GRUNDFOS INSTRUCTIONS. Control HVAC. Installation and operating instructions. Other languages. net.grundfos.com/qr/i/

GRUNDFOS INSTRUCTIONS Control HVAC Installation and operating instructions Other languages net.grundfos.com/qr/i/98800750

English (GB) English (GB) Installation and operating instructions Original installation and operating instructions. These installation and operating instructions describe the Grundfos Control HVAC. Sections 1-6 give the information necessary to be able to unpack, install and start up the product in a safe way. Sections 7-13 give important information about the product, as well as information on service, fault finding and disposal of the product. These instructions are available in other languages. Use the URL or QR code below to download them: http://net.grundfos.com/qr/i/98800750. CONTENTS Page 1. General information 2 1.1 Symbols used in this document 2 1.2 Abbreviations used in this document 2 2. Safety instructions 2 3. Receiving the product 2 3.1 Inspecting the product 2 4. Installing the product 3 4.1 Location 3 4.2 Mechanical installation 3 4.3 Electrical connection 3 5. Commissioning 4 5.1 Configuring the controller 4 5.2 Testing the system 8 6. Starting up the product 10 7. Product introduction 10 7.1 Product description 10 7.2 System control 10 7.3 Pump cascade control 10 7.4 Control of the bypass valve 11 7.5 Controller reaction time 11 7.6 Type key 11 8. Operating the controller 11 8.1 Reading the system status 11 8.2 Alarms 12 8.3 Operating modes 12 8.4 Changing settings 13 8.5 Locking and unlocking menus 13 8.6 Adding new components to the system 14 8.7 Adding new data communication system 14 9. Servicing the product 14 9.1 Maintaining the product 14 9.2 Repairing the product 14 10. Taking the product out of operation 14 11. Fault finding the product 15 12. Technical data 18 12.1 General 18 12.2 CP6606 controller 18 12.3 I/O modules and terminals 19 13. Disposing of the product 19 QR98800748 Warning Prior to installation, read these installation and operating instructions. Installation and operation must comply with local regulations and accepted codes of good practice. 1. General information 1.1 Symbols used in this document Note 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. 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. 1.2 Abbreviations used in this document BMS CUE GRM HVAC VFD Building management system Grundfos frequency converter Grundfos Remote Management Heating, ventilation and air-conditioning Variable frequency drive 2. Safety instructions Warning The product must be installed and put into operation by a person authorised by Grundfos. Warning Make sure that the power supply cannot be accidentally switched on during electrical installation. 3. Receiving the product 3.1 Inspecting the product Before installation, check that the system is as ordered, and that no visible parts have been damaged. If components are damaged or missing, contact your local Grundfos sales company. 3.1.1 Scope of delivery Main cabinet installation and operating instructions in English wiring diagram for main cabinet Optional: 1-3 subcabinets differential-pressure sensors temperature sensors flow sensor wiring diagram for subcabinets. 2

4. Installing the product 4.3 Electrical connection 4.1 Location The product is not designed for outdoor installation and must not be exposed to direct sunlight. Main cabinet The main cabinet must be installed in a well-ventilated room to ensure sufficient cooling of its components. Install the cabinet so that the user can easily access the touchscreen and switches. The cabinet can be mounted on a wall. Use screws and rawlplugs appropriate to the type of wall. Subcabinets (optional) The subcabinets must be installed in a well-ventilated room to ensure sufficient cooling of its components. The maximum distance to the main cabinet is 100 m (328 feet). The subcabinets can be mounted on a wall. Use screws and plugs appropriate to the type of wall. 4.2 Mechanical installation The Control HVAC is designed exclusively for variable-primaryflow systems. The system must include pumps, chillers, zones, sensors and a bypass valve. See fig. 1. Up to 26 sensors for air-handling zones can be connected to the controller. We recommend that you install differential-pressure sensors in the most critical zones, for example those located the farthest from the chillers. Fig. 1 Example of variable-primary-flow HVAC system with 3 pumps, 3 chillers and 3 air-handling zones Pos. Temperature sensor Flow sensor Differential-pressure sensor Bypass valve Isolating valve of the chiller Speed-controlled pump Chiller T F CHILLER CHILLER CHILLER T Air-handling zone: air-handling unit (AHU), fan coil, etc. T M ZONE ZONE ZONE Up to 8 pumps Up to 8 chillers Up to 26 zones T F M CHILLER ZONE TM062399 4614 Warning The electrical installation must be carried out by an authorised person in accordance with local regulations and the relevant wiring diagram. Warning During electrical installation, make sure that the power supply cannot be accidentally switched on. Before connecting your devices to the main cabinet and the subcabinets, check that the following requirements are met: The electrical installation must comply with enclosure class IP54 or UL type 3R. The supply voltage and frequency must correspond to the values stated on the nameplate. The wire cross-section must correspond to the specifications in the wiring diagrams. The type of control and/or feedback signal of your devices must correspond to your Control HVAC version. The signals are described in the table below: Available signal Device Standard Control HVAC Option Grundfos E- pumps or CUE GENIbus External VFD 0-10 V Bypass valve 4-20 ma 0-10 V Main cabinet Connect the following devices to the terminals in the main cabinet according to the wiring diagram delivered with your product. power supply Grundfos E-Pumps, CUE or VFD differential-pressure sensors (pumps, chillers and the two first air-handling zones) chiller on/off signals (from chiller controller, BMS or isolating valve) bypass valve. Optional Temperature sensor(s) flow sensor external emergency switch for system external emergency switches for pumps. Note Grundfos E-pumps and CUE: Make sure that each pump has a unique GENIbus address (1 to 8), and that the pump is connected to the corresponding terminal. If there is only one air-handling zone in your system, you can connect a redundant differential-pressure sensor for the zone. Connect the redundant sensor to the terminal for the sensor of the second air-handling zone. Subcabinets (optional) Connect the following devices to the subcabinets according to the wiring diagram delivered with your product. power supply EtherCAT cable to main cabinet EtherCAT cable to the next subcabinets, if any differential-pressure sensors (air-handling zones). English (GB) 3

