GRUNDFOS INSTRUCTIONS. MGE model F. s Service instructions, extended

Transcription

1 GRUNDFOS INSTRUCTIONS MGE model F s Service instructions, extended

2 Preface These service instructions describe fault finding and correction of pumps with Grundfos motors, type MGE model F (hereafter called MGE-F). The service instructions are aimed at specially trained staff who are familiar with the service of electrotechnical products. The use of these service instructions presupposes knowledge of these documents: Installation and operating instructions for MGE 160, MGE 180, advanced I/O Installation and operating instructions for the pump system incorporating the motor. Note These service instructions include only MGE-F and its user interfaces (control panel, R100 and PC Tool E-products). If the application includes other Grundfos products or systems, please refer to the service instructions of these products. These service instructions are published and updated in the Grundfos GTI database. Symbols used in this document Warning If these safety instructions are not observed, it may result in personal injury. Warning If these instructions are not observed, it may lead to electric shock with consequent risk of serious personal injury or death. Warning One or more components may be so hot that it may cause personal injury. Caution Note 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. 2 / 61

3 Contents 1. Identification Nameplates Type key Configuration General description Wiring diagrams and signal terminals Control panel Indicator lights Setting using the R100 remote control R100 menu structure Alarms and warnings Alarm overview Fault correction Safety instructions Fault correction procedure The R100 as service tool PC Tool E-products as service tool Operating conditions Fault correction using the indicator lights on the control panel Fault correction using alarm and warning codes Checking the printed-circuit boards Safety check of discharged intermediate circuit Indicator lights on the control board Mains supply Intermediate-circuit voltage Rectifier Insulation resistance (megging) Winding resistance Replacement of modules Replacement of varistor Replacement of control board Replacement of rectifier board Replacement of inverter board Replacement of terminal box Calibration of terminal box Configuration of terminal box Maintenance Lubrication of motor bearings Replacement of motor bearings Emergency operation (bypass) Establishing emergency operation Re-establishment of frequency converter operation Drawings and diagrams Winding resistances Tightening torques and lubrication Tightening torques Lubricating intervals and grease Service tools / 61

4 1. Identification 1.1 Nameplates The MGE-F nameplate (fig. 1) is fitted on the side of the terminal box (fig. 2) Type: P.N. : Env.Type : 3R PF : INPUT U in : 3 ~ I in 1/1 : f in : V A Hz Serial No : IP : TP 211 P.C. : TAmb : C CL : Wgt : kg Made in Hungary U out P 2 f out OUTPUT : 0 - : : 0 - V kw Hz Fig. 1 Nameplate for MGE-F, efficiency 1 motor Fig. 2 Position of nameplate TM TM Pos. Description Pos. Description 1 Type designation 12 Max. supply current at min. and max. supply voltage 2 Product number 13 Supply voltage 3 Power factor 14 Rated power 4 Production code, year/week 15 Output frequency 5 Serial number 16 Output voltage 6 Weight 17 CE mark 7 Enclosure class according to IEC VDE mark 8 Maximum ambient temperature 19 Standard motor efficiency according to CEMEP 9 Motor protection according to IEC C-Tick mark 10 Insulation class according to IEC Country of manufacture 11 Frequency 22 Bar code The motor nameplates (fig. 3) are fitted under the terminal box (fig. 4). MG180MB2-48FF300-F1 22, D/Y / ,5-38,5/23,8-22,8 91,9-92,8 45,5-42,5/26,0-25,0 0,91-0, D/Y / ,0-92,5 0,92-0,89 42,0-33,5/24,2-22,8 46,0-37,0/26,6-25, Fig. 3 Nameplates for standard motors with CE and UL approvals MG180MB2-48FF300-F F 7310BE 6310.C4 UNIREX N3 ESSO Protector type PTC 160 C TP211 TM Fig. 4 Position of motor nameplates TM / 61

5 1.2 Type key Example MG E 160 M D 2-42 FF 300 -F 1 Motor Grundfos Electronically controlled Frame size according to IEC (centre line height of shaft of foot motor) [mm] Size of foot M L Length of stator core B D Number of poles 2 4 Diameter of shaft end [mm] Flange version FF (free-hole flange) Pitch circle diameter, flange version [mm] Model designation for motor F Efficiency class for standard motor [ ] = not stated 1 = EFF 1 motor 2 = EFF 2 motor 1.3 Configuration The terminal box is configured from factory for the application and the pump type the motor is to be used for. The configuration file number appears from the terminal box configuration label which is placed inside the terminal box on the frame of the control panel. See figs 5 and 6. Fig. 5 Configuration label TM Fig. 6 Position of configuration label TM If the terminal box is replaced or mounted on another motor, it must be reconfigured. See section 5.7 Configuration of terminal box. 5 / 61

6 2. General description Rectifier Intermediate circuit Inverter RFI filter Inrush circuit Driver circuit Control circuit TM Fig. 7 Block diagram showing the functional blocks of the frequency converter A more detailed block diagram appears from fig Wiring diagrams and signal terminals The wiring diagram and the signal terminals depend on the pump application. Figures 8 to 11 are examples of the different functional modules available. Refer to the figure corresponding to the functional module fitted. OPTIONAL 0-10V 0/4-20mA A: RS485 A Y: RS485 GND B: RS485 B 7: SENSOR INPUT 8: +24V 9: GND 1: DIGITAL INPUT PE OPTIONAL 0-10V 0/4-20mA 0-10V 0/4-20mA A: RS485 A Y: RS485 GND B: RS485 B 17: PT100 A 18: PT100 A 19: PT100 B 20: PT100 B 7: SENSOR INPUT 8: +24V 9: GND 1: DIGITAL INPUT 2 10: DIGITAL INPUT 3 11: DIGITAL INPUT 4 12: ANALOG OUTPUT 13: GND 14: SENSOR INPUT 2 15: +24V (2) 16: GND SUPPLY : SEE NAMEPLATE : FOR FURTHER DATA: 0/4-20mA 0-10V + 10k SIGNAL RELAY : MAX: 250V/2A AC1 MIN: 5V/10mA SIGNAL RELAY : MAX: 250 V/2A AC1 MIN: 5V/10mA L3 L2 L1 2: RUN/STOP 3: GND 4: SETPOINT 5: +10V 6: GND STATUS LED CONNECTION FOR PC- TOOL NO1 C1 NC1 NO2 C2 NC2 TM SUPPLY: SEE NAMEPLATE : FOR FURTHER DATA: 0/4-20 ma 0-10V + 10k SIGNAL RELAY : MAX: 250 V/2A AC1 MIN: 5V/10mA SIGNAL RELAY : MAX: 250V/2A AC1 MIN: 5V/10mA PE L3 L2 L1 2: RUN/STOP 3: GND 4: SETPOINT 5: +10V 6: GND STATUS LED CONNECTION FOR PC-TOOL NO1 C1 NC1 NO2 C2 NC2 TM Fig. 8 I/O module and GENIbus Fig. 9 Extended I/O module and GENIbus 6 / 61

