipe.

• System with supply-pipe temperature control.

Temperature influence is suitable in:

• systems with variable flows (e.g. two-pipe heating

systems), in which the activation of the

temperature influence function will ensure a

further reduction of the pump performance in

periods with small heating demands and

consequently a reduced supply-pipe temperature.

• systems with almost constant flows (e.g. one-pipe

heating systems and radiant floor heating

systems), in which variable heating demands

cannot be registered as changes in the head as is

the case with two-pipe heating systems. In such

systems, the pump performance can only be

adjusted by activating the temperature influence

function.

Selection of Tmax.

In systems with a dimensioned supply-pipe

temperature of:

• up to and including 131 °F (55 °C), select Tmax. =

122 °F (50 °C),

• above 131 °F (55 °C), select Tmax. = 176 °F

(80 °C).

TM02 0245 0904TM00 5547 4596

Max.

Min.

Max.

Min.

TM03 8791 2507

30%

100%

17612268

Tactual

Hactual

7.7 External start/stop

The pump can be started or stopped via an external

potential-free contact or a relay connected to

terminals 7 and 8, see section 5.2 Connection

diagram.

Functional diagram: Start/stop input

7.8 Signal relay

The pump incorporates a signal relay, terminals

1, 2 and 3, for a potential-free fault and operating

signal. The function of the signal relay, fault signal

(factory setting) or operating signal, is set with the

R100.

The output, terminals 1, 2 and 3, is electrically

separated from the rest of the controller.

The signal relay is activated as follows:

•Fault signal

The signal relay is activated together with the

red indicator light on the pump, see section

8.2 Control panel.

•Operating signal

The signal relay is activated together with the

green indicator light on the pump, see section

8.2 Control panel.

Functions of signal relay

Resetting of fault indications

A fault indication can be reset in one of the following

ways:

• Briefly press , or on the pump. This will

not influence the pump performance set.

• Briefly switch off the electricity supply to the

pump.

• With the R100, see section 8.4 R100 display

overview.

Before the pump can revert to normal duty, the fault

cause must be eliminated.

If the fault disappears by itself, the fault indication

will automatically be reset.

The fault cause will be stored in the pump alarm log.

The latest five faults can be called up with the R100.

7.9 Indicator lights

For position on pump, see fig. 13, section 8.2 Control

panel.

The indicator lights, pos. 2, are used for operating

and fault indication. Furthermore, they indicate

whether the pump is externally controlled.

The function of the operating and fault indicator

lights can be found in section 9. Fault finding chart.

The indicator light for external control is on

• if the pump control panel is inactive,

• if the pump is in constant-curve operating mode,

• if the temperature influence is active or

• if the pump is controlled by an external unit.

Start/stop input

Normal duty

Stop

Signal relay Fault signal

Not activated:

• The electricity supply has been

switched off.

• The pump has not registered

afault.

Activated:

• The pump has registered a fault.

Signal relay Operating signal

Not activated:

• The pump has been set to stop.

• The pump has registered a fault

and is unable to run.

Activated:

• The pump is running.

• The pump has registered a fault,

but is able to run.

132

NC NO C

12 3

NC NO C

132

NC NO C

12 3

NC NO C

Note When the R100 remote control

communicates with the pump, the red

indicator light will flash rapidly.

7.10 Expansion modules

The pump can be fitted with an expansion module

enabling communication with external signals

(signal transmitters).

Two types of expansion module are available:

• GENI module.

For mounting and operation, see separate

installation and operating instructions for the

GENI module.

• LON module.

For mounting, see separate fitting instructions for

the LON module.

7.11 GENI module

The GENI module offers the following functions:

• External analog 0-10 V control

• External forced control

• Bus communication via GENIbus

• Control of two pumps in parallel.

See separate installation and operating instructions

for the GENI module.

7.12 LON module

The LON module offers the possibility of connecting

the pump to a LonWorks network. The module is

used for data transmission between a network and

pumps of the type MAGNA 40-120, 65-120 and

65-60.

For further information, see the documentation files

on the CD-ROM supplied with the LON module.

8. Setting the pump

For the setting of the pump, use:

• control panel

• R100 remote control

• bus communication (not described in detail in

these instructions, contact Grundfos).

The table shows the application of the individual

operating units and in which section the function has

been described.

"–" = not available with this operating unit.

8.1 Factory setting

The pump is factory-set to AUTOADAPT without

automatic night-time duty.