English (GB) 5. Commissioning After connecting the power supply and all the devices to the cabinet, you must configure the controller and check that all components of the system are connected properly to the controller and that they function correctly. Warning The product must be installed and put into operation by a person authorised by Grundfos. Switch off all chillers, pumps and air-handling zones and set the system selector switch on the main cabinet to "Off". Text Enable pump changeover Time of day for changeover Enable fixed intervals for periodic stop attempts Interval between stop attempts Set a check mark if you want the controller to automatically change the operating pump after a defined time. Enter the time for pump changeover (1-24) Set a check mark if you want the controller to check at fixed intervals whether a pump can be stopped for better efficiency. Set the interval in minutes. 5.1 Configuring the controller It is important to follow these steps in the correct order to successfully configure the controller. To start the configuration, switch on the controller via the main switch on the front panel. 5.1.1 Setting the controller clock 1. Press the clock in the bottom left corner. See fig. 2. 2. In the new window, press [date/time]. 3. Enter date and time. 4. Press [Apply]. 5. Press [x] to close the window. Pump ramp up/ ramp down time Min. time between start and stop Stop speed Start speed Cut-out speed Enter the time for the pump ramp up (time for the pump to accelerate to its operating speed) and ramp down (time for the pump to decelerate to its stop speed). Enter the minimum time in seconds for a pump to stop after having started. Enter the speed at which the pump is to be stopped. Enter the speed at which the pump is to be started. Enter the speed at which a pump is to be cut out. Cut-in speed Enter the speed at which a new pump is to be cut in. Fig. 2 Clock 5.1.2 Setting the pump cascade control 1. Press [Settings] [Pump cascade control]. 2. Enter the parameters using the table below. 3. Press [Save]. TM064539 2515 For more information about the pump cascade control, see section 7.3 Pump cascade control. 5.1.3 Tuning the controller 1. Press [Settings] [Controller tuning]. 2. Set the gain (Kp) and the integral time (Ti) for the pump controller and for the main controller. You may need to adjust the values after having started the product. If you want a faster reaction, increase the gain and reduce the integral time. If you want a slower reaction, reduce the gain and increase the integral time. 3. Press [Save] for both controllers. TM064556 2515 Fig. 3 Pump cascade control TM064555 2515 Fig. 4 Text Kp (x - y) Ti (x - y) Controller tuning Enter the gain. The value must be between x and y. Enter the integral time. The value must be between x and y. 4

5.1.4 Enabling and disabling data logging 1. Press [Settings] [Data log]. 2. Set a check mark if you want data logging. Data logging requires a USB stick plugged into the controller. See section 12.2 CP6606 controller. 3. Press [Save]. 5.1.5 Selecting the communication channels 1. Press [Settings] [Communication channels]. 2. Select your communication system. 3. Press [Save]. Fig. 5 Text Enable/disable communication channels Enter the AMS address Communication channels Set a check mark if you want to enable communication between the controller and the remote management system. Only enter a new AMS address when replacing the controller. The original controller has been given an AMS address from factory. TM064558 2515 Locking a menu 1. Press [Settings] [Passwords]. 2. In "Menu", set a check mark in "Enable/Disable". 3. Enter a password (maximum four digits). 4. Press [Save]. 5. Press [Status]. The menu is now locked. It is no longer possible to press the menu button in the sidebar. Note: When the setting menu is locked, it is still possible to press [Settings] [Passwords]. Unlocking a menu temporarily 1. Press [Settings] [Passwords]. 2. In menu "Password status", enter the password. 3. Press [Unlock]. The menu is now unlocked. The menu will be locked again when you go to the "Status" menu. Unlocking a menu permanently 1. Press [Settings] [Passwords]. 2. In "Menu", remove the check mark in "Enable/Disable". 3. Enter the password. 4. Press [Save]. The menu is now unlocked and the password is erased. 5.1.8 Configuring the application Before entering the settings related to each device, you must configure the system according to your application: 1. Press [Application configuration]. 2. Enter the system parameters using the table below. 3. If status says "OK", press [Save]. If not, check that the values entered are correct, or that the devices are connected properly to the cabinet. English (GB) 5.1.6 Selecting units 1. Press [Settings] [Units]. 2. Select SI (metric system) or US (imperial system) to set the units automatically, or use the drop-down menus to select your preferred units. 3. Press [Save]. 5.1.7 Locking menus You can set two passwords to control the access to the following menus: Operation Configurations and settings. Fig. 7 Application configuration TM062846 2515 Text Number of pumps Enter the number of pumps connected to the controller. Number of chillers Enter the number of chillers connected to the controller. Zone sensors, main cabinet Enter the number of sensors of air-handling zones connected to the main cabinet. Fig. 6 Password menu TM064560 2515 Zone sensors, subcabinets Status Enter the number of sensors of air-handling zones connected to the subcabinets. Enter 0 if there are no subcabinets. The controller checks that the values entered correspond to the connections at the terminals. If the status is not OK, check that the values are correct and/or that the connection is well established. 5