7 TWIN PUMP SWITCH A: RS485A (ext. bus) Y: RS485 GND (ext. bus) B: RS485B (ext. bus) TPED 0-10V 0/4-20mA CONNECTION FOR TWIN PUMP 7: SENSOR INPUT 8: +24V 9: GND 1: DIGITAL INPUT 1 A: RS485A Y: RS485 GND B: RS485B Multi-E 0-10V 0/4-20mA A1: RS485A (int. bus) Y: RS485 GND (int. bus) B1: RS485B (int. bus) 7: SENSOR INPUT 8: +24V 9: GND 1: DIGITAL INPUT 1 PE PE SUPPLY : SEE NAMEPLATE FOR FURTHER DATA L3 L2 L1 SUPPLY : SEE NAMEPLATE FOR FURTHER DATA L3 L2 L1 0/4-20mA 0-10V + 10k 2: RUN/STOP 3: GND 4: SETPOINT 5: +10V 6: GND STATUS LED CONNECTION FOR PC -TOOL 0/4-20mA 0-10V + 10k 2: RUN/STOP 3: GND 4: SETPOINT 5: +10V 6: GND STATUS LED CONNECTION FOR PC-TOOL SIGNAL RELAY : MAX: 250 V/2A AC1 MIN: 5V/10mA SIGNAL RELAY : MAX: 250V/2A AC1 MIN: 5V/10mA NO1 C1 NC1 NO2 C2 NC2 TM SIGNAL RELAY : MAX: 250 V/2A AC1 MIN: 5V/10mA SIGNAL RELAY : MAX: 250 V/2A AC1 MIN: 5V/10mA NO1 C1 NC1 NO2 C2 NC2 TM Fig. 10 TPED module Fig. 11 Multi-E module 2.2 Control panel Fig. 12 CRE and TPE, TPED Fig. 13 TPE, TPED Series 2000 TM TM Operation The motor control panel has the following buttons and indicator lights: Buttons and for setting of setpoint. Light fields, yellow, for indication of setpoint. Indicator lights, green (operation) and red (fault). Switch control mode by pressing in this sequence: constant pressure, proportional pressure,. Set the pump head by pressing or. The light fields of the control panel will indicate the set head (setpoint). 7 / 61

8 2.3 Indicator lights Indicator lights on the control panel The indicator lights on the control panel show the MGE-F motor's operating and alarm condition Indicator lights inside the terminal box The indicator lights beside the terminal block on the control board normally have the same functions as the indicator lights on the control panel. See fig. 14. Note In case of certain faults in the electronics, the indicator lights on the control panel may indicate differently from the indicator lights on the control board. In these cases, the indicator lights on the control board indicate the current operating and alarm condition. Indicator lights for operation and alarm on the control board Fig. 14 Indicator lights inside the terminal box TM See section 3.6 Fault correction using the indicator lights on the control panel to get an overview of the meaning of the indicator lights. 2.4 Setting using the R100 remote control The Grundfos R100 remote control is designed for wireless (IR) communication with the Grundfos E-products, including the MGE-F. TM Fig. 15 The R100 communicates with the motor via infrared light During communication, the R100 must be pointed at the control panel. When the R100 communicates with the motor, the red indicator light will flash rapidly. Keep pointing the R100 towards the control panel until the red indicator light stops flashing. The R100 gives access to settings and status displays for the motor. The displays are divided into four parallel menus. See fig. 16: 0. GENERAL (see operating instructions for the R100) 1. OPERATION 2. STATUS 3. INSTALLATION. 8 / 61

9 2.5 R100 menu structure Figure 16 shows an overview of all the R100 displays available for the MGE-F. Note The R100 menus will adapt to the application set and possible functional modules. The menu structure below applies to a CRE pump. To see the correct menu structure, see installation and operating instructions for the pump on which the MGE-F motor is mounted. 0. GENERAL 1. OPERATION 2. STATUS 3. INSTALLATION Fig. 16 R100 menu structure (for CRE pump) 9 / 61

10 2.6 Alarms and warnings An alarm or a warning is indicated by a red indicator light on the control panel and inside the terminal box. The alarm and warning indication can be read with the R100. Fault code Fault text Actual alarm and warning Alarms and warnings are shown at the bottom of the OPERATION menu. The first line shows the fault code. See section Alarm and warning list. The second line shows the fault text. Reset the alarm or warning by pressing [OK]. If there are no alarms or warnings, the display will show "No alarm indication" or "No warning indication". Alarm and warning logs In case of alarm or warning, the latest five alarms and warnings appear from the alarm and warning logs. "Alarm log 1" and "Warning log 1" show the latest alarm and warning, respectively. "Alarm log 2" and "Warning log 2" show the latest alarm and warning but one, respectively, etc. The display shows the logged alarm or warning with fault code and fault text. The top right corner shows how long ago the alarm or warning occurred. If the log in question is empty, the display will show "No alarm indication" or "No warning indication". 2.7 Alarm overview In section Alarm and warning list, you will find an overview of the MGE-F alarms and warnings. 10 / 61

11 3. Fault correction 3.1 Safety instructions Warning All service work must be carried out by specially trained staff. Warning Due to the capacitors of the MGE-F, touching live electrical parts may be fatal, even after the mains supply has been switched off. Disconnect the mains supply, and as a minimum wait the amount of time stated on the warning label under the terminal box cover, or see section 4.1 Safety check of discharged intermediate circuit, before touching any live parts. Note that the relay may be connected to an external power supply and still be live after the mains supply to the motor has been disconnected. Warning The MGE-F may be hot! 3.2 Fault correction procedure Fault correction is based on these sections in this order: 3.5 Operating conditions 3.6 Fault correction using the indicator lights on the control panel 3.7 Fault correction using alarm and warning codes 10. Tightening torques and lubrication. The necessary tools for the fault correction can be seen in section 11. Service tools. 3.3 The R100 as service tool When set to "Service mode", the R100 can be used for service purposes on the product in question Setting the R100 to "Service mode" Enter the service code in the display Name and address. The service code can also be used in combination with other name and address settings. Fig. 17 Service code has been entered Note The service code will remain active until the R100 is switched off. The service code is intended for Grundfos' service engineers and, consequently, it must be deleted before the R100 is returned to the customer, if the customer's R100 has been used Menu GENERAL The service menus are an extension of the GENERAL menu and open the GENI menu. The displays in this section are only accessible if the service code has been entered in the display Name and address. Store service data Fig. 18 Storing a service data file 11 / 61

12 When you press OK, a service data file is generated automatically. The file name will be made up of the product name and a two-digit suffix. An example is shown in fig. 19. The maximum number of automatically generated file names for every product type is 10. This means that file number 11 will cause the automatic file counter to be reset. When all the file names automatically generated by the R100 have been used, the R100 will use file number 00 (e.g. MGE_00.TXT) and overwrite this file every time a new file is generated. It is possible to store more than 10 files if the files are renamed. Fig. 19 A service data file is generated and stored The files can be transferred to a PC if the R100 is connected to it via a USB connection. Call up service data Fig. 20 Calling up data from a service data file Call up service data calls up the service data files generated under Store service data. Open the menu by pressing OK. A list of stored service data files will be shown. See fig. 21. Fig. 21 Example of service data file Select the file to be used, and press OK to open the file. You have three options. See fig. 22. DELETE: Deletes the file selected. An information box confirming the deletion will appear in the display. See fig. 23. RENAME: Renames the file selected. The character editor will appear. See fig. 24. CANCEL: Cancels the action. Fig. 22 Options 12 / 61

13 If you select DELETE, this box will appear. Fig. 23 Information box If you select RENAME, the character editor will appear. See fig. 24. Fig. 24 Character editor Menu GENI With the R100 in "Service mode" access is open to the GENI menu. This menu gives access to selected data registers. We consider that these data registers will very rarely be required in connection with fault correction. The data registers will not be documented here as we expect them only to be used in co-operation with Grundfos' support engineers. The Grundfos GENI protocol structures the data in classes (CL 1-16). Each class has 256 data items (id). 13 / 61

14 3.4 PC Tool E-products as service tool PC Tool E-products The PC Tool E-products is a software tool which enables communication with GENIbus products from a PC using Microsoft Windows. The PC Tool E-products can be used for fault correction of E-products, including the MGE-F Acquisition of PC Tool E-products The PC Tool E-products can be acquired via GTI, which is a Lotus Notes database Connecting the PC to the MGE-F A Grundfos PC Tool Link is used for the physical connection between the PC and the MGE-F. The PC Tool Link converts RS-485 used by the MGE-F to RS-232 or USB used by the PC. The PC Tool Link also provides galvanic separation between the MGE-F and the PC. RS-232 null modem PC Tool Link TTL cable 5 V cable Fig. 25 Example of connection of a PC to the MGE-F using a RS-232 cable Connect the TTL cable to the service plug in the MGE-F. See fig. 26. Plug for connection of PC Tool Link Fig. 26 Plug for connection of PC Tool Link TM Using the PC Tool E-products on pumps running duty/standby The MGE-F enables the connection of PC Tool E-products to a pump running duty/standby without having to deactivate the function temporarily. This was not possible in previous versions of MGE. 14 / 61

