Service instructions. MAGNA Series 2000

Transcription

1 Service instructions MAGNA Series 2000 Magna , , 50-60, , 65-60, phase 50/60 Hz The pump must be serviced by a qualified person. Service must be carried out in accordance with local regulations and accepted codes of good practice. 1. Type identification Nameplate Type key Dismantling and assembly Dismantling the pump Fault correction Fault finding Fault correction procedure R100 alarm codes Winding resistance Repl GB 1 / 15

2 TS Type identification 1.1 Nameplate 1 A 56 R TS E F L=250 mm P/N: Model : F PC: 0834 Made in Germany 1 x V 50/60 Hz I1/1 (A) P1 (W) TF MIN 22 MIN IP Max. 1.0MPa MAX MAX TM Pos. Description Pos. Description 1 Type designation 8 Production code (year + week) 2 Product number 9 Country of origin 3 Model designation 10 Direction of rotation 4 Rated voltage and number of phases 11 Rated frequency 5 Maximum full-load current 12 Liquid temperature limit 6 Maximum input power 13 Enclosure class 7 Mark of conformity 14 Insulation class 1.2 Type key Example MAGNA (D) F (N) Model: E Type range Twin-head pump Nominal flange diameter [mm] Maximum head [dm] Pump housing with flanges Pump housing of stainless steel 2 / 15

3 2. Dismantling and assembly The pump must be serviced by a qualified person. Service must be carried out in accordance with local regulations and accepted codes of good practice. Before dismantling Disconnect the electricity supply to the motor. Close the isolating valves, if fitted, or drain the system, as the pumped liquid may be burning hot and under high pressure. Before assembly Gaskets and O-rings should always be replaced when the pump is overhauled. Clean and check all parts. Order new O-ring kits. Replace defective parts by new parts. 3 / 15

4 2.1 Dismantling the pump Changing the position of the terminal box 1. Remove the inspection screw pos. 1 and the four screws pos. 2 in the stator housing, see Fig Turn the stator housing pos. 3 to the position required. If the stator housing has been prised/lifted off the pump housing, continue with point 2 in Replacing the stator unit including the rotor unit. 3. Fit the four screws and the inspection screw TM Fig. 1 Changing the position of the terminal box Replacing the stator unit including the rotor unit 1. Remove the inspection screw pos. 1 and the four screws pos. 2 in the stator housing, see Fig Lift off the stator housing pos Remove the rotor and the O-ring from the pump housing or stator housing. 4. Check that the O-ring pos. 6 is intact. If the O-ring is damaged, it must be replaced. 5. Fit the rotor and the O-ring on the pump housing. 6. Put a tee key or a long screwdriver through the stator and hold the rotor while fitting the stator on the pump housing. See Fig. 2. The purpose is to protect the O-ring, as otherwise the magnetic force will cause the rotor to jerk up in the stator TM Fig. 2 Holding the rotor 7. Turn the stator housing pos. 3 to the position required. 8. Fit the four screws and the inspection screw. 4 / 15

5 3. Fault correction The pump must be serviced by a qualified person. Service must be carried out in accordance with local regulations and accepted codes of good practice. 3.1 Fault finding Fault finding should always start with a check that the external conditions for correct function are OK. This is done by checking: that the mains supply is in accordance with the data on the nameplate, that the installation was carried out according to the installation and operating instructions, that the external on/off switch has been connected correctly, that the desired setpoint signal is available, that the requested sensor signal is available Printing of data registers The Grundfos R100 remote control enables the printing of status for the data registers by means of a Hewlett Packard infrared printer. The purpose of this is to ensure that the service technician can print out the data registers before starting the fault finding so that this print stating the original fault information can be enclosed, in case the product is returned to Grundfos. The following figure shows an example of a print of MAGNA Series 2000 pump data registers. 5 / 15

6 3.1.2 Fault indication MAGNA Series 2000 pumps feature a fault indication function: The following fault indications can appear: Pump blocked. Internal fault Undervoltage Overvoltage Overtemperature Module fault (fault in the module fitted (GENI, LON...)) Fault in module communication. The fault indication can also be reset in this display. If the fault has not disappeared when attempts are made to remove the fault indication, the indication will return in the display when communicating with the pump Fault reading via R100 Possible fault and log can be read via R100 in the GENI menu and/or in the OPERATION menu. Fault indications Alarm log Fig. 3 Actual fault indication Magna Series 2000 pums feature also a alarm log function. The alarm log function memory can recall the five latest faults. The alarm log can be read out via R100. The alarm log cannot be reset. States the type of alarm, code and time since the fault arose. The alarm log shows the alarm code, the fault indication and for how many minutes the pump has been connected to supply voltage since the fault arose. Fault code Time since the fault arose Fault indication List of alarm code priority, see 3.3 R100 alarm codes. Fig. 4 Example of alarm log 6 / 15