English (GB) 5.1.9 Setting the pumps 1. Press [Configuration]. 2. Press the pump icon. 3. Enter the settings using the table below. 4. Press [Save]. 5. Repeat steps 1-3 for the other pumps, if any. 5.1.10 Setting the chiller sensors 1. Press [Configuration]. 2. Press the chiller icon. 3. Enter the settings using the table below. 4. Press [Save]. 5. Repeat steps 1-3 for the other chillers, if any. TM064551 2515 TM064549 2515 Fig. 8 Setting the pump Fig. 9 Setting the chiller sensor Text Pump number Select Genibus number Enable VFD alarms Enable Genibus alarms Max. head Max. flow Max. power Number of the selected pump Set a check mark if you want the pump to be part of the pump system. If you leave the box empty, the pump is ignored. GENIbus number of the selected pump Versions with VFD only: Set a check mark if you want the controller to register alarms related to the VFD and report them in the "Alarms" menu. Versions with E-pumps or CUE only: Set a check mark if you want the controller to register alarms related to the E-pumps/ CUE and report them in the "Alarms" menu. Enter the maximum head in the pressure unit selected in the "Units" menu. Enter the maximum flow rate in the unit selected in the "Units" menu. Enter the maximum power in the unit selected in the "Units" menu. Text Chiller number Select Enable sensor alarm Sensor range Min. Max. Fault signal Number of the selected chiller Set a check mark if you want the sensor to be part of the system. If you leave the box empty, the sensor is ignored. Set a check mark if you want the controller to register alarms related to the sensor and report them in the "Alarms" menu. Enter the maximum pressure that can be measured by the sensor in the unit selected in the "Units" menu. Enter the minimum pressure allowed through the chiller in the unit selected in the "Units" menu. Enter the maximum pressure allowed through the chiller in the unit selected in the "Units" menu. Enter the pressure that the controller is to use as reference in the event of sensor failure. 6

5.1.11 Setting the zone sensors 1. Press [Configuration]. 2. Press the icon for air-handling zones. 3. Enter the settings using the table below. 4. Press [Save]. 5. Repeat steps 1-3 for the other zones, if any. 5.1.12 Setting the bypass valve 1. Press [Configuration]. 2. Press the icon for the bypass valve. 3. Enter the settings using the table below. 4. Press [Save]. English (GB) Fig. 10 Setting the zone sensor TM064553 2515 Fig. 11 Setting the bypass valve TM064548 Text Zone number Select Enable sensor alarm Sensor range Reference Fault signal The number of the selected zone Set a check mark if you want the sensor to be part of the system. If you leave the box empty, the sensor is ignored. Set a check mark if the controller is to register alarms related to the sensor and report them in the "Alarms" menu. Enter the maximum pressure that the sensor can measure in the unit selected in the "Units" menu. Enter the differential pressure required by the air-handling zone. It is the reference for the controller. Enter the pressure that the controller is to use as reference in the event of sensor failure. If you want to stop the flow through the zone when its sensor fails, enter a value greater than the reference value. If you want the flow to continue through the zone, enter a reasonable value, for example the most frequently measured value. Text Enable feedback Enable sensor alarm Type Gain factor Gamma Deadband Set a check mark if there is a position feedback connected to the controller. Set a check mark if you want the controller to register alarms related to the bypass valve and report them in the "Alarms" menu. Select the type of bypass valve. Enter the gain factor for the valve. The higher the gain factor, the faster the bypass valve reacts.* Enter the gamma factor of the valve. This value can be found in the instructions for the bypass valve.* Note: For linear types of valve, gamma is 0. Enter the deviation in bar between the reference and the measured differential pressure across the air-handling zones within which the bypass valve must not react. Enter a value in the unit selected in the "Units" menu. We recommend a deadband of 10 % of the maximum reference required by your airhandling zones.* * For more information about the gain factor, gamma factor and deadband, see section 7.4 Control of the bypass valve. 7

English (GB) 5.1.13 Setting the flow sensor 1. Press [Configuration]. 2. Press [FS]. 3. Enter the settings using the table below. 4. Press [Save]. Fig. 12 Setting the flow sensor Text Select Type Sensor range Set a check mark if you want the sensor to be part of the system. If you leave the box empty, the sensor is ignored. Select the sensor type. Enter the maximum flow rate that the sensor can measure in the unit selected in the "Units" menu. 5.1.14 Setting the temperature sensor 1. Press [Configuration]. 2. Press [TS1]. 3. Enter the settings using the table below. 4. Press [Save]. 5. Repeat steps 1-3 for TS2 and TS3. TM064550 2515 TM064552 2515 5.2 Testing the system 5.2.1 Testing the connections Test all analog and digital inputs using the LEDs on the terminals. See section 12.3 I/O modules and terminals for a detailed description of the terminals and LEDs. For each device, check the following: The device has been connected to the right terminal. Example: LED 1 receives signals from chiller 1, LED 2 from chiller 2, etc. The signal is rational. Digital inputs Switch off all chillers, pumps and air-handling zones and set all pump selector switches on the main cabinet to "Off". Set the system selector switch to "Manual/Local". Do not switch on the chillers to test their connections. Open and close the isolating valves of the chillers instead. Switch each device on and off, one at a time, to test the digital inputs. Analog inputs Check that the LEDs indicate the status of the sensors and bypass valve. Version with VFD: As you must not start the pumps at this point, you cannot check the analog signal from the VFD. You can do this when you start the pumps for the first time. See section 5.2.3 Testing the pumps. 5.2.2 Testing the bypass valve 1. Set the operating mode of the bypass valve to "Manual": Press [Operation]. Press the icon for the bypass valve. Select "Manual" and enter a value between 0 and 100, i.e. the valve opening in percentage. Press [Save]. 2. Check that the bypass valve changes its position according to the setting. You may have to remove the cover of the bypass valve. 3. Bypass valves with position feedback: Press [Status] and check that the value shown next to the icon for the bypass valve corresponds to the setting. See section 8.1 Reading the system status. Bypass valves without position feedback: Disregard this step. Fig. 13 Setting the temperature sensor Text Sensor number Select Sensor range Offset Number of the selected temperature sensor Set a check mark if you want the sensor to be part of the system. If you leave the box empty, the sensor is ignored. Enter the maximum temperature that the sensor can measure in the unit selected in the "Units" menu. Enter the temperature offset, if any, in the unit selected in the "Units" menu. 8