15 3.4.5 Display of alarms The PC Tool E-products makes it possible to read and reset alarms and warnings. See fig Select Monitor: 2 2. Select Operating log: 3 3. The alarm log is shown in the Alarm log window. 1 Fig. 27 Display of alarms in PC Tool E-products TM Special functions Limit exceeded This is a monitoring function offering information, warning or alarm if a value is below a lower or above an upper limit. Use the PC Tool E-products to activate the function and carry out setting. See fig. 28: 1. Select Custom configuration: Select Functions: Click the tab Limit exceeded: 4. Activate monitoring. 5. Set the limits. Fig. 28 The function "Limit exceeded" in PC Tool E-products 1 TM / 61

16 Monitoring of bearing temperature This is a monitoring function giving warning or alarm if the motor bearing temperature exceeds the set maximum temperature. The temperature is measured by means of Pt100 sensors fitted in the motor from factory. First set up the MGE-F to use the Pt100 inputs for monitoring of bearing temperature. See fig Select Custom configuration: Select Input/Output: 3. Click the tab Sensors: 4 4. Set Measured value to Motor bearing drive-end and Motor bearing nondrive end. Fig. 29 The function "Bearing temperature" in PC Tool E-products 1 TM Then set the warning and alarm limits. See fig Select Custom configuration: Select Functions: 3. Click the tab Bearing temperature: 4. Activate monitoring. Fig. 30 The function "Bearing temperature" in PC Tool E-products 1 TM Set the limits. 16 / 61

17 Monitoring of bearing lubrication This is a monitoring function giving a warning if bearings need to be lubricated or replaced. Use the PC Tool E-products to activate the function. See fig Select Custom configuration: 2. Select Maintenance: Activate monitoring. 4. Set the limits. 4 Fig. 31 The function "Motor bearing monitoring" in PC Tool E-products Confirmation of bearing lubrication or replacement can also be made with the R TM / 61

18 3.5 Operating conditions Correct functioning of the MGE-F depends on these points: Mains supply Check nameplate data, and measure the actual supply voltage with a digital voltmeter (true RMS). Check the earth leakage circuit breaker and the backup fuses. The MGE-F has no internal fuses. Pump and motor load Check nameplate data, and measure the actual current consumption with a digital amperemeter (true RMS). Do the pump and the MGE-F match? External signals, for instance from another controller Check that the external signals are suitable for the MGE-F. See section 2.1 Wiring diagrams and signal terminals and installation and operating instructions for MGE 160, MGE 180, advanced I/O. Check that terminals 2 and 3 are connected and that the MGE-F has been started via the control panel. Sensors connected Check that the sensor measuring range matches the pump application. Check that the settings of the MGE-F match the sensors (current, voltage, minimum and maximum values) (requires an R100). Condensation Check whether condensation occurs in the terminal box. This may happen if the ambient temperature becomes very low. The problem may be overcome by enabling the standstill heating function and by removing the drain plug in the motor. See installation and operating instructions for MGE 160, MGE 180, advanced I/O. Electromagnetic disturbances Check that the wiring complies with the EMC Directive. See installation and operating instructions for MGE 160, MGE 180, advanced I/O. Start-up, installation and operating settings via the control panel or the R100 Check that the green indicator light on the control panel (or inside the terminal box) is on. Check that the settings in the INSTALLATION menu match the pump application (requires an R100). The menu displays are described in detail in the installation and operating instructions for MGE 160, MGE 180, advanced I/O. If the above points are according to the installation and operating instructions for MGE 160, MGE 180, advanced I/O, and the pump application, but a fault still exists and the red indicator light is on, continue the fault correction in sections 3.6 Fault correction using the indicator lights on the control panel and 3.7 Fault correction using alarm and warning codes. 18 / 61

19 3.6 Fault correction using the indicator lights on the control panel The operational state of the motor incl. possible faults can be read via the indicator lights on the control panel. Remedy of possible faults requires an R100 remote control. We recommend to start fault correction via the R100 fault code. See section 3.7 Fault correction using alarm and warning codes. Note In case of certain faults in the electronics, the indicator lights on the control panel may indicate differently from the indicator lights on the control board. In these cases, the indicator lights on the control board indicate the current operating and alarm condition. Indicator lights Green Red Condition/cause Remedy On On Normal operation + indication of previous fault 1. The pump is running at normal performance. The pump's duty/standby function has been activated, but there is no communication with the standby pump. 2. The pump is running at maximum speed. The sensor signal is outside the set signal range. See fault code 77 in section 3.7 Fault correction using alarm and warning codes. a) Does the sensor setting correspond to the sensor type installed? (0-10 V, 0-20 ma, 4-20 ma) NO: YES: Correct the setting using the R100. Proceed to point b). b) Is the voltage to the sensor connection 24 VDC? 8: +24V 9: GND TM V 0/4-20mA NO: YES: Replace the I/O module. Proceed to point c). 12: ANALOG OUTPUT 13: GND 14: SENSOR INPUT 2 15: +24V (2) 16: GND c) Is the sensor signal below 10 V (type 0-10 V sensor)? below 20 ma (type 0-20 ma sensor)? between 4 and 20 ma (type 4-20 ma sensor)? TM OUT 0-10V 0/4-20mA OUT mA 7: SENSOR INPUT 8: +24V 9: GND TM V 0/4-20mA NO: YES: Replace the sensor. Proceed to point d). d) Has the sensor been connected correctly, and does the sensor signal correspond to the system pressure? NO: YES: 12: ANALOG OUTPUT 13: GND 14: SENSOR INPUT 2 15: +24V (2) 16: GND Connect the sensor signal correctly. Replace the I/O module or the terminal box. [To be continued on the next page] TM / 61

20 Indicator lights Green Red Condition/cause On On 3. The pump is running at minimum speed. The setpoint signal is outside the set signal range. Remedy a) Set the pump to "open loop" operation, and connect 10 V supply to the setpoint input. Does the pump switch to maximum speed? NO: YES: Proceed to point b). The pump is OK. b) Does the setpoint setting correspond to the setpoint type installed? (0-10 V, 0-20 ma, 4-20 ma) NO: YES: Correct the setting using the R100. Proceed to point c). c) Is the voltage to the setpoint connection 10 VDC? NO: YES: Replace the terminal box. Proceed to point d). d) Is the setpoint signal below 10 V (type 0-10 V sensor)? below 20 ma (type 0-20 ma sensor)? between 4 and 20 ma (type 4-20 ma sensor)? NO: YES: 0/4-20mA 0-10V K 4: SETPOINT 5: +10V 6: GND Check for fault in the external setpoint signal. Re-establish the correct setpoint signal, if necessary. If the pump still does not run correctly, replace the terminal box. [To be continued on the next page] TM / 61

21 Indicator lights Green Red Condition/cause Remedy On Off Normal operation 1. The pump is running. Normal operational state. 2. The pump is not running. Operational stop which may be caused by the flow switch connected the pump stop function. a) The flow switch is closed. Is there 5 VDC across terminals 1-9? (If an extended I/O module is installed, the flow switch may be connected to DI3 (terminals 9-10) or DI4 (terminals 9-11)). NO: Flow switch closed = Pump is not supposed to run. YES: Flow switch open = Pump must be running. Does the pump start when the connection between the flow switch terminals is cut? NO: YES: Replace the I/O module. The digital input is OK. The flow switch is defective. Replace it. b) The stop function has stopped the pump. Does the pump start when you increase the flow and/or reduce the pressure in the system? NO: YES: If the sensor is OK, replace the terminal box. The input is OK. [To be continued on the next page] 21 / 61