Possible settings

Control

panel

R100

AUTOADAPT 8.2.1 8.7.1

Automatic night-time duty 8.2.1 8.7.2

Proportional-pressure

control 8.2.1 8.7.1

Constant-pressure control 8.2.1 8.7.1

Setpoint setting 8.2.2 8.5.1

Max. curve duty 8.2.3 8.5.2

Min. curve duty 8.2.4 8.5.2

Constant-curve duty – 8.5.2

Temperature influence – 8.7.3

Activation/deactivation of

pump buttons –8.7.4

Allocation of pump number – 8.7.6

Start/stop 8.2.5 8.5.2

Resetting of fault

indications 8.2.6 8.5.3

Reading of various data –8.6.1 -

8.6.7

8.2 Control panel

The control panel, fig. 13, incorporates:

For further information, see section 9. Fault finding

chart.

Fig. 13 Control panel

8.2.1 Control mode setting

Description of function, see section 7.1 Control

modes.

To change the control mode, press , pos. 3,

according to this cycle:

Fig. 14 Cycle of control modes

Automatic night-time duty can be activated together

with each of the control modes.

The light symbols in pos. 4, see fig. 13, indicate the

pump settings:

"–" = no light.

WARNING!

At high liquid temperatures, the pump

may be scalding hot, only the buttons

should be touched to avoid burns.

Pos. Description

1 Buttons for setting

• Indicator lights for operating and fault

indication and

• symbol for indication of external control

3 Button for change of control mode

4Light symbols for indication of control

mode and night-time duty

5Light fields for indication of head, flow and

operating mode

TM03 8798 2507

EXT

Q100%

MAX

STO P

AUTO

ADAPT

TM03 1288 1505

Light in Control mode Automatic

night-time

duty

AUTOADAPT AUTOADAPT NO

Proportional

pressure NO

Constant pressure NO

–Constant curve NO

AUTO

ADAPT AUTOADAPT YES

Proportional

pressure YES

Constant pressure YES

–Constant curve YES

AUTO

ADAPT

AUTO

ADAPT

8.2.2 Setpoint setting

Set the setpoint of the pump by pressing or

when the pump has been set to proportional-

pressure control, constant-pressure control or

constant-curve duty.

The light fields, pos. 5, on the control panel indicate

the setpoint set.

MAGNA 40-120, 65-120

The light fields can indicate a maximum setpoint of

10 corresponding to 32 feet (10 m).

Fig. 15 Light fields MAGNA xx-120

MAGNA 65-60

The light fields can indicate a maximum setpoint of

5 corresponding to 16 feet (5 m).

Fig. 16 Light fields MAGNA 65-60

8.2.3 Setting to max. curve duty

Description of function, see section 7.5 Max. or min.

curve duty.

To change over to the max. curve, press

continuously until "MAX" illuminates, see fig. 17. To

change back, press continuously until the desired

setpoint is indicated.

Fig. 17 Max. curve

8.2.4 Setting to min. curve duty

Description of function, see section 7.5 Max. or min.

curve duty.

To change over to the min. curve, press

continuously until "MIN" illuminates, see fig. 18. To

change back, press continuously until the desired

setpoint is indicated.

Fig. 18 Min. curve

8.2.5 Start/stop of pump

To stop the pump, press continuously until

"STOP" illuminates. When the pump is stopped, the

green indicator light will be flashing.

To start the pump, press continuously.

8.2.6 Resetting of fault indications

The fault indications are reset by briefly pressing

any button. The settings remain unchanged. If the

fault has not disappeared, the fault indication will

reappear. The time until the fault reappears may vary

from 0 to 255 seconds.

8.3 R100 remote control

The pump is designed to communicate with the

Grundfos R100 remote control via infra-red light.

During communication, the R100 must be pointed at

the pump control panel. When the R100 is

communicating with the pump, the red indicator light

will flash rapidly.

The R100 offers additional possibilities of setting and

status displays for the pump.

TM02 0482 2507TM02 0483 2507TM02 0246 2507

MAX

TM02 0247 2507

Note

If the pump is to be stopped, it is

recommended to use the start/stop

input, the R100 or to switch off the

electricity supply. In this way, the

setpoint will remain unchanged when

the pump is started again.

H MIN

8.4 R100 display overview

The R100 displays are divided into four parallel

menus, see fig. 19:

0. GENERAL, see operating instructions for R100

1. OPERATION

2. STATUS

3. INSTALLATION

The number stated at each individual display in

fig. 19 refers to the section in which the display is

described.