5.2.3 Testing the pumps Set all pump selector switches on the main cabinet to "Off". Versions without pump selector switches: Disconnect all pump wires (24 V) from the terminals "Auto pump X". See the wiring diagram delivered with the product. Versions with pump selector switches on the main cabinet 1. Set the bypass valve position to 100 %. See step 1 in section 5.2.2 Testing the bypass valve. 2. Set a low speed for all pumps: Press [Operation]. Press the first pump icon. Select "start" and in the field "Manual speed", enter a low value in percentage, for instance 20 % of the maximum speed. Press [Save]. Repeat this step for all pumps. 3. Open the isolating valve of one chiller. Do not start the chillers. Note: The controller prevents the pumps from starting if the isolating valves of all other chillers are closed. 4. Set the first pump selector switch to "Manual". 5. Switch on the pump system. 6. Check that the first pump starts and runs at the selected speed. Depending on the product, you can read the pump speed on the following: Grundfos CUE: Grundfos E-pumps: External VFD: Display Grundfos GO See the product manual. 7. Press [Status] and check that the pump icon is green and that the measured speed displayed on the icon is correct. 8. Set the pump selector switch to "Off" to switch the pump off. 9. Follow steps 4 to 8 to test the other pumps, one at a time. Make sure to set each pump selector switch to "Off" after testing the pump and before testing the next one. Versions without pump selector switches 1. Set the bypass valve position to 100 %. See step 1 in section 5.2.2 Testing the bypass valve. 2. Set a low speed for all pumps: Press [Operation]. Press the first pump icon. Select "start" and in the field "Manual speed", enter a low value in percentage, for instance 20 % of the maximum speed. Press [Save]. Repeat this step for all pumps. 3. Set pump 1 to manual mode: Connect the wire (24 V) for pump 1 to the terminal "Manual pump 1". See the wiring diagram delivered with the product. 4. Open the isolating valve of one chiller. Do not start the chillers. Note: The controller prevents the pumps from starting if the isolating valves of all other chillers are closed. 5. Switch on the pump system. 6. Check that the first pump starts and runs at the selected speed. Depending on the product, you can read the pump speed on the following: Grundfos CUE: Grundfos E-pumps: External VFD: Controller display Grundfos GO See the product manual. 7. Press [Status], and check that the pump icon is green and that the measured speed displayed on the icon is correct. 8. Switch off the pump system. 9. Set pump 1 to "Auto" mode: Disconnect the wire (24 V) from the terminal "Manual pump 1". See the wiring diagram delivered with the product. 10. Follow steps 3 to 9 to test the other pumps, one at a time. Make sure to disconnect the pump wire (24 V) from the terminal "Manual pump X" after testing each pump and before testing the next one. Note VFD: If no value is displayed on the touchscreen, check the connections via the LEDs of the terminals corresponding to the analog signal from the VFD. See section 12.3 I/O modules and terminals. 5.2.4 Testing the pump cascade 1. Versions with pump selector switches: Set all pump selector switches to "Auto". Versions without pump selector switches: Connect all pump wires (24 V) to the "Auto pump X" terminals. See the wiring diagram delivered with the product. 2. Open the isolating valve of one chiller. Do not start the chiller. Check that at least one pump is starting. 3. Open the other isolating valves one at a time and check that the pump system reacts normally. Pumps must cut in and/or increase in speed. See section 7.3 Pump cascade control. 5.2.5 Testing the overall system 1. Open some of the isolating valves of the chillers, for example half of them. Do not start the chillers. 2. Set the operating mode of the bypass valve to "Auto": Press [Operation] and press the icon for the bypass valve. Select the operating mode "Auto". 3. Change the cooling load, for example by turning on and off some air-handling zones or fan coils. Check that the system reacts correctly: Check that the value of the sensors is rational. Check that the colour of the device icons corresponds to the status of the devices. Check that the bypass valve opens when necessary. 4. Turn on all air-handling zones. 5. Switch on the chillers one at a time and check that the system reacts correctly. The system is now ready to start. English (GB) 9