22 Indicator lights Green Red Condition/cause On Off 3. The pump is running at unexpectedly high or low speed. Can be caused by fault in installation, setting or signal from setpoint/sensor or that the sensor input has been set to "active". Remedy a) Has the correct setpoint type been set in the motor? (0-10 V, 0-20 ma, 4-20 ma) NO: YES: Correct the setting using the R100. Proceed to point b). b) Has the external setpoint signal from potentiometer or external controller been connected correctly? NO: YES: 0/4-20mA 0-10V K 4: SETPOINT 5: +10V 6: GND Connect the setpoint signal correctly. Proceed to point c). c) Has the correct sensor type been set in the motor? (0-10 V, 0-20 ma, 4-20 ma) TM NO: YES: Correct the setting using the R100. Proceed to point d). d) Has the sensor been connected correctly, and does the sensor signal correspond to the system pressure? - +OUT 0-10V 0/4-20mA OUT mA 7: SENSOR INPUT 8: +24V 9: GND TM Off Off The pump is not running 1. The power supply to the motor has been cut. 2. The control panel or one of the functional modules is defective. 0-10V 0/4-20mA NO: YES: Connect the sensor signal correctly. If the pump does not run correctly, replace the I/O module or the terminal box. If the sensor is defective, replace it. Re-establish correct power supply. 12: ANALOG OUTPUT 13: GND 14: SENSOR INPUT 2 15: +24V (2) 16: GND Switch off the power supply. Then remove the control panel and the functional modules, one at a time, and switch on the power supply every time a component has been removed. When the fault has disappeared after switching on the power supply, the defective component has been localised and can be replaced. 3. The terminal box is defective. Replace the terminal box. [To be continued on the next page] TM / 61

23 Indicator lights Green Red Condition/cause Remedy Off On The pump has stopped due to a fault The pump has been stopped due to one of the following causes: See the fault indication on the R100 or PC Tool E-products. 1. The pump is blocked or overloaded. Remove the blockage, or reduce the load. 2. The ambient temperature is too high, Re-establish sufficient cooling. or the cooling is insufficient. 3. Power supply fault: undervoltage overvoltage phase failure mains supply failure. Check that the supply voltage is within the stated voltage range. If not, re-establish correct power supply. 4. External fault. a) Has the R100 been set to external fault? NO: The pump is not set to react to external fault. Proceed to point 5. YES: Proceed to point b). b) Can 5 VDC be measured across terminals 1-9? Flashing, 1 Hz Flashing, 1 Hz Flashing, 5 Hz Off On On 5. Other faults: wrong terminal box wrong configuration fatal fault. Normal operational stop The pump has been stopped with the button with the R100 using the Grundfos GENIbus by the motor start/stop function. (Input on terminal 2-3 is open). NO: YES: Normal operational stop + indication of previous fault The pump has been stopped with the button with the R100 using the Grundfos GENIbus by the motor start/stop function, but was previously stopped due to a fault which has now disappeared. Contact between terminals 1 and 9 is closed. Seek the cause of fault in external signal transmitter. Contact between terminals 1 and 9 is open. The E-pump is OK. Proceed to the next fault possibility. Replace the terminal box. Reconfigure the terminal box. Replace the terminal box. The pump has been stopped due to a fault in the product Pump is not running and Try resetting the fault by communication with the R100 is not disconnecting the power supply. possible. no reaction when you press or. waiting until all diodes are off. fatal internal communication fault in re-establishing the power supply. the pump. If this does not remedy the fault, the terminal box is defective. Replace the terminal box. 0/1 9: GND 1: DIGITAL INPUT TM / 61

24 3.7 Fault correction using alarm and warning codes Apart from being indicated by the indicator lights on the control panel, alarms, warnings and their fault codes can be read using the R100 or PC Tool E-products Alarm and warning list The list below gives you an overview of the possible alarms and warnings and a description of their causes and suggestions for remedy. These abbreviations are used in the column "Fault type": W: Warning. A: Alarm. 1): The alarm can be configured to Warn/Max/Min/Stop/User using the PC Tool E-products. Fault code Fault reading in the R100 Fault reading in PC Tool E-products Fault type Explanation/cause Remedy 3 External fault External fault signal A The digital input set for "External fault" was or is closed (terminal 1, 10 or 11). When the digital input is no longer closed, the fault indication can be reset either with the R100 or by pressing or. 4 Too many restarts Too many restarts (from standby mode per 24 hours) A The number of attempted restarts at 10-second intervals after a fault has exceeded four within one minute. The number of attempted restarts at five-minute intervals after a fault has exceeded 16 within 24 hours. Seek the cause under the fault log code numbers in the R100. The pump will automatically attempt to restart after 24 hours. The fault indication can be reset either with the R100 or by pressing or. 30 Replace motor bearings Motor bearings need change (service information) W The motor has reached the number of operating hours Replace the bearings. See section 6.2 Replacement of motor bearings. for the bearing service life that is stated in the configuration. 31 Replace varistor Motor varistor(s) need change (service information) W The varistor has been exposed to the allowable Replace the varistor. See section 5.1 Replacement of varistor. number of transients and needs replacing. 32 Overvoltage Overvoltage A The supply voltage has been or is too high. Reduce the voltage to the specified level (see the nameplate). 40 Undervoltage Undervoltage A The supply voltage has been or is too low. Increase the voltage to the specified level (see the nameplate). 41 Undervoltage Undervoltage transient A There has been a voltage drop in the supply voltage caused by one of the following: Supply cable too small. Another big user is supplied from the same panel. 45 Mains voltage asymmetry Voltage asymmetry A The supply voltage has been or is asymmetric. Check the supply voltage while the motor is loaded. 49 Overload Overcurrent (i_line, i_dc, i_mo) A The terminal box or the motor is heavily overloaded. Cause: Blocked pump. Remove the blockage. Blocked rotor. Remove the blockage. Continued overload. Reduce the load. Incorrect configuration of the terminal box. Reconfigure the terminal box. See section 5.7 Configuration of terminal box. Wrong terminal box. Replace the terminal box. See section 5.5 Replacement of terminal box. Fault in stator windings. Check the stator windings. See section4.7 Winding resistance. Power supply failure (phase failure). Re-establish correct power supply. 51 Overload Blocked motor/pump A The pump is blocked during start-up which causes Remove the blockage. a heavy overload. The input current is very high; the motor P > 120 % for 60 seconds. 24 / 61

25 Fault code Fault reading in the R100 Fault reading in PC Tool E-products Fault type Explanation/cause Remedy 55 Overload Motor current protection activated (MCP) A The built-in motor-current protection function has registered a continued overload of more than 125 % of rated current for 60 seconds. Cause: Continued overload. Reduce the load by limiting the pump flow. Incorrect configuration of the terminal box. Reconfigure the terminal box. See section 5.7 Configuration of terminal box. Fault in stator windings. Check the stator windings. See section 4.7 Winding resistance. 56 Underload Underload A The motor is underloaded. Cause: Incorrect configuration of the terminal box. Check the settings of the terminal box. The pump has run dry. Make sure that all valves in the piping system are open and that there is water in the piping system. 57 Dry running Dry running A The pump has run dry. Make sure that all valves in the piping system are open and that there is water in the piping system. 65 Too high motor temperature Motor temperature A The temperature sensor in the motor has measured a too high winding temperature. Cause: Dust and dirt in the cooling fins. Clean the cooling fins. Too high ambient temperature. Improve the cooling. Fault in stator windings. Check the stator windings. See section 4.7 Winding resistance. 73 Undervoltage Hardware shutdown (HSD) A The current limit of the electronic module has been exceeded. Cause: Incorrect configuration of the terminal box. Reconfigure the terminal box. See section 5.7 Configuration of terminal box. Fault in stator windings. Check the stator windings. See section 4.7 Winding resistance. Terminal box defective. Replace the terminal box. See section 5.5 Replacement of terminal box. 77 Duty/standby, Communication fault Twin pump communication fault W Communication between the two pumps which have been set to duty/standby function has been interrupted. Cause: Power supply to standby pump has been cut. Re-establish the power supply. Communication cable has been cut. Check the communication cable. Communication module defective. Replace communication module. 85 Other fault Freq. conv. parameter verification error (EEPROM) A The EEPROM has lost its contents. Try to reconfigure the terminal box. See section 5.7 Configuration of terminal box. If this does not remedy the fault, replace the control board. See section 5.2 Replacement of control board. General sensor signal fault / feedback sensor signal 88 Sensor 1 signal outside signal range 1) fault Sensor signal type 4-20 ma: signal below 2 ma or above 22 ma. Sensor signal type 0-20 ma: signal above 22 ma. Sensor signal type 0-10 V: signal above 11 V. Signal range set incorrectly. Correct the signal range setting. Sensor incorrectly connected. Connect the sensor correctly. Incorrect power supply to sensor. Check the power supply from the terminal box. If it is not 24 V ± 1 V, replace the terminal box. Sensor defective. Replace the sensor. Sensor cable defective. Check the sensor cable. 25 / 61