Fig. 19 Menu overview

8.7.5

8.7.4

8.7.1

8.7.2

8.7.6

8.6.5

8.6.4

8.6.1

8.6.2

8.6.6

8.6.3

8.5.4

8.5.1

8.5.2

8.5.3

8.6.7

8.7.3

3. INSTALLATION2. STATUS0. GENERAL 1. OPERATION

This display appears only once, i.e. when the R100

gets contact with the pump.

8.5 Menu OPERATION

When the communication between the R100 and the

pump has been established, "Contact with" appears

in the display. When the "arrow down" on the R100 is

pressed, menu OPERATION appears.

8.5.1 Setpoint

This display depends on the control mode selected

in the display "Control mode" in menu

INSTALLATION.

If the pump is forced-controlled via external signals,

the number of possible settings will be reduced, see

section 8.8 Priority of settings. Attempts to change

the settings will result in an indication in the display

saying that the pump is forced-controlled and

changes therefore cannot be made.

This display will appear when the pump is in

AUTOADAPT mode.

Set the desired setpoint by pressing the buttons

"+" and "–" on the R100 (not possible when the pump

is in AUTOADAPT mode).

Furthermore, it is possible to select one of the these

operating modes:

•Stop

•Min. (min. curve)

•Max. (max. curve).

If proportional pressure, constant pressure or

constant curve has been selected, the display is

different.

The actual duty point of the pump is indicated by a

square in the Q/H field. No indication at low flow.

8.5.2 Operating mode

Select an operating mode:

•Stop

•Min. (min. curve)

•Normal (AUTOADAPT, proportional pressure,

constant pressure or constant curve)

•Max. (max. curve).

8.5.3 Fault indications

If the pump is faulty, the cause will appear in this

display.

Possible causes:

•Pump blocked

•Internal fault

•Overvoltage

•Undervoltage

•Overtemperature

•Module fault

•Fault in module communication.

The fault indication can be reset in this display.

If the fault has not disappeared when resetting is

attempted, the fault indication will reappear in the

display when communicating with the pump.

8.5.4 Alarm log

The alarm code with text appears in this display.

The display also shows the number of minutes the

pump has been connected to the electricity supply

after the fault occurred.

The last five fault indications will appear in the alarm

log.

Note The display "Contact with" appears

only once, i.e. when the R100 gets

contact with the pump.

8.6 Menu STATUS

The displays appearing in this menu are status

displays only. It is not possible to change or set

values.

The actual values in the display are indicative and

based on estimation.

8.6.1 Actual setpoint

Field "Actual setpoint":

Actual setpoint of pump.

Field "corresponding to":

Actual setpoint in % of the setpoint set if the pump is

connected to an external analog 0-10 V signal

transmitter or if temperature influence or

proportional-pressure control is activated.

8.6.2 Operating mode

This display shows the actual operating mode (Stop,

Min., Normal or Max.) and where it was selected

(Pump, R100, BUS or External).

8.6.3 Head and flow

The actual head and flow of the pump.

If "<" is indicated in front of the flow, the flow is less

than the displayed value.

8.6.4 Speed

The actual pump speed.

8.6.5 Liquid temperature

The actual temperature of the pumped liquid.

8.6.6 Power input and power consumption

Actual power input and power consumption of the

pump.

The value of power consumption is an accumulated

value and cannot be set to zero.

8.6.7 Operating hours

Operating hours of the pump.

The value of operating hours is an accumulated

value and cannot be set to zero.

8.7 Menu INSTALLATION

This menu shows the settings that should be

considered when installing the pump.

8.7.1 Control mode

Description of function, see section 7.1 Control

modes or section 7.4 Constant-curve duty.

Select one of the control modes:

•AUTO

ADAPT

•Prop. pressure (proportional pressure)

•Const. pressure (constant pressure)

•Const. curve (constant curve).

Setting of setpoint and curve is carried out in display

8.5.1 Setpoint in menu OPERATION (not possible

when the pump is in AUTOADAPT mode).

8.7.2 Automatic night-time duty

In this display, automatic night-time duty can be

activated or deactivated.

Automatic night-time duty can be set to:

•Active

•Not active,

irrespective of the control mode selected.

8.7.3 Temperature influence

Description of function, see section 7.6 Temperature

influence.

The temperature influence function can be activated

in this display when the control mode is proportional

pressure or constant pressure, see section

8.7.1 Control mode.

In the case of temperature influence, the pump must

be installed in the supply pipe. It is possible to

choose between maximum temperatures of 122 °F

(50 °C) and 176 °F (80 °C).