English (GB) 6. Starting up the product Before starting up the system, make sure that it has been tested by an authorised person. See section 5. Commissioning. 1. Switch on the controller via the main switch on the front panel. 2. Check the following: The pump selector switches have been set to "Auto". Disregard this step if your cabinet does not have pump selector switches. The system selector switch has been set to "Manual/Local" or "Auto/Remote", depending on your configuration. See section 8.3.2 Pump operating modes. The operating mode of the bypass valve has been set to "Auto": Press [Operation], press the icon for the bypass valve and check the operating mode. 3. Switch on the pumps. 4. Switch on all air-handling zones. 5. Switch on the chillers one at a time. 7. Product introduction 7.1 Product description The Control HVAC is designed to optimise pump operation in variable-primary-flow systems, as part of air-conditioning systems. It controls speed-controlled pumps and a bypass valve placed between the flow pipe and return pipe of the air-handling zones. According to the demand from the air-handling zones, the Control HVAC operates the pumps in the most efficient way. Additionally, when the demand is too low, the controller adjusts the opening of the bypass valve to ensure a minimum flow through the operating chillers. The Control HVAC can support the following: eight speed-controlled pumps: Grundfos E-pumps, Grundfos pumps with CUE or other pumps with VFD (0-10 V) eight chillers 26 air-handling zones. The main cabinet supports the connection to two differentialpressure sensors for air-handling zones. More sensors can be connected via up to three subcabinets connected to the main cabinet via an EtherCAT cable. 7.2 System control The air-handling zones, chillers and isolating valves are controlled by a building management system. The Control HVAC controls the pumps and the bypass valve, based on the feedback from the sensors and isolating valves of the chillers. The cooling load from the air-handling zones determines the number of chillers in operation. According to the number of chillers in operation, the controller adapts the pump operation to maintain a differential flow across the chillers within the allowed range. The controller then adjusts the pump operation further to reach the demand from the air-handling zone with the largest difference between its reference and its actual value. When the flow demand from the zones is lower than the minimum flow rate required across the chillers, the controller opens the bypass valve and hence maintains a minimum flow through the chillers. Fig. 14 Variable-primary-flow system with three pumps, three chillers and three air-handling zones 7.3 Pump cascade control The Control HVAC is designed to control Grundfos E-pumps and CUE frequency converters, as well as other types of pumps with variable frequency drives (VFD). The performance is adjusted to the demand through cutting pumps in or out and through parallel control of the pumps in operation. The Control HVAC maintains a constant pressure through continuous adjustment of the speed of the pumps. Pump changeover is automatic and depends on load, operating hours and fault. All operating pumps run at the same speed. The number of pumps in operation also depends on the energy consumption of the pumps. If only one pump is required, two pumps will run at a lower speed if this results in a lower energy consumption. Examples of operation with one and three E-pumps: H H set Fig. 15 One E-pump in operation H H set Fig. 16 Three E-pumps in operation T F Pump start, stop, cut-out and cut-in speeds When the speed of the operating pumps reaches the cut-in speed, a new pump is cut in. The pump starts at its start speed and accelerates until it reaches the speed of the operating pumps. This is called ramp up. When the speed of the operating pumps reaches the cut-out speed, a pump is cut out. The pump decelerates until it reaches its stop speed and stops. This is called ramp down. CHILLER CHILLER CHILLER T T M ZONE ZONE ZONE Q Q TM062399 4614 TM00 7995 2296 TM00 7996 2296 10

7.4 Control of the bypass valve The controller takes the characteristics of the bypass valve into consideration when adjusting the valve position. 7.4.1 Gamma There are two types of bypass valve: linear and equal percentage. Linear valves open linearly from 0 to 100 %, whereas equal percentage valves open exponentially. This exponential characteristic, called gamma, can be different from valve to valve, and the controller takes this into consideration when calculating the valve position. 7.4.2 Deadband When the differential pressure measured across the air-handling zones differs from the reference value, the controller adjusts the position of the bypass valve in order for the measured pressure to reach the reference. In order to prevent the bypass valve from opening and closing too frequently, which could wear the valve, the controller does not adjust the valve position within a certain deviation between the reference and the measured value. This deviation is called deadband. Example A system has three zone sensors with reference values of 2, 3 and 4 bar. If the deadband has been set to 0.4 bar, the bypass valve does not react when the measured value is between 3.6 and 4.4 bar. Note: The reference for the controller is the zone with the largest difference between its reference value and the its actual value. 7.4.3 Gain factor The gain factor determines how quickly the bypass valve reacts to a change in the differential pressure measured across the airhandling zones. The higher the gain factor, the faster the bypass valve reacts. A high gain factor may, however, result in a unstable system. 7.5 Controller reaction time The system includes a standard proportional-integral (PI) controller which ensures that the pressure is stable and corresponds to the setpoint. It involves two parameters that can be adjusted to obtain a faster or slower reaction to changes of consumption, i.e. the gain (Kp) and the integral time (Ti). To obtain a faster reaction, increase Kp and reduce Ti. To obtain a slower reaction, reduce Kp and increase Ti. Setting range of main controller Gain Kp: 0.5-20. Integral time Ti: 2 to 80 seconds. Setting range of pump controller Gain Kp: 0.5-100. Integral time Ti: 0.1 to 20 seconds. 7.6 Type key Example: Control HVAC 3x 0-13 3x380 Type 3R OPT Type range Number of pumps (2x - 8x) Current range of pumps in Ampere (A) Supply voltage Panel type: Type 3R (UL) or IP54 (IEC) OPT: Optional equipment. See the nameplate. 8. Operating the controller The front door of the cabinet hosts the user interface where you can read the system status and alarms, and change settings and operating modes. 8.1 Reading the system status To read the system status, press [Status] on the touchscreen. The table below describes the different elements that can be read on the status screen. Fig. 17 "Status" menu Text Mode R M Temp. 1 Temp. 2 Temp. 3 Flow rate Spec. energy System operating mode: "Remote", "Local" or "Off". See section 8.3.1 System modes. R: reference value Pumps: The pressure reference currently calculated by the controller for the pump system. Chillers: The minimum differential pressure required across the chiller in focus.* Zones: The pressure reference over the airhandling zone in focus.* M: measured value Pumps: The pressure delivered by the pump system. It is equal to the maximum pressure measured across all the chillers. Chillers: The pressure measured across the chiller in focus.* Zones: The pressure measured across the airhandling zone in focus.* The temperature measured at the booster outlet. A temperature sensor must be installed and activated in the "Configuration" menu. The temperature measured at the chiller outlet. A temperature sensor must be installed and activated in the "Configuration" menu. The temperature measured at the outlet of the airhandling zones. A temperature sensor must be installed and activated in the "Configuration" menu. The flow rate measured at the booster outlet. It is equal to the flow rate created by the booster system. A flow sensor must be installed at booster outlet and activated in the "Configuration" menu. The specific energy of the pump system if a flow sensor is installed at the booster outlet and has been activated in the "Configuration" menu. TM064539 2515 English (GB) 11

