GRUNDFOS INSTRUCTIONS. UPE Series 2000 UPE(D) FZ, UPE FZ. Installation and operating instructions

GRUNDFOS INSTRUCTIONS UPE Series 2000 UPE(D) 80-120 FZ, UPE 100-120 FZ Installation and operating instructions

UPE Series 2000 Declaration of Conformity.......................................... 4 English (GB) Installation and operating instructions................................. 5 Deutsch (DE) Montage- und Betriebsanleitung.................................... 27 Appendix 1.................................................... 52 Table of contents 3

Declaration of conformity Declaration of Conformity GB: EC declaration of conformity We, Grundfos, declare under our sole responsibility that the products UPE(D) Series 2000, to which this declaration relates, are in conformity with these Council directives on the approximation of the laws of the EC member states: Machinery Directive (2006/42/EC). Standard used: EN 809: 2009. Low Voltage Directive (2006/95/EC). Standards used: EN 60335-1: 2002 and EN 60335-2-51: 2003. EMC Directive (2004/108/EC). Standard used: EN 61800-3. DE: EG-Konformitätserklärung Wir, Grundfos, erklären in alleiniger Verantwortung, dass die Produkte UPE(D) Series 2000, auf die sich diese Erklärung bezieht, mit den folgenden Richtlinien des Rates zur Angleichung der Rechtsvorschriften der EU-Mitgliedsstaaten übereinstimmen: Maschinenrichtlinie (2006/42/EG). Norm, die verwendet wurde: EN 809: 2009. Niederspannungsrichtlinie (2006/95/EG). Normen, die verwendet wurden: EN 60335-1: 2002 und EN 60335-2-51: 2003. EMV-Richtlinie (2004/108/EG). Norm, die verwendet wurde: EN 61800-3. Bjerringbro, 15th March 2011 Svend Aage Kaae Technical Director Grundfos Holding A/S Poul Due Jensens Vej 7 8850 Bjerringbro, Denmark Person authorised to compile technical file and empowered to sign the EC declaration of conformity. 4

English (GB) Installation and operating instructions Original installation and operating instructions. CONTENTS Page 1. Symbols used in this document 5 2. General description 5 3. Applications 6 3.1 Pumped liquids 6 4. Installation 6 4.1 Positioning the pump 6 4.2 Mounting the pressure sensor 6 4.3 Control box positions 6 4.4 Twin-head pumps 7 4.5 Non-return valve 7 4.6 Insulation 7 4.7 Frost protection 7 5. Electrical connection 7 5.1 Ferrite core 7 5.2 Wiring diagram 8 6. Start-up 9 6.1 Venting the pump 9 7. Functions 10 7.1 Control modes 10 7.2 Control of twin-head pumps 10 7.3 Selection of control mode 11 7.4 Max. or min. curve duty 12 7.5 Constant-curve duty 12 7.6 Temperature influence 13 7.7 Indicator lights 13 7.8 External fault indication 14 7.9 External analog 0-10 V controller 14 7.10 External forced control 15 7.11 Deactivating the control panel 15 7.12 Bus communication 15 7.13 Remote control 15 8. Setting the pump 16 8.1 Factory settings 16 8.2 Control panel 16 8.3 R100 18 8.4 Menu OPERATION 20 8.5 Menu STATUS 20 8.6 Menu INSTALLATION 21 8.7 Priority of settings 22 9. Fault finding 23 10. Megging 24 10.1 Megging of UPE pumps 24 10.2 High-voltage test 24 11. Service kits 25 12. Technical data 26 13. Disposal 26 1. Symbols used in this document Caution Note Warning Prior to installation, read these installation and operating instructions. Installation and operation must comply with local regulations and accepted codes of good practice. Warning The use of this product requires experience with and knowledge of the product. Persons with reduced physical, sensory or mental capabilities must not use this product, unless they are under supervision or have been instructed in the use of the product by a person responsible for their safety. Children must not use or play with this product. Warning If these safety instructions are not observed, it may result in personal injury! If these safety instructions are not observed, it may result in malfunction or damage to the equipment! Notes or instructions that make the job easier and ensure safe operation. 2. General description The Grundfos UPE(D) FZ is a range of circulator pumps with differential-pressure control enabling adjustment of the pump performance to the actual system requirements. In many systems, this will reduce the power consumption considerably, reduce noise from thermostatic valves and similar fittings, and improve the control of the system. The desired head can be set on the pump control panel. These instructions apply to the pump types UPE(D) 80-120 FZ and UPE 100-120 FZ. The pump offers the following functions: Proportional-pressure control (factory setting). The pump head is changed in accordance with the flow demand. The desired head can be set on the pump control panel. Constant-pressure control. A constant head is maintained, irrespective of the flow demand. The desired head can be set on the pump control panel. Constant-curve duty. The pump runs at a constant speed on or between the max. and min. curves. English (GB) 5