When the temperature influence is active, a small

thermometer is shown in the display "Setpoint" in

menu OPERATION, see section 8.5.1 Setpoint.

8.7.4 Buttons on pump

To prevent unauthorized persons from operating the

pump, the function of the buttons , and can

be deactivated in this display. The buttons can be

reactivated only with the R100.

The buttons can be set to:

•Active

•Not active.

8.7.5 Signal relay

In this display, the function of the internal signal

relay can be set:

•Fault (functions as a fault signal relay)

•Operation (functions as an operating signal

relay).

8.7.6 Pump number

A number from 1 up to and including 64 can be

allocated to a pump or can be changed so that the

R100, Pump Management System 2000 or other

systems can distinguish between two or more

pumps.

Note

If the pump is in control mode

AUTOADAPT or constant curve, the

temperature influence cannot be set

with the R100.

8.8 Priority of settings

The external forced-control signals will influence the

settings available on the pump control panel and with

the R100. However, the pump can always be set to

max. curve duty or to stop on the pump control panel

or with the R100.

If two or more functions are activated at the same

time, the pump will operate according to the setting

with the highest priority.

The priority of the settings is as shown in the table.

Without expansion module

Example: If the pump has been forced to stop via an

external signal, the pump control panel or the R100

can only set the pump to max. curve.

With expansion module

As illustrated in the table, the pump does not react to

external signals (max. curve and min. curve) when

the pump is controlled via bus.

If the pump is to react to external signals (max. curve

and min. curve), the system must be configured for

that function.

For further details, please contact Grundfos.

Priority

Possible settings

Pump control

panel or R100 External signals

1 Stop

2Max. curve

3Stop

4Min. curve

5 Setpoint setting

Priority

Possible settings

Pump

control

panel

or R100

External

signals Bus

signal

1 Stop

2 Max. curve

3Stop

Stop

4Max.curve Max.curve

5Min. curve Min. curve Min. curve

6Setpoint

setting Setpoint

setting

Not active when the pump is controlled

via bus.

Only active when the pump is

controlled via bus.

9. Fault finding chart

WARNING!

Before removing the control box cover, make sure that the electricity supply has been

switched off for at least 5 minutes.

The pumped liquid may be scalding hot and under high pressure. Before any removal or

dismantling of the pump, the system must therefore be drained or the isolating valves on

either side of the pump must be closed.

Indicator light is off.

Indicator light is on.

Indicator light is flashing.

Indicator

lights Fault Cause Remedy

Green Red

The pump is not

running. One fuse in the installation is

blown/tripped off. Replace/reset the fuse.

Check that the electricity supply falls

within the specified range.

The current-operated or voltage-

operated circuit breaker has tripped

off.

Reset the circuit breaker.

Check that the electricity supply falls

within the specified range.

The pump may be defective. Replace the pump or call

GRUNDFOS SERVICE for

assistance.

The pump is not

running. The pump has been stopped in one

of the following ways:

1. With the button .

2. With the R100.

3. External on/off switch in position

off.

4. Via bus signal.

1. Start the pump by pressing .

2. Start the pump with the R100 or

by pressing .

3. Switch on the on/off switch.

4. Start the pump via bus signal.

The pump has

stopped due to a

fault.

Electricity supply failure. Check that the electricity supply falls

within the specified range.

Pump blocked and/or impurities in

the pump. Dismantle and clean the pump.

The pump may be defective. Use the R100 for fault finding, see

section 8.5.3 Fault indications.

Replace the pump or call

GRUNDFOS SERVICE for

assistance.

The pump is

running but is

faulty.

The pump is faulty, but is able to

operate. The pump is able to operate.

Try to reset the fault indication by

briefly switching off the electricity

supply or by pressing the button ,

or .

Use the R100 for fault finding, see

section 8.5.3 Fault indications.

In the case of repeated faults,

contact GRUNDFOS SERVICE.

The pump has

been set to stop

and is faulty.

The pump is faulty, but is able to

operate (has been set to STOP).

10. Megging

Megging of an installation incorporating a

GRUNDFOS MAGNA pump is not allowed, as the

built-in electronics may be damaged. If megging of

the pump is necessary, the pump should be

electrically separated from the installation.

Megging of the pump can be carried out as

described below.

Noise in the

system. Air in the system. Vent the system.