English (GB) Icon Bypass valve Pumps The position of the bypass valve as percentage of its maximum opening. 8.3 Operating modes You can manage the operating modes via the selector switches on the front panel and via the touchscreen. Chillers Zones Green icon and black text: The pump is running, and the measured speed is displayed as percentage of the maximum speed. Green icon and red text: The pump is switched off. Red icon: Alarm. Find more information about the alarm in the "Alarms" menu. Green with pipes at both ends: The chiller is on and is in focus.* The differential pressure measured across the chiller is displayed. Green without pipe: The chiller is on. The differential pressure measured across the chiller is displayed. Blue: The chiller is off. Blue with a cross: The chiller is off and not selected. Red: Alarm. Find more information about the alarm in the "Alarms" menu. Green with pipes at both ends: The air-handling zone is on and is in focus.* The measured differential pressure across the zone is displayed. Green without pipe: The zone is on. The differential pressure measured across the zone is displayed. Blue: The zone is off. Blue with a cross: The zone is off and is not selected. Red: Alarm. Find more information about the alarm in the "Alarms" menu. Fig. 18 "Operation" menu 8.3.1 System modes The table below describes the three system operating modes that can be activated with the system selector switch. Mode Auto/ Remote Manual/ Local Off The system operates according to the data collected by the controller. It can be controlled and monitored via the remote management system. The communication to the remote management system is deactivated. The controller operates according to the data configured via the touchscreen only. The user can set a manual setpoint for the pump system and can stop the pump system. The controller is switched off. It cannot be activated via the touchscreen nor by the remote management system. Note: The touchscreen is still on and settings can be changed. 8.3.2 Pump operating modes The table below describes the three pump operating modes that can be activated via the pump selector switches. Cabinets without pump selector switches are by default set to "Auto". TM064540 2515 * The air-handling zone in focus is the zone in operation with the highest differential pressure. The controller uses this pressure as a reference value for operating the pumps. The chiller in focus is the chiller with the greatest deviation between the minimum differential pressure required and the actual differential pressure. 8.2 Alarms 8.2.1 Reading alarms Press [Alarms] to read the alarms status. Press [Logs] to read the alarm log. If the controller registers an alarm for every chiller, it stops the pumps. 8.2.2 Resetting alarms 1. Press [Alarms]. 2. Select the row of the alarm you wish to reset. 3. Press [Reset]. If the alarm disappears, the controller removes the alarm record. Mode Auto Manual Off The pump is controlled by the internal pump controller and operates as part of the pump cascade system. The pump runs according to the settings set via the touchscreen. It can either start at a selected speed or stop. See section Setting the manual mode of pumps (cabinets with pump selector switches) on page 13. It is not controlled by the internal pump controller and therefore runs independently of the pump cascade system. The pump is switched off. It cannot be started via the touchscreen nor the remote management system. 12

Setting the manual mode of pumps (cabinets with pump selector switches) To operate the pump manually, you must configure the manual mode via the touchscreen: 1. Press [Operation]. 2. Press the pump icon. 3. Select "Start" or "Stop". 4. If you have selected "Start", enter a speed for the manual mode as percentage of the maximum speed. If you have selected "Stop", go to step 5. 5. Press [OK]. Setting the operating mode of the bypass valve 1. Press [Operation]. 2. Press the icon for the bypass valve. 3. Select the operating mode: "Auto", "Manual", "Off". 4. If you have selected "Auto" or "Off", go to step 5. If you have selected "Manual", enter a position between 0 and 100, i.e. the valve opening as percentage. 5. Press [OK]. In manual mode, the valve changes to the entered value. English (GB) TM064542 2515 Fig. 19 Setting the manual mode of pumps Operating the pump system in manual mode The pump system can be set to run in manual mode and can be stopped via the touchscreen. 1. Set the system selector switch to "Manual/Local". 2. Set all the pump selector switches to "Auto". Disregard this step if your cabinet does not have pump selector switches. 3. Press [Operation]. 4. Select "Start" if you want to start the pump system. Select "stop" if you want to stop the pump system. 5. In the field "R", enter the reference speed for the pump system as percentage of the maximum speed. 6. Press. If you have chosen "Start", the pump system starts and accelerates until it reaches the reference speed set in step 5. If you have chosen "Stop", the pump system stops. 8.3.3 Operating modes of the bypass valve The table below describes the three operating modes for the bypass valve that can be activated via the touchscreen. Mode Auto Manual Off The valve is controlled by the controller. The valve is not controlled by the controller, and its position is adjusted according to the manual position set via the touchscreen. The valve cannot be operated by the controller. TM064541 2515 Fig. 20 Setting the operating mode of the valve 8.4 Changing settings 8.4.1 Changing the controller clock See section 5.1.1 Setting the controller clock. 8.4.2 Changing pump cut-in and cut-out speed See section 5.1.2 Setting the pump cascade control. 8.4.3 Changing the controller gain and integral time For tuning the pump controller, see section 5.1.3 Tuning the controller. For tuning the main controller, see section 5.1.3 Tuning the controller. 8.4.4 Changing sensor fault signals This operation must be carried out by a person authorised by Grundfos. This operation must be carried out by a person authorised by Grundfos. This operation must be carried out by a person authorised by Grundfos. You can adjust the fault signals of the chiller and zone sensors. See section 5.1.10 Setting the chiller sensors and 5.1.11 Setting the zone sensors. 8.5 Locking and unlocking menus You can set two passwords to control the access to the following menus: Operation Configurations and settings See section 5.1.7 Locking menus. 13