26 Fault code Fault reading in the R100 Fault reading in PC Tool E-products Fault type Explanation/cause Remedy Temperature sensor 1 signal outside 91 signal range The sensor signal has been short-circuited or cut. Temperature sensor 1 signal fault 1) Replace the temperature sensor. 93 Sensor 2 signal outside signal range Sensor 2 signal fault 1) Same as fault 88. Same as fault Setpoint signal outside signal range Reference input signal fault 1) Sensor signal type 4-20 ma: signal below 2 ma or above 22 ma. Sensor signal type 0-20 ma: signal above 22 ma. Sensor signal type 0-10 V: signal above 11 V. Signal range set incorrectly. Correct the signal range setting. Setpoint signal incorrectly connected. Connect the setpoint signal correctly. Incorrect supply voltage to the setpoint. Check the supply voltage from the terminal box. If it is not 10 V, replace the terminal box. 105 Overload Electronic rectifier protection activated (ERP) A The electronic module/motor is heavily overloaded, and the temperature of the electronics is above 100 C. The measured temperature can be read via PC Tool E-products. Cause: Temperature sensor defective. Replace the rectifier board. See section 5.3 Replacement of rectifier board. Continued overload. Reduce the load. The ambient temperature is too high, or Improve the cooling. the cooling is insufficient. Incorrect configuration of the terminal box. Reconfigure the terminal box. See section 5.7 Configuration of terminal box. 106 Overload Electronic inverter protection activated (EIP) A The electronic module/motor is heavily overloaded, and the temperature of the electronics is above 100 C. The measured temperature can be read via PC Tool E-products. Cause: Temperature sensor defective. Replace the inverter board. See section 5.4 Replacement of inverter board. Continued overload. Reduce the load. The ambient temperature is too high, or Improve the cooling. the cooling is insufficient. Incorrect configuration of the terminal box. Reconfigure the terminal box. See section 5.7 Configuration of terminal box. 148 DE bearing temperature high Motor drive-end (DE) bearing temp. warning limit Motor drive-end (DE) bearing temp. alarm limit The drive-end motor bearing has become too hot. Cause: The bearing is worn. Replace the bearing. See section 6.2 Replacement of motor bearings. The motor is dirty. Check and clean, if necessary, the fan the motor cooling fins. Motor non-drive-end (NDE) bearing temp. warn. limit 149 NDE bearing temperature high Motor non-drive-end (NDE) bearing temp. alarm limit The non-drive-end motor bearing has become too hot. Cause: The bearing is worn. Replace the bearing. See section 6.2 Replacement of motor bearings. The motor is dirty. Check and clean, if necessary, the fan the motor cooling fins. W A W A 26 / 61

27 Fault code Fault reading in the R100 Fault reading in PC Tool E-products Fault type Explanation/cause Remedy 155 Undervoltage Inrush fault A The terminal box voltage is outside the alarm limit. Cause: Fault in the voltage supply. Re-establish the voltage supply. Transients in the voltage supply during operation. Replace the inverter board. See section 5.4 Replacement of inverter board. 156 Other fault Internal communication failure in frequency converter A Internal communication fault in the pump due to defect Replace the terminal box. See section 5.5 Replacement of terminal box. in the terminal box. Temperature sensor 2 signal outside 175 Temperature sensor 2 signal fault 1) signal range Same as fault 91. Same as fault Limit 1 exceeded Limit 2 exceeded This is a monitoring function offering information, alarm or warning if a low or high limit is exceeded. The function can only be set with the PC Tool E-products. The limit set has been exceeded either upwards or downwards. Limit 1 exceeded Limit 2 exceeded The function can be set to monitor sensor 1 or 2 Pt100 sensor 1 or 2 external setpoint the feedback signal. Procedure: 1. Using PC Tool E-products, check which function is being monitored. 2. Check in the pump system whether the alarm or warning is real. If it is real, remedy the fault. 3. If the alarm or warning seems to be wrong for the pump system, troubleshoot according to the selected sensor using these service instructions. 240 Relubricate motor bearings Motor bearings need lubrication (service information) W The motor has reached the number of operating hours Lubricate the bearings. See section 6.1 Lubrication of motor bearings. stated in the configuration for the bearing lubrication. 1) 27 / 61

28 DC + Test DC + Test 4. Checking the printed-circuit boards Warning All service work must be carried out by specially trained staff. Warning Due to the capacitors of the MGE-F, touching live electrical parts may be fatal, even after the mains supply has been switched off. Disconnect the mains supply, and as a minimum wait the amount of time stated on the warning label under the terminal box cover, or see section 4.1 Safety check of discharged intermediate circuit, before touching any live parts. Note that the relay may be connected to an external power supply and still be live after the mains supply to the motor has been disconnected. Caution Always use an antistatic service kit (see section 11. Service tools, pos. B) when dismantling and assembling the terminal box as the electronics are sensitive to static electricity. Connect the antistatic service kit to the connection terminal of the protective earth conductor (PE terminal). See fig Safety check of discharged intermediate circuit The intermediate-circuit voltage [VDC] can be measured using a multimeter. Before a possible dismantling of the product, the VDC must be < 5 VDC. This can be accelerated by short-circuiting DC+ and GND. Caution DC+ and GND must not be short-circuited until VDC < 55 VDC. DC+ GND U < 55 V U = 0 V Fig. 32 Measuring the intermediate-circuit voltage TM / 61

29 Fig. 33 Connecting an antistatic service kit to a terminal box The check procedure for the MGE-F is divided into these steps: 4.2 Indicator lights on the control board 4.3 Mains supply 4.4 Intermediate-circuit voltage 4.5 Rectifier 4.6 Insulation resistance (megging) 4.7 Winding resistance. The tools to be used during the check procedures can be seen in section 11. Service tools. 4.2 Indicator lights on the control board The control board is provided with two blocks of indicator lights which are useful in connection with fault correction: Fault monitoring: The indicator lights are on in case of faults. Voltage monitoring: The indicator lights are on when the voltage supply works correctly. In order to see the indicator lights, remove the cover over the control board. See section Dismantling the control board, points 1 to 5. Remember to disconnect the mains supply and as a minimum wait the amount of time stated on the warning label under the terminal box cover so that the capacitors can be discharged. TM / 61