The flow is too high. Reduce the setpoint and possibly

change over to AUTOADAPT or

constant pressure.

The pressure is too high. Reduce the setpoint and possibly

change over to AUTOADAPT or

proportional pressure.

Noise in the

pump. Air in the pump. Vent the pump.

The inlet pressure is too low. Increase the inlet pressure and/or

check air volume in the expansion

tank (if installed).

Indicator

lights Fault Cause Remedy

Green Red

Note The R100 can also be used for fault

finding.

Megging of pumps

1. Switch off the electricity supply.

2. Remove the wires from terminals L and N and the earth

conductor.

3. Short-circuit terminals L and N using a short wire

(see B).

4. Remove the screw for electronics frame connection

(see A).

5. Test between terminals L/N and earth (see C).

Maximum test voltage: 1000 VAC/1500 VDC.

Note: Never test between supply terminals (L and N).

Maximum permissible leakage current: < 35 mA.

6. Fit the screw for electronics frame connection (see A).

7. Remove the short wire between terminals L and N

(see B).

8. Fit the supply wires to terminals L and N and the earth

conductor.

9. Switch on the electricity supply.

TM02 0238 0904

11. Technical data

Supply voltage

1 x 230 ± 10 %, 50/60 Hz.

Motor protection

The pump requires no external motor protection.

Enclosure class

IP 44.

Insulation class

Relative air humidity

Maximum 95 %.

Ambient temperature

32 °F to 104 °F (0 °C to +40 °C).

Temperature class

TF110 to EN 60335-2-51.

Liquid temperature

Maximum +230 °F (+110 °C).

Continuously: +59 °F to +203 °F (+15 °C to +95 °C).

Pumps in domestic hot-water systems:

Continuously: +59 °F to +140 °F (+15 °C to +60 °C).

Maximum system pressure

175 psi (12 bar/1.2 MPa).

Number of bolt holes in the pump flange:

• 2 holes (MAGNA 40-120) and

• 4 holes (MAGNA 65-120, 65-60).

Inlet pressure

Recommended inlet pressures:

• Min. 13.1 psi at 167 °F (0.9 bar at +75 °C).

• Min. 17.5 psi at 203 °F (1.2 bar at +95 °C).

EMC (electromagnetic compatibility)

EN 61800-3.

Sound pressure level

The sound pressure level of the pump is lower than

54 dB(A).

Leakage current

The pump mains filter will cause a discharge current

to earth during operation. Ileakage < 3.5 mA.

Standby loss

Lower than 3 W.

Pump inputs and outputs

Inputs of pump with GENI module

Input of pump with LON module

12. Disposal

90 percent of this product is recyclable. Please

utilize public or private waste collection services for

recycling.

Ambient

temperature Liquid temperature

[°F] [°C] Min.

[°F] Max.

[°F] Min.

[°C] Max.

[°C]

32 0 59 203/230 15 95/110

86 30 59 203/230 15 95/110

95 35 59 194/194 15 90/90

104 40 59 158/158 15 70/70

Signal output

Internal potential-free change-

over contact.

Maximum load:

250 V, 2 A, AC1.

Minimum load: 5 V, 100 mA.

Screened cable, depending on

signal level.

Input for external

start/stop

External potential-free switch.

Contact load: 5 V, 10 mA.

Screened cable.

Loop resistance:

Maximum 130 Ω.

Inputs for max.

and min. curves

External potential-free switch.

Contact load: 5 V, 1 mA.

Screened cable.

Loop resistance:

Maximum 130 Ω.

Input for analog

0-10 V signal

External signal: 0-10 VDC.

Maximum load: 1 mA.

Screened cable.

Bus input

Grundfos bus protocol,

GENIbus protocol, RS-485.

Screened cable.

Wire cross section:

0.25 - 1 mm2.

Cable length:

Maximum 3900 feet (1200 m).

Bus input

LonTalk® protocol, FTT 10.

Twisted-pair cable.

Wire cross section:

0.25 - 1 mm2.

Subject to alterations.