English (GB) 8.6 Adding new components to the system This operation must be carried out by a person authorized by Grundfos. You can add pumps, chillers, zones and sensors to the system. See section 4.3 Electrical connection. See section 5. Commissioning. 8.6.1 Adding a subcabinet In order to add zones to your system, you may need to connect a new subcabinet to the main cabinet. Contact your local Grundfos sales company and use the product number below to order a new subcabinet. Product name Product number Kit set extension, I/O 98913800 Connect an EtherCAT cable from the free ethernet port of the EK1100 bus coupler to one of the ethernet ports of the subcabinet. Connect the zone sensors to the terminals of the subcabinet according to the wiring diagram delivered with the product. Note: The maximum cable length between cabinets is 100 m (328 feet). See section 12.3 I/O modules and terminals. 8.7 Adding new data communication system Contact your local Grundfos sales company in order to add a new communication system. 9.2 Repairing the product 9.2.1 Replacing parts Part Whom to contact Remarks Lithium battery for the controller clock Micro SD card I/O modules and terminals Controller including touchscreen Contact the nearest Beckhoff sales company. See www.beckhoff.com. Contact your local Grundfos sales company. Contact the nearest Beckhoff sales company. See www.beckhoff.com. Contact the nearest Beckhoff sales company. See www.beckhoff.com. The battery is located underneath the controller. See fig. 21. The micro SD hosts the Grundfos software. The card is located underneath the controller. See fig. 21. The product name of each terminal is written at the bottom of it. Follow the instructions below when ordering a new controller. 9.2.2 Ordering a new controller If your controller is defective, contact the nearest Grundfos sales company to order a new one. You will receive a serial number with the new controller. Keep it as you will have to place it on the new controller. 9. Servicing the product Use the URL or QR code below to download the complete service instructions. http://net.grundfos.com/qr/i/98800748 Warning Before starting work on the cabinets, pumps, bypass valve, etc., switch off the power supply. Lock the main switch with a padlock to ensure that the power supply cannot be accidentally switched on. 9.1 Maintaining the product In order to ensure that the system is operating efficiently and prevent any breakdowns, check the following items regularly. Backup battery Check that the backup battery of the controller is operational. After a few years, it may be necessary to replace the backup battery. See fig. 21. Contact the nearest Beckhoff sales company. See www.beckhoff.com. Selector switches Check that all selector switches on the front panel of the cabinet are operational. Test all switch positions. Alarms Check regularly the alarm list and fix the related problems: 1. Press [Alarm]. 2. Fix problems according to the alarm log, if any. 3. Reset each alarm and make sure that it has been removed from the list. See section 8.2.2 Resetting alarms. QR98800748 Note Do not discard the micro SD card of your controller. It contains the Grundfos firmware that you need for the new controller. 10. Taking the product out of operation Follow these instructions to take the Control HVAC out of operation and remove the cabinet. 1. Switch off all chillers. 2. Switch off all pumps. 3. Switch off the bypass valve. 4. Switch off the system by turning the main switch to position "0". Lock the switch in this position with a padlock. 5. Remove all cables connected to the main cabinet. The Control HVAC has now been taken out of operation and the cabinet can be removed. Warning The conductors in front of the main switch are still energised. Before starting any work on the cabinet, lock the switch with a padlock to ensure that the controller cannot be accidentally switched on. 14