30 Fault monitoring Voltage monitoring Fig. 34 Indicator lights on the control board TM Fault monitoring Indicator lights Colour Description of function/fault Remedy HB Green Heartbeat Flashing when a command is executed in the microcontroller. Light is permanently on (not flashing): The software is hanging. Light is off, and all voltage monitoring indicator lights are on: The control board is defective. F_IA, F_IB, F_IC Red Excess current phase A, B or C Hardware-shutdown. Excess current was so high that the MGE-F tripped out. The limit for this alarm is higher than for fault code 49. F_24V Red Failure on the 24 V supply The 24 V supply is too low. The voltage supplied by the voltage supply on the inverter board is too low. Switch off the mains supply, and switch it on again to reset the controller. Replace the control board. See 5.2 Replacement of control board. Reset the MGE-F. If the fault returns after resetting, check the pump application. Check the motor. See 4.6 Insulation resistance (megging) and 4.7 Winding resistance. Check the intermediate-circuit voltage. If it is OK, the inverter board is defective. Replace the inverter board. See 5.4 Replacement of inverter board. F_DRV Red Driver fault There is a fault in the IGBT, or the motor has shortcircuited. Measure the motor insulation resistance. See 4.6 Insulation resistance (megging) and 4.7 Winding resistance. If both the insulation resistance and the winding resistance are OK, replace the control board and the inverter board. See 5.2 Replacement of control board and 5.4 Replacement of inverter board. F_UDC Red Fault in the intermediate-circuit voltage The intermediate-circuit voltage is too high. Check the mains supply. See 4.3 Mains supply. Caused by a transient or too high supply voltage. F_IA, F_IB, F_IC and F_DRV Red Both indicator lights are on Hardware-shutdown. Excess current was so high that the MGE-F tripped out. The limit for this alarm is higher than for fault code 49. Measure the motor insulation resistance. See 4.6 Insulation resistance (megging) and 4.7 Winding resistance. If both the insulation resistance and the winding resistance are OK, replace the control board and the inverter board. See 5.2 Replacement of control board and 5.4 Replacement of inverter board. 30 / 61

31 4.2.2 Voltage monitoring Indicator lights Colour Description of function/fault Remedy 24V Green 24 V supply Supplied from the voltage supply on the inverter board. The indicator light is off. 15V Green 15 V supply The voltage comes from the control board. The indicator light is off, and the 24 V light is on. The control board is defective. 7V Green 7 V supply The voltage comes from the control board. The indicator light is off, and the 24 V and the 15 V lights are on. The control board is defective. 5V Green 5 V supply The voltage comes from the control board. The indicator light is off, and the 24 V light is on. The 5 V supply has been cut due to overload. 3V5 Green 3.5 V supply The voltage comes from the control board. The indicator light is off, and the 24 V and the 5 V lights are on. The control board is defective. 6V Green 6 V supply Supplied from the voltage supply on the inverter board. The indicator light is off. 28VS Green 28 V supply on the safe side of the board Supplied from the voltage supply on the inverter board. The indicator light is off. 5VS Green 5 V supply on the safe side of the board The voltage comes from the control board. The indicator light is off, and the 28 V light is on. The control board is defective. Check the intermediate-circuit voltage. See 4.4 Intermediate-circuit voltage. If the intermediate-circuit voltage is missing, the rectifier board is defective. Replace the rectifier board. See 5.3 Replacement of rectifier board. If the intermediate-circuit voltage is OK, the inverter board is defective. Replace the inverter board. See 5.4 Replacement of inverter board. Replace the control board. See 5.2 Replacement of control board. Replace the control board. See 5.2 Replacement of control board. Switch off the mains supply, remove the functional modules, and switch on the mains supply again. If the fault has disappeared, one of the functional modules is defective. Replace one of the functional modules. If the fault is not in the functional modules, the control board is defective. Replace the control board. See 5.2 Replacement of control board. Replace the control board. See 5.2 Replacement of control board. Check the intermediate-circuit voltage. See 4.4 Intermediate-circuit voltage. If the intermediate-circuit voltage is missing, the rectifier board is defective. Replace the rectifier board. See 5.3 Replacement of rectifier board. If the intermediate-circuit voltage is OK, the inverter board is defective. Replace the inverter board. See 5.4 Replacement of inverter board. Check the intermediate-circuit voltage. See 4.4 Intermediate-circuit voltage. If the intermediate-circuit voltage is missing, the rectifier board is defective. Replace the rectifier board. See 5.3 Replacement of rectifier board. If the intermediate-circuit voltage is OK, the inverter board is defective. Replace the inverter board. See 5.4 Replacement of inverter board. Replace the control board. See 5.2 Replacement of control board. 31 / 61

32 Indicator lights Colour Description of function/fault Remedy All indicator lights are off 4.3 Mains supply If all the voltage monitoring indicator lights are off, the voltage supply to the control board is missing. Check the intermediate-circuit voltage. See 4.4 Intermediate-circuit voltage. If the intermediate-circuit voltage is missing, the rectifier board is defective. Replace the rectifier board. See 5.3 Replacement of rectifier board. If the intermediate-circuit voltage is OK, the controller is in a state of overvoltage. Switch off the mains supply, and wait at least 30 minutes until switching it on again. If the fault has not disappeared, the mains supply fuse resistor has blown. Replace the inverter board. See 5.4 Replacement of inverter board. Check that the mains supply matches the motor nameplate (L1 - L2 - L3). Are the backup fuses OK? YES: Continue fault correction. NO: 1. Using an ohmmeter, check that none of the supply terminals have been short-circuited. 2. Check that no diode in the rectifier has been shortcircuited. See section 4.5 Rectifier. 3. Replace the fuses. If the fault has not been located yet, replace the entire terminal box. Fig. 35 Supply terminals L1, L2 and L3 TM Intermediate-circuit voltage 1. Go through section 5.2.1, points 1 to Switch on the mains supply. 3. Measure the intermediate-circuit voltage on the measuring points of the control board. See fig. 36. The intermediate-circuit voltage must be as stated in the table below. Measuring points Fig. 36 Measuring points for intermediate-circuit voltage on the control board TM Supply voltage and intermediate-circuit voltage The normal voltage level for supply voltage and intermediate-circuit voltage appears from this table: Supply voltage VAC Intermediate-circuit voltage VDC / 61

33 4.5 Rectifier Measuring on diodes Note The diodes are not fitted directly on the terminals where the measurement takes place. OL (Open Line, i.e. no connection) may therefore indicate that the diode is not connected to the terminal. Check this before replacing the diode or the board where the diode is fitted. Diode drop voltage approx. 0.4 V = OK. < 0.3 V or > 0.5 V: Diode defective. OL: Diode blocked = OK. Other indication: Diode defective. Rectifier +DC -DC L1 L3 Measured values L1 L2 L3 -DC Fig. 37 Measuring points for check of rectifier +DC L2 Fig. 38 Measuring points on the board for check of rectifier 1. Switch off the mains supply, and as a minimum wait the amount of time stated on the warning label under the terminal box cover so that the capacitors can be discharged, or see section 4.1 Safety check of discharged intermediate circuit. 2. Remove the mains supply cables. 3. Remove the control board. See section 5.2 Replacement of control board. 4. Remove the six screws at the edge of the cover, and remove the cover. 5. Set the multimeter to diode check. 6. Connect the negative test conductor to the positive intermediate-circuit voltage (+DC in figs 37 and 38). 7. Connect the positive test conductor to each of the diode soldering islands (L1, L2 and L3 in figs 37 and 38) one by one. At each measurement, the multimeter must show a diode drop voltage of approx. 0.6 V. (The diode drop voltage varies from multimeter to multimeter). 8. Connect the positive test conductor to the positive intermediate-circuit voltage (+DC in figs 37 and 38). 9. Connect the negative test conductor to the supply terminals L1, L2 and L3 one by one. At each measurement, the multimeter must indicate blocked (= open) diode. 10. Connect the positive test conductor to the negative intermediate-circuit voltage (-DC in figs 37 and 38). 11. Connect the negative test conductor to each of the diode soldering islands (L1, L2 and L3 in figs 37 and 38) one by one. At each measurement, the multimeter must show a diode drop voltage of approx. 0.6 V. 12. Connect the negative test conductor to the negative intermediate-circuit voltage (-DC in figs 37 and 38). 13. Connect the positive test conductor to each of the diode soldering islands (L1, L2 and L3 in figs 37 and 38) one by one. At each measurement, the multimeter must indicate blocked (= open) diode. TM Step 1 Step 2 Step 3 Step 4 +DC - + -DC + - L L L Indication 0.6 OL 0.6 OL + = positive test conductor - = negative test conductor 33 / 61