English (GB) Temperature influence. The pump head varies depending on the liquid temperature. External fault signal via a potential-free output. External analog control of head or speed from an external 0-10 V signal transmitter. External forced control via inputs for start/stop min. curve. Bus communication. The UPE(D) FZ circulator pumps incorporate an input for bus communication. The pump can be controlled and monitored by a building management system. Remote control. The pump can be operated with the Grundfos R100 remote control. 3. Applications The UPE(D) FZ circulator pumps are designed for circulating liquids in heating systems. The UPE(D) FZ range is suitable for systems with a constant flow where it is desirable to optimise the setting of the pump duty point. systems with variable flow-pipe temperatures. 3.1 Pumped liquids Thin, clean, non-aggressive and non-explosive liquids, not containing solid particles, fibres or mineral oil. In heating systems, the water should meet the requirements of accepted standards on water quality in heating systems, for example the German standard VDI 2035. 4.2 Mounting the pressure sensor Mount the pressure sensor only after Note the pump has been installed in the system. See fig. 1. 1. Place the O-ring in the seat of the pump housing. 2. Place the sensor housing without damaging the O-ring. 3. Fit and tighten the two screws. Fig. 1 Mounting the pressure sensor 4.3 Control box positions Note The control box must only be turned to the positions shown on page 310. The arrows show the allowed/possible flow directions. 4.3.1 Changing the control box position Warning Before any dismantling of the pump, the system must be drained, or the isolating valves on either side of the pump must be closed, as the pumped liquid may be scalding hot and under high pressure. TM04 4631 1809 Warning The pump must not be used for the transfer of flammable liquids, such as diesel oil, petrol or similar liquids. 4. Installation 4.1 Positioning the pump The arrow on the pump housing indicates the liquid flow direction through the pump. Warning Make sure that persons cannot accidentally come into contact with the hot surfaces of the pump. The pump must be installed with the motor shaft horizontal. See mounting dimensions at the end of these instructions. Fig. 2 Correct control box position Change the control box position as follows: 1. Slacken the cable clamp of the pressure sensor. 2. Remove the four screws holding the pump head. 3. Turn the pump head to the desired position. 4. Refit the four screws and tighten securely. 5. Adapt the pressure sensor cable, and tighten the cable clamp. Warning Make sure that the pressure sensor cable cannot come into contact with the pump head. TM04 4633 1809 6

4.4 Twin-head pumps Twin-head pumps offer these operating modes: alternating operation standby operation synchronous operation single-pump operation. 4.4.1 Master pump and slave pump The master pump will always be the pump to the right when seen from the control box end and the pump is pumping upwards. See fig. 3, pos. 1. Fig. 3 Master pump (1) and slave pump (2) 4.5 Non-return valve If a non-return valve is fitted in the pipe system (fig. 4), it must be ensured that the minimum discharge pressure is always higher than the closing pressure of the valve. This is especially important in proportional-pressure control mode (reduced head at low flows). TM04 4629 1809 5. Electrical connection The electrical connection and protection must be carried out according to local regulations. Warning Never make any connections in the pump control box unless the power supply has been switched off for at least 5 minutes. The indicator light must be off. See fig. 6, pos. 21. The earth terminal of the pump must be earthed. The pump must be connected to an external mains switch with a minimum contact gap of 3 mm in all poles. Earthing or neutralisation can be used for protection against indirect contact. Megging must be carried out as described in section 10. Megging. If the pump is connected to an electric installation where an earth leakage circuit breaker (ELCB) is used as an additional protection, this circuit breaker must trip out when earth fault currents with DC content (pulsating DC) and smooth DC earth fault currents occur. The earth leakage circuit breaker must be marked with these symbols: English (GB) Fig. 4 Non-return valve TM02 0640 0301 The pump requires no external motor protection. Check that the supply voltage and frequency correspond to the values stated on the pump nameplate. 5.1 Ferrite core Install the ferrite core as shown below. 4.6 Insulation If the pump is insulated without using Grundfos insulating kits, it must be ensured that the differential-pressure and temperature sensor in the pump housing is not covered. 4.7 Frost protection If the pump is not being used during periods of frost, the necessary steps must be taken to prevent frost bursts. TM04 9584 4610 Fig. 5 Ferrite core installed 7

English (GB) 5.2 Wiring diagram TM04 4634 4709 Fig. 6 Internal view of the control box Pos. Description A, Y, B Terminal block for GENIbus T Terminal block for twin-head pump D Terminal block for pressure and temperature sensor on the pump (standard) 1, 2 (START/STOP) 3, 4 (MIN.) Terminals for external start/stop (connect only contacts with no voltage) Terminals for min. curve input (connect only contacts with no voltage) Terminals for external analog input 0-10 VDC 5, 6 (0-10 V) Terminal 5 = +10 V Terminal 6 = 0 V 7, 8 (ALARM) Terminal block for remote alarm contact. Maximum load: 250 VAC, 5 A. 9, 10, 11 Terminals for supply voltage, 1 x 230 V, 50-60 Hz Terminal 9 = Line (L) Terminal 10 = Earth ( ) Terminal 11 = Neutral (N) Terminals for connection of motor cables 12, 13, 14 Terminal 12 = brown lead Terminal 13 = grey lead Terminal 14 = black lead 15 Motor earthing screw 16, 17 Terminals for connection of motor protector, white lead (T1, T2) 18 Terminal for control panel 8