* 3 1/8" (80 mm), stainless-steel pump housing /

corps du circulateur en acier inoxydable

TM03 9055 3207

Rp 1/4

H2H1

B6 B7

B4 B3

1/4" NP

MAGNA 40-120

GF 15/40

[Inch/pouce] [mm]

L1 8 1/2 216

L3 4 1/4 108

B1 3 1/16 77

B2 4 1/2 115

B3 2 15/16 75

B4 3 1/8 80

B5 3 3/4 or 3 1/8* 96 or 80*

B6 5 1/2 140

B7 4 5/16 110

H1 2 11/16 68

H2 9 1/2 242

H3 12 3/16 310

H4 3 3/4 96

D1 1 9/16 40

D2 2 15/16 75

D3 3 1/8 or 3 7/16 80/87

D4 4 3/4 120

D5 1/2 12

D6 1 15/16 49

D7 2 3/8 60

* 3 1/8" (80 mm), stainless-steel pump housing / corps du circulateur en acier inoxydable

TM03 9058 3307

MAGNA 65-120 MAGNA 65-60

GF 53 GF 53

[Inch/pouce] [mm] [Inch/pouce] [mm]

L1 11 1/2 292 11 1/2 292

L3 5 3/4 146 5 3/4 146

B1 3 1/16 77 3 1/16 77

B2 4 15/16 125 4 15/16 125

B3 3 7/16 88 3 7/16 88

B4 4 1/8 104 4 1/8 104

B5 3 3/4 or 3 1/8* 96 or 80* 3 3/4 or 3 1/8* 96 or 80*

B6 5 1/2 140 5 1/2 140

B7 4 5/16 110 4 5/16 110

H1 3 1/4 82 3 1/4 82

H2 9 15/16 252 9 15/16 252

H3 13 1/8 334 13 1/8 334

H4 4 3/16 107 4 3/16 107

D1 2 1/2 63 2 1/2 63

D2 3 15/16 100 3 15/16 100

D3 5 127 5 127

D4 6 152 6 152

D5 5/8 16 5/8 16

NPT 1/4

H2H1

B6 B7

B4 B3

1/4" NP

Connection diagram without optional expansion modules

Diagramme montrant la connexion sans l'utilisation d'un module d'extension

optionnel

MAGNA 40-120, 65-120, 65-60

TM02 0477 1004

NONC

78321

Connection diagram with optional GENI module with no external stop function

Diagramme montrant la connexion en utilisant le module GENI optionnel sans

fonction d'arrêt externe

MAGNA 40-120, 65-120, 65-60 with GENI module (avec module GENI)

TM02 0478 1004

Max. ø7

CNONCNL

AY B XQZ

MIN

MAX

10 V

2322211211109765478321

Max. OD:

0.275 inches/

pouces (7 mm)

Connection diagram with optional GENI module with external stop function

Diagramme montrant la connexion en utilisant le module GENI optionnel avec

fonction d'arrêt externe

MAGNA 40-120, 65-120, 65-60 with GENI module (avec module GENI)

TM02 0479 1004

CNONCNL

AY B XQZ

MIN

MAX

10 V

2322211211109765478321

Max. ø7

Max. OD:

0.275 inches/

pouces (7 mm)

Wiring diagram for two pumps in parallel (master)

Diagramme de connexion pour deux circulateurs en parallèle (maître)

MAGNA 40-120, 65-120, 65-60 with GENI module (avec module GENI)

TM02 0480 1004

Max. ø7

CNONCNL

AY B XQZ

MIN

MAX

10 V

2322211211109765478321

Max. OD:

0.275 inches/

pouces (7 mm)

Wiring diagram for two pumps in parallel (slave)

Diagramme de connexion pour deux circulateurs en parallèle (esclave)

MAGNA 40-120 65-120, 65-60 with GENI module (avec module GENI)

TM02 0481 1004

Max. ø7

CNONCNL

AY B XQZ

MIN

MAX

10 V

2322211211109765478321

Max. OD:

0.275 inches/

pouces (7 mm)

U.S.A.

GRUNDFOS Pumps Corporation

17100 West 118th Terrace

Olathe, Kansas 66061

Phone: +1-913-227-3400

Telefax: +1-913-227-3500

Canada

GRUNDFOS Canada Inc.

2941 Brighton Road

Oakville, Ontario

L6H 6C9

Phone: +1-905 829 9533

Telefax: +1-905 829 9512

México

Bombas GRUNDFOS de México

S.A. de C.V.

Boulevard TLC No. 15

Parque Industrial Stiva

Aeropuerto

Apodaca, N.L.C.P. 66600

Phone: +52-81-8144 4000

Telefax: +52-81-8144 4010

Addresses revised 22.09.2005

www.grundfos.com

Being responsible is our foundation

Thinking ahead makes it possible

Innovation is the essence

96746689 0907 243

L-MAG-TL-01

17554 2 Grundfos 96734489 Instructions User Manual

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