34 4.6 Insulation resistance (megging) Never meg the motor with the motor conductors connected to the motor terminals Caution (U1/W2, V1/U2 and W1/V2). The MGE-F contains components that may be damaged by the high voltage from the megger. The insulation resistance, i.e. the resistance between the windings and the stator housing, should be checked regularly with a megger. The minimum insulation resistance can be calculated by multiplying the rated motor voltage (in kv) by the factor 0.5. See the following examples. Rated voltage Minimum insulation Calculation resistance V kv [MΩ] x 0.5 = 0.24 Stop using the motor immediately if the insulation resistance falls below this value. Procedure: 1. Remove the motor conductors from the motor terminals U1/W2, V1/U2 and W1/V2. See figs 39 and 40. Measuring the minimum insulation resistance 2. Apply 500 VDC to the winding while the winding temperature is approx. 25 C ± 15 C. 3. Read the megger. Measuring the maximum insulation resistance 4. Apply 500 VDC to the winding while the winding temperature is approx. 80 to 120 C. 5. Read the megger. 6. Reconnect the motor conductors to the motor terminals. Fig. 39 Motor conductors connected TM Fig. 40 Motor conductors disconnected TM Motor conductor colours U1 U2 V1 V2 W1 W2 Blue Grey White Yellow Orange Black 4.7 Winding resistance See section 9. Winding resistances for the winding resistances of the individual motors. The motor's winding resistances are so small that even the resistance in the test conductors may affect the measurement. 1. Determine the resistance in the multimeter test conductors by holding the test conductors against each other while reading the instrument. 2. Remove the motor conductors from the motor terminals U1/W2, V1/U2 and W1/V2. 3. Measure each of the windings with a multimeter: U: blue and grey V: white and yellow W: orange and black. 4. Deduct the test conductor resistance from each of the winding measurements. 5. Reconnect the motor conductors to the motor terminals. 34 / 61

35 5. Replacement of modules Warning All service work must be carried out by specially trained staff. Replacement of the modules in the terminal box covers various procedures that are all described in the following sections. Follow these instructions if it is necessary to dismantle the motor or the terminal box to replace components. Position numbers of components (numbers in brackets) refer to section 8. Drawings and diagrams. Position letters of tools (letters in brackets) refer to section 11. Service tools. Prior to dismantling Disconnect the mains supply in accordance with local regulations. Warning Due to the capacitors of the MGE-F, touching live electrical parts may be fatal, even after the mains supply has been switched off. Disconnect the mains supply, and as a minimum wait the amount of time stated on the warning label under the terminal box cover, or see section 4.1 Safety check of discharged intermediate circuit, before touching any live parts. Note that the relay may be connected to an external power supply and still be live after the mains supply to the motor has been disconnected. Warning The MGE-F may be hot! During assembly Tighten screws and nuts to the correct torque. See section 10.1 Tightening torques. Caution Always use an antistatic service kit (see section 11. Service tools, pos. B) when dismantling and assembling the terminal box as the electronics are sensitive to static electricity. Connect the antistatic service kit to the connection terminal of the protective earth conductor (PE terminal). See fig / 61

36 5.1 Replacement of varistor Removing the varistor 1. Loosen the four screws in the terminal box cover, and remove it from the terminal box. 2. Wait at least the amount of time stated on the warning label under the terminal box cover, or see section 4.1 Safety check of discharged intermediate circuit. See fig Remove the cover over the varistor. 4. Remove the two screws holding the varistor, and take the varistor out. See fig. 42. DC+ GND Fig. 41 Check measurement as described in section 4.1 TM Fig. 42 Removing the varistor DC + Test TM Fitting the varistor 1. Put in the new varistor, and tighten the two screws to 1.5 Nm. 2. Refit the cover over the varistor. 3. Connect a PC to the MGE-F by means of a PC Tool Link. See section Connecting the PC to the MGE-F. The PC Tool E-products must be installed on the PC. 4. Disconnect the mains supply to the MGE-F. 5. Confirm replacement of the varistor using PC Tool E-products. See fig Select Custom configuration: 2. Select Maintenance: Click [Varistor changed]: Fig. 43 Confirmation of replacement of varistor 1 6. Disconnect the PC Tool Link from the MGE-F. 7. Put the terminal box cover back on, and fasten it with the four screws. Tighten the screws to 7 Nm. TM / 61

37 5.2 Replacement of control board Dismantling the control board 1. Loosen the four screws in the terminal box cover (pos. 164), and remove it from the terminal box. 2. If functional modules are fitted in the terminal box, remove the plugs from the functional modules. 3. Remove the cover (pos. 284) over the supply terminals. 4. Loosen the control panel (pos. 259), and remove the plug from the socket. 5. Remove functional modules (pos. 263), if fitted. 6. Loosen the seven screws in the terminal box top (pos. 251b), and remove it from the terminal box. 7. Remove the cover (pos. 278) over the control board by detaching the four locks holding the cover. 8. Pull out the control board (pos. 273). The board is connected to the inverter board below by means of three multiple plugs that may hold back the control board. Fig. 44 Multiple plugs for control board TM Fitting the control board 1. Fit the control board in such a way that the three multiple plugs fit into the inverter board (fig. 44), and press the control board home. 2. Fit the control board cover. 3. Fit the terminal box top, and fasten it with the seven screws. The five screws at the edge of the terminal box top (pos. 251d) must be tightened to 7 Nm. The two screws above the control board (pos. 251e) must be tightened to 5 Nm. 4. Fit functional modules, if any. 5. Fit the control panel plug, and place the control panel correctly. 6. Fit the cover over the supply terminals. 7. Fit the plugs into the functional modules. 8. If the control board or the inverter board has been replaced by a new one, Calibrate the terminal box. See section 5.6 Calibration of terminal box. Configure the terminal box. See section 5.7 Configuration of terminal box. 9. Put the terminal box cover back on, and fasten it with the four screws. Tighten the screws to 7 Nm. 37 / 61

38 5.3 Replacement of rectifier board Removing the busbar 1. First go through section Dismantling the control board. 2. Remove the six screws at the edge of the cover (pos. 277), and remove the cover. 3. Remove the nuts on the busbar and the coil conductor. See fig. 45. Fig. 45 Nuts on the busbar 4. Remove the coil conductor from the screws. 5. Remove the busbar. TM Removing the rectifier board 1. First go through section Removing the busbar. 2. Remove the screws in the rectifier board. See fig. 46. Fig. 46 Screws in the rectifier board 3. Remove the rectifier board (pos. 274). TM / 61

39 5.3.3 Fitting the rectifier board 1. Remove the remains of cooling paste on the contact face for the rectifier (do not scratch the surface). See fig. 47. Caution It is very important that the contact face is completely clean as even small dirt particles may cause the ceramic surface of the rectifier to crack when the board is fastened. Rectifier contact face Fig. 47 Rectifier contact face 2. Remove possible remaining gap filler on the two contact faces of the RFI coil at the bottom of the terminal box. See fig. 48. TM Fig. 48 Contact face of the RFI coil and RFI coil RFI coil Contact faces of the RFI coil 3. Fit new gap fillers on the RFI coil. Place the gap fillers with the reinforced layer downwards towards the bottom of the terminal box. See fig. 49. TM / TM Fig. 49 Gap filler Reinforced layer TM / 61