19 Control panel retaining screws 20 Terminal for fan 21 High-voltage indicator 22 Terminal for screened motor cable 23 Fan Note: All cables used must be heat-resistant up to at least +85 C. All cables used must be installed in accordance with EN 60204-1. Warning Wires connected to outputs 7 and 8, inputs 1 to 6, supply terminals and differential-pressure and temperature sensor must be separated from each other and from the supply by reinforced insulation. All wires connected to a terminal block must be tied up at the terminals. Concerning demands on signal wires and signal transmitters, see section 12. Technical data. 6. Start-up Do not start the pump until the system has been filled with liquid and vented. Furthermore, the required minimum inlet pressure must be available at the pump inlet. See section 12. Technical data. Note The system cannot be vented through the pump. 6.1 Venting the pump Vent the pump before start-up. See fig. 7. Warning When the vent screw is slackened, scalding hot liquid under high pressure may escape. Care must be taken to ensure that the escaping liquid does not cause personal injury or damage to other components. English (GB) Vent screw TM04 4635 1809 - TM04 4636 1809 Fig. 7 Venting the pump The pump may be noisy, when first switched on, due to air remaining in the pump. This noise should cease after a few minutes running. After start-up, set the desired operating mode and possibly pump head. 9

English (GB) 7. Functions Some functions can only be selected with the Grundfos R100 remote control. Where and how the various settings are made appear from section 8. Setting the pump. 7.1 Control modes The UPE(D) FZ pumps can be set to the control mode which is most suitable for the individual system. Two control modes are available: proportional pressure (factory setting) constant pressure. Proportional-pressure control To be set on the control panel or with the R100. The pump head is reduced at falling water demand and increased at rising water demand. See fig. 8. This is the factory setting as, in most cases, this is the optimum control mode, and at the same time it consumes the least energy. Constant-pressure control To be set on the control panel or with the R100. The pump maintains a constant pressure, irrespective of water demand. See fig. 8. H set H H set 2 Fig. 8 Pressure control 7.2 Control of twin-head pumps The factory setting can be changed with the R100. Fig. 9 Proportional pressure Slave pump Q H H set Constant pressure Master pump Master and slave pumps Q TM00 5546 4596 TM04 4629 1809 Four operating modes are available. The selection of operating mode depends on whether reliability, lifetime or performance has top priority. Alternating operation (factory setting). Pump operation alternates every 24 hours. If the power supply to the pump has been switched off, any of the pumps may start when the power supply is switched on again. Reaction in case of fault: In case of fault in one pump, the duty pump will operate continuously as a single-head pump. Standby operation. The master pump is operating continuously. Every 25 hours the slave pump will start and run for approx. 10 seconds to prevent it from seizing up. Reaction in case of fault: If the master pump stops due to a fault, the slave pump will operate continuously as a single-head pump. Synchronous operation. The pumps are operating at the same motor frequency. This operating mode is suitable if the flow demand exceeds the flow of one pump. Reaction in case of fault: In case of fault in one pump, the duty pump will operate continuously as a single-head pump. Single-pump operation. The pumps are operating completely independently of each other without internal communication, but the twin-head cable must be connected. All functions of each pump are identical to those of a single-head pump. All the other functions mentioned in sections 7.1 Control modes to 7.13 Remote control are possible in the four operating modes. 7.2.1 Why select single-pump operation Select single-pump operation when the twin-head pump is to be controlled or monitored by a Grundfos pump management system. in all other situations where the master and slave pumps are to operate independently of each other as two single-head pumps. 7.2.2 R100 remote control Single-pump operation is to be selected with the R100. See section 8.6.6 Twin-head pump. 7.2.3 Operation in parallel In single-head operation mode, the pumps must never run at the same time, unless the pump is controlled by a Grundfos pump management system. 7.2.4 Setting the slave pump When single-pump operation mode has been selected, the slave pump settings will correspond to the settings of the last working pump. 10

7.3 Selection of control mode Systems with specified control mode If the pump control mode (proportional or constant pressure) and head have been specified for the system in which the pump is to be installed, set the pump as specified. See section 8. Setting the pump. If problems should arise, see section 9. Fault finding. Systems with no specified control mode If the pump control mode and head have not been specified for the system (for instance, an uncontrolled standard pump is replaced by the UPE pump), it is advisable to use the settings in the table below and in section 7.3.1 Setting in connection with pump replacement. English (GB) System type 1. Relatively great head losses in the boiler circuit and the distribution pipes. 2. Relatively small head losses in the boiler circuit and the distribution pipes. Description a) Two-pipe heating systems with thermostatic valves and with a dimensioned pump head higher than 4metres, very long distribution pipes, strongly throttled pipe balancing valves, differential pressure regulators, great