7 3.2 Fault correction procedure The following fault correction procedure is based on indications by the green and red indicator lights on the terminal box of the MAGNA Series 2000 pump. The next two pages give a complete overview of the possible signal lights combinations. Remedy for some of the situations is further elaborated on the three next pages ( A1, A2, B1, B2, B3, C1, C2). Legend for signal lights: = signal light is off. = signal light is permanently on = signal light is flashing Signal lights Green Red Description Explanation Remedy/reference Pump is not running. Voltage supply to pump has been cut off. Re-establish correct voltage supply. Normal operation Pump is running. 1. Normal operational state. The pump is keeping up the pressure according to the setpoint set. 2. Pump is running but not as the expected pump type. Cause: Configuration error Check the automatic configuration of the terminal box. See A1. 3. Pump is running but making noise. Cause may be: - Air in the pump - Inlet pressure too low. Vent the pump. Increase the inlet pressure. 4. Pump is running at too low or high pressure. Is the pressure set correct? Check the external 0-10 V signal. See A2. Normal operational stoppage Pump is not running. Pump has been stopped... - by means of the operating button - - via R via Grundfos GENIbus - - by the pump start/stop function. (Input on terminals STOP - is open meaning that 5 VDC can be measured across the terminals.) - Pump is not running. Pump has been stopped due to: 1. Supply voltage outside specified range - automatic restart. Re-establish correct voltage supply. 2. Pump blocked or overloaded - manual restart. Remove blockage/reduce load. 3. Frequent restarts - manual restart after stop. The pump starts and stops at short intervals until it stops permanently. Replace the terminal box. 4. Fatal fault - Cause may be: - Terminal box defective - Stator winding defective Automatic and manual restart have been factoryset. - Replace the terminal box. - Replace the stator. 7 / 15

8 Legend for signal lights: = signal light is off. = signal light is permanently on = signal light is flashing Signal lights Green Red Description Explanation Remedy/reference Normal operation + indication of fault Pump is running at normal performance. Pump has been stopped due to fault and has restarted automatically. 1. GENI module (if installed) Max., min., 0-10 V inputs do not react. 2. LON module (if installed). Pump does not react to changes from the LON input. 3. Setpoint changes cannot be stored. See B2. 4. No signal is registered from the HALL sensor in the stator. Normal operational stoppage + indication of fault Pump is not running. Pump has been stopped... - by means of the operating button Fault in internal communication to the module, see B1. Fault in internal communication to the module, see B1. See B3. - via R100 - via Grundfos GENIbus - by the pump start/stop function. Pump can run, however, even if there has previously been a fault. 1. GENI module (if installed). Max., min., 0-10 V inputs do not react. 2. LON module (if installed). Pump does not react to changes from the LON input. 3. Setpoint changes cannot be stored. See B2. 4. No signal is registered from the HALL sensor in the See B3. stator. Fault in internal communication to the module, see B1. Fault in internal communication to the module, see B1. 8 / 15

9 A1 Description Explanation Check/remedy Pump is running but not as the expected pump type. Configuration error In case the terminal box cannot identify the stator type, the pump will run default as a or a Check by means of R100 which pump type the terminal box has registered: 1. Switch R100 to service mode. 2. Go into the GENI menu in the display on the right. 3. Enter code 13. R100 will now show which pump type the terminal box has registered. Check that the indication corresponds to the actual pump type. In case of error in the stator coding, the indication will be "ERR". Is the pump type correct? Fault is not due to a configuration error, but possibly to a setting error or a system fault. Check the stator coding according to the drawing. In new R100 software updates the pump type can be read in the start-up display. See C2. Description The twin-head pump does not control its performance optimally. A2 Explanation Check/remedy Description Explanation Configuration error The terminal box uses a wrong set of parameters. As the right and the left pump head do not have the same hydraulic performance, there are a right and left set of parameters. Correct configuration is carried out by means of the GENI modules where the Master module must always be fitted on the right pump head. (Terminals X and Q are short-circuited.) The modules must be product number VO1 or higher. If no GENI modules are used on the twin-head pumps, the configuration can be carried out by means of R100 Turbo. Pump is running at too low or high pressure. Setpoint setting is incorrect. Check/remedy 1. Is an external setpoint signal connected? Set setpoint according to system specifications. Check the connection to the GENI module and the external setpoint signal. Note that the terminals MIN - must be closed for the setpoint setting to work. 2. Does the pump speed vary (listen to the pump) according to the input signals on terminals 10 V -? Pump is OK. Proceed to point B1. 9 / 15