40 4. Apply new cooling paste to the rectifier. See fig. 50. Use all the paste in the tube. Fig. 50 Application pattern for cooling paste on the rectifier TM Fit the rectifier board. 6. Fit and tighten the screws in the rectifier and the rectifier board in the right order. See fig. 51. The tightening order is also stated next to the screw holes in the board. The screws in the board must be tightened to 6 Nm, and the screws in the rectifier must first be tightened to 4 Nm, then to 6 Nm Nm Nm Nm Rectifier Fig. 51 Tightening order for screws in the rectifier board 7. Continue to section Fitting the busbar. TM Fitting the busbar 1. Place the busbar. 2. Fit the conductors to the coil. 3. Fit the nuts (pos. 276a) on the busbar. See fig. 52. Tighten the nuts to 2.2 Nm. Fig. 52 Nuts on the busbar TM Fit the cover (pos. 277) over the printed-circuit boards. Fit the six screws (pos. 277a) at the edge of the cover and tighten them to 6.5 Nm. 5. Continue to section Fitting the control board. 40 / 61

41 5.4 Replacement of inverter board Removing the inverter board 1. First go through section Removing the busbar. 2. Remove the screws in the inverter board. See fig. 53. Fig. 53 Screws in the inverter board TM Remove the inverter board (pos. 275) Fitting the inverter board 1. Remove the remains of cooling paste from the contact face of the IGBT (do not scratch the surface) and possible remains of gap filler on the contact face of the capacitors. See fig. 54. Contact faces of the capacitors Contact face of the IGBT Fig. 54 Contact faces of capacitors and IGBT 2. Fit a new gap filler on the contact face of the capacitors. Place the gap filler with the reinforced layer downwards towards the bottom of the terminal box. See fig. 49. TM / 61

42 3. Apply new cooling paste to the IGBT. See fig. 50. Use all the paste in the tube. Fig. 55 Application pattern for cooling paste on the IGBT TM Fit the inverter board. 5. Fit and tighten the screws in the IGBT and the inverter board in the right order. See fig. 56. The tightening order is also stated next to the screw holes in the board. The screws in the board (pos. 275a) must be tightened to 6 Nm. The screws in the IGBT must first be tightened to 4 Nm, then to 6 Nm Nm Nm Nm 23, 26 6 Nm IGBT Fig. 56 Tightening order for screws in the inverter board 6. Go to section Fitting the busbar. TM / 61

43 5.5 Replacement of terminal box Warning Note the weight of the terminal box and the motor before you start dismantling them. The terminal box weighs 30 kg. The weight of the motor incl. the terminal box appears from the MGE-F nameplate Removing the terminal box 1. Loosen the four screws in the terminal box cover (pos. 164), and remove it from the terminal box. 2. If functional modules are fitted in the terminal box, remove the plugs from the modules. See fig Remove the cover over the supply terminals (pos. 284). See fig. 58. Unscrew the screws from the supply terminals, and remove the supply conductors from the terminals. Fig. 57 Removing the plugs from the functional modules TM Fig. 58 Removing the cover over the supply terminals 4. Remove the cover over the motor terminals (pos. 283). See fig. 59. Note the position of the individual motor conductors for later use. Unscrew the nuts from the motor terminals, and remove the motor conductors from the terminals. 5. Remove the protective earth conductor from the PE terminal. See fig. 60. TM Fig. 59 Removing the cover over the motor terminals TM Fig. 60 Removing the protective earth conductor TM / 61

44 6. Unscrew the screws in the cable entry block. See fig. 61. Remove cable entry block (pos. 252). See fig. 62. Fig. 61 Removing the screws in the cable entry block TM Fig. 62 Removing the cable entry block TM Horizontal pump 1. Fit eyebolts (pos. N) in the terminal box. See fig Mount a hook from a crane or similar lifting equipment in the eyebolts. Fig. 63 Fitting eyebolts in a horizontal pump TM Fig. 64 Fitting the lifting bracket to a vertical pump TM Vertical pump 1. Fit lifting bracket (pos. M) on the terminal box (fig. 64), and fasten it with the screw supplied. 2. Mount a hook from a crane or similar lifting equipment in the eyebolt of the lifting bracket, and tighten the chain/wire. 3. Remove the four screws (pos. 178 in fig. 78) fixing the terminal box to the motor. 4. Lift the terminal box from the motor. Make sure that the motor conductors are not caught in the terminal box. 5. Loosen control panel (pos. 259), and remove the plug (remember to use the antistatic service kit). 6. Remove functional modules, if fitted. 44 / 61

45 5.5.2 Fitting the terminal box 1. Connect the antistatic service kit to the PE terminal. See fig Remove the blind control panel. 3. Fit functional modules, if any, from the old terminal box. 4. Fit the control panel from the old terminal box. Vertical pump 1. Fit lifting bracket (pos. M) on the terminal box, and fasten it by means of the screw supplied. 2. Mount a hook from a crane or similar lifting equipment in the eyebolt of the lifting bracket, and lift the terminal box up to mounting height on the motor. 3. Take the motor conductors through the hole into the terminal box. 4. Move the terminal box to its position on the motor. Horizontal pump 1. Fit eyebolts (pos. N) in the terminal box. See fig Mount a hook from a crane or similar lifting equipment in the eyebolts, lift the terminal box up over the motor, and take the motor conductors through the hole into the terminal box. 3. Lower the terminal box to its position on the motor. 4. Fit the four screws (pos. 178 in fig. 79) fixing the terminal box to the motor, and tighten them to 27 Nm. 5. Remove the crane hook and the eyebolts/lifting bracket. 6. Fit cable entry block (pos. 252), and tighten the screws (pos. 253) to 7 Nm. 7. Fit the motor conductors to the motor terminals (blue/black to U1/W2, white/grey to V1/U2 and orange/yellow to W1/V2), and tighten them to 2.2 Nm. 8. Fit the cover over the motor terminals (pos. 283). 9. Fit the protective earth conductor to the PE terminal (pos. 268), and tighten it to 6 Nm. 10. Fit the supply conductors to the supply terminals, and tighten them to 2.2 Nm. 11. Fit the cover over the supply terminals (pos. 284), and tighten screw (pos. 284a) to 7 Nm. 12. If functional modules are fitted in the terminal box, fit the plugs into the functional modules. 13. Configure the terminal box. See section 5.7 Configuration of terminal box. 14. Put the terminal box cover (pos. 164) back on, and fasten it with the four screws (pos. 166). Tighten the screws to 7 Nm. 45 / 61

46 5.6 Calibration of terminal box Use the PC Tool E-products for calibration of the terminal box. Connect the PC to the terminal box by means of a PC Tool Link. See section Connecting the PC to the MGE-F. The calibration function is part of the service routine if either the control board or the inverter board has been replaced, and the function should only be activated in this service situation. The calibration function ensures that the microcontroller on the control board measures the motor current correctly without offset. The control board and inverter board are then being matched together. The calibration is carried out via the PC Tool E-products. The calibration function can be found together with all other maintenance functions under Custom configuration. Note Before the calibration is carried out, the pump/motor must be stopped to prevent calibration faults. 1. Select Custom configuration: 3 2. Select Mainetance: 2 3. Click [Calibration]: Fig. 65 Calibration of terminal box 1 TM When the calibration is completed, a "calibration succeeded" or "calibration failed" window will pop up. If "calibration failed" appears, carry out the calibration again. 46 / 61

47 5.7 Configuration of terminal box If the control board or the inverter board has been replaced, the terminal box must be calibrated before it can be configured. Use the PC Tool E-products for calibration of the terminal box. Connect the PC to the terminal box by means of a PC Tool Link. See section Connecting the PC to the MGE-F. Find the desired configuration file in PC Tool E-products in this way: Search by configuration number. Search on the basis of the application that the MGE-F is part of. Choose the file position on the PC hard disk via the PC Tool E-products browser. Searching by configuration number: 1. Select Standard configuration: Select Number: 4 3. Enter a number or part of a number. 4. Click [Search now]: Fig. 66 Configuration of terminal box TM Select the configuration file in the list of search results. 6. Click [Send...] to download the configuration file to the MGE-F. 47 / 61