11. Fault finding the product Warning Before starting work on the cabinets, pumps, bypass valve, etc., make sure that the power supply has been switched off. Lock the main switch with a padlock to ensure that the power supply cannot be accidentally switched on. English (GB) Fault Cause Remedy 1. The touchscreen is black. The power supply is switched on. 2. The Control HVAC has stopped and cannot be restarted. a) The LED next to the power connection of the controller is off. The controller is defective. b) The LED next to the power connection of the controller is yellow. Power supply failure. Contact your local Grundfos sales company for assistance in ordering a new controller. Check the power supply. a) System bug 1. Stop the chillers. 2. Switch off the power supply by means of the main switch on the cabinet. 3. Wait 20 seconds and switch on the power supply. 4. Start the chillers one at a time. b) The system selector switch on the front panel has been set to "Off". c) The remote management system is switched off. d) The pump selector switches on the front panel have been set to "Off". e) The external emergency switch has been set to "Off". f) The on/off chiller signal is not detected by the controller. All chiller icons are grey on the touchscreen. Chillers are switched off. g) The on/off chiller signal is not detected by the controller. All chiller icons are grey. The chillers are defective. h) The on/off chiller signal is not detected by the controller. All chiller icons are grey. The cables connecting the chillers to the main cabinet are defective. Set the system selector switch to "Manual/Local" or "Auto/ Remote", depending on your configuration. Switch on the remote management system or set the system selector switch on the front panel to "Manual/Local". Set the pump selector switches to "Auto". Set the external emergency switch to "On". Switch on the chillers one at a time. Check the power supply, isolating valve, contactor, etc. of the chiller. Check cables. Repair or replace defective cables. i) Cables are defective. Check cables. Repair or replace defective cables. j) Cables are short-circuited. Check cables. Repair or replace defective cables. Note: Short circuits can occur at the cable ends if wires are crossing each others. k) Voltage drop. The touchscreen may still be on, but the controller does not react properly. Check the power supply. 15

English (GB) Fault Cause Remedy 3. The bypass valve does not react. a) The operating mode of the bypass valve is "Manual" or "Off". b) The cables of the bypass valve are defective. c) The cables of the bypass valve are short-circuited. d) The feedback signal of the bypass valve is inaccurate. To find out whether the feedback is inaccurate, test the bypass valve manually. See section 5.2.2 Testing the bypass valve. 1. Set the bypass valve to "Auto": 2. Press [Operation]. 3. Press the icon for the bypass valve. 4. Select "Auto". 5. Press [Save]. Check cables. Repair or replace defective cables. Check cables. Repair or replace defective cables. Note: Short circuits can occur at the cable ends if wires cross each others. Replace the bypass valve. e) No power supply to the bypass valve. Check the power supply. f) The fuse of the bypass valve has blown. Replace the fuse. g) The motor of the bypass valve is defective. To find out whether the motor is defective, connect an external power supply to the motor. It may be necessary to remove the cover of the bypass valve. Replace the bypass valve. 4. No sensor signal a) The sensor is not connected properly. Connect the sensor according to the wiring diagram delivered with the sensor and the Control HVAC. Make sure the sensor cable is correctly connected to the terminal in the cabinet. Note: Most differential-pressure sensors must to be connected to a 24 V supply, whereas most flow meters must to be connected to 0 V. b) The sensor cable is defective. Depending on the terminal, the LED of the related sensor is red or off. See section 12.3 I/O modules and terminals. Check cables. Repair or replace defective cables. 5. Irrational sensor signal c) The sensor is defective. Depending on the terminal, the LED of the related sensor is red or off. See section 12.3 I/O modules and terminals. d) Cables are short-circuited. Check cables. Repair or replace defective cables. Note: Short circuits can occur at the cable ends if wires are crossing each others. e) The I/O module is defective. The sensor and the cable are intact. a) The sensor is connected to the wrong terminal. b) The sensor is defective and sends irrational signal to the controller, for instance the measured flow decreases when the pumps speed increase. Contact the nearest Beckhoff sales company for assistance in replacing the I/O module. See www.beckhoff.com. Connect the sensor to the correct terminal according to the wiring diagram delivered with the Control HVAC. Replace the sensor. 16

Fault Cause Remedy 6. The pump does not start. 7. The pump does not operate correctly. 8. The pump has stopped and does not restart. a) The pump selector switch on the front panel has been set to "Off. b) The cable connecting the E-pumps/CUE/ VFD to the controller is defective (the E- pump/cue/vd does not detect the start/ stop signal sent by the controller) c) Version with VFD: The LED of the I/O module is on when the controller sends a start signal, but the VFD does not detect the start/stop signal sent by the controller. d) Version with VFD: The corresponding EL2008 module is defective. The LED is not on when the controller sends a start signal to the VFD. Set the pump selector switch to "Auto". Check cables. Repair or replace defective cables. Check cables. Repair or replace defective cables. Contact the nearest Beckhoff sales company for assistance in replacing the I/O module. See www.beckhoff.com. e) The external pump emergency switch is Check the external emergency switch. defective, if any. f) The E-pump and CUE or VFD are not Check the power supply to the E-pump and CUE or VFD. supplied with power. g) Cables are defective. Check cables. Repair or replace defective cables. h) Cables are short-circuited. Check cables. Repair or replace defective cables. Note: Short circuits can occur at the cable ends if wires are crossing each others. i) The pump is defective. To find out if the pump is defective, test it in manual mode. See section 5.2.3 Testing the pumps. Repair or replace the pump. For E-pumps and CUE, contact your local Grundfos sales company. j) System bug 1. Stop the chillers. 2. Switch off the power supply by means of the main switch on the cabinet. 3. Wait 20 seconds and switch on the power supply. 4. Start the chillers one at a time. k) The relay inside the cabinet is defective. Replace the relay. l) The pump selector switch on the front panel has been set to "Manual", and the manual mode defined via the touchscreen has been set to "Stop". a) The E-pump and the CUE or VFD are not configured correctly, for instance with incorrect minimum and maximum speed. a) The controller has registered an alarm and stopped the pumps. If you want to operate the pump in manual mode, set the manual mode to "Start". See section 5.2.3 Testing the pumps. If not, set the pump selector switch to "Auto". Check the settings of the E-pump and CUE or VFD. See the "Alarms" menu. Fix the problem if needed. Reset the alarm and check that it has been removed from the list. See section 8.2.2 Resetting alarms. English (GB) 17