10 B1 Description Pump is running at normal performance. B2 B3 Explanation Pump has been stopped due to fault and has restarted automatically. The fault may be due to fault in the GENI module or the LON module. Check/remedy 1. Is the GENI module connected? Proceed to points 2, 3 and 4. Proceed to point Short-circuit terminals MAX -. Is the MAX diode on? Description Explanation Check/remedy Description Explanation GENI module is OK. Replace the GENI module. 3. Short-circuit terminals MIN -. Is the MIN diode on? GENI module is OK. Replace the GENI module. 4. Change the signal to the 0-10 V input. Does the pump change speed accordingly (listen to the pump)? GENI module is OK. Replace the GENI module. 5. LON module is connected. Get assistance from the LON system administrator to change the operating conditions of the pump. Does the pump react to this? LON module is OK. Replace the LON module. Pump is running at normal performance. The fault may be that setpoint changes cannot be stored. Change the setpoint by means of the operating buttons. Is the new setting saved when the supply voltage is switched off (the pump is completely off) and then switched on again? Setpoint function is OK. Replace the terminal box. The pump is running at reduced performance and cannot be controlled. No signal is registered from the HALL sensor in the stator. Check/remedy Test the HALL sensor in the stator by means of a multimeter according to the description under C1. Sensor OK? Replace the terminal box. Replace the stator. 10 / 15

11 C1 The HALL sensor in the stator can be tested by measuring the winding resistance using an ordinary multimeter. The test is more than 95% reliable. All three measurements must be OK. Test of diode 0,5-0,7 V DC + - Ca. 21 k + - ID 1 ID 2 ID 3 GND U V W X Y Z Wire colours from HALL Black Red White sensor in stator HALL sensor in stator TM Fig. 5 Numbering of the pump's terminal block 11 / 15

12 C2 HALL sensor in stator "+5V" Output Black Red White Wire colours ID 1 ID 2 ID 3 GND U V W X Y Z TM Fig. 6 Numbering of the pump's terminal block Comments to the diagram: 1. Coding definition Combination Pump ID 1 (1) ID 2 (3) ID 3 (5) "O" indicates that the coding wire must be connected to the terminal block of the stator (Magmate). All combinations are to be connected to GND (13). Combination 1 is not allowed (corresponds to a situation where no terminal box fitted). Combination 8 is free for a future pump type. GND (13) 1. Undefined No connections O O O O O O O O O O O O O O O 8 Undefined O O O O 12 / 15

13 3.3 R100 alarm codes The table shows the fault log possibilities in prioritized order. If two faults occurs at the same time, the fault with the highest priority will be shown! Priority Code (fault log) Pump blocked Fault indication R100 PMU 2000 Pump reaction * Depending on the expansion module. Blocked Stopped Motor, rotor, impeller or pump blocked Fault in terminal box Cause Remedy Start after fault Internal fault Fault Stopped The terminal box current limit has been exceeded which may be caused by: Fault in the terminal box Replace the terminal box. Fault in the stator Replace the stator. Overtemperature Fault Stopped A too high temperature has been measured in the pump, which may be caused by: Too high motor temperature due to stator fault Extremely high liquid temperature Extremely high ambient temperature Fault in the terminal box Undervoltage Undervoltage Stopped The supply voltage from mains is too low. Overvoltage Overvoltage Stopped The supply voltage from mains is too high. Internal fault Internal fault Internal fault No fault indication No fault indication No fault indication Fault in module No fault indi- communication cation 11 * Fault in module No fault indication Pump is running. Pump is running. Pump is running. Pump is running. Pump is running. The terminal box registers no signal from the HALL sensor in the stator. Too low DC voltage measured in the terminal box. Fault in the storing of set values (pressure) or measured values (hour counter) in the internal memory of the terminal box. The terminal box cannot communicate with the module fitted (GENI or LON). (The fault also occurs if the module is removed while the pump is operating.) Disassemble pump and remove blockage. ally before the pump can run. The fault must be reset manu- Replace the terminal box. Replace the stator. Reduce the liquid temperature. Reduce the ambient temperature. Replace the terminal box. Check that the supply voltage is in accordance with the data on the nameplate. Check that the supply voltage is in accordance with the data on the nameplate. Replace the stator Replace the terminal box. Reset the fault indication. If the fault re-occurs, replace the terminal box. Cut off the supply voltage, wait for approx. 1 minute, then cut in the supply voltage again. A new setpoint has now been stored, and if no fault is indicated, the fault was temporary. If the fault re-occurs, replace the terminal box. Check that the connection between module and terminal box is OK. See point 3 in section B1. The terminal box has received Replace the expansion a feedback from the expansion module. module fitted. There is a fault in the expansion module. Pump will start automatically when the fault has disappeared and the red indicator light is no longer on. The pump tries to restart once every minute. Pump will start automatically when the fault has disappeared and the red indicator light is no longer on. Pump will start automatically when the fault has disappeared and the red indicator light is no longer on. Pump will start automatically when the fault has disappeared and the red indicator light is no longer on. When the fault has disappeared, the red indicator light goes out automatically. When the fault has disappeared, the red indicator light goes out automatically. Once it has occurred, the fault will be indicated periodically. See "Remedy". When the fault has disappeared, the red indicator light goes out automatically. When the fault has disappeared, the red indicator light goes out automatically. 13 / 15

14 4. Winding resistance Pump type Terminal number Ω 5.0 Ω 5.0 Ω Ω 5.0 Ω 5.0 Ω Ω 11.7 Ω 11.7 Ω Ω 3.7 Ω 3.7 Ω Ω 11.7 Ω 11.7 Ω Ω 3.7 Ω 3.7 Ω 15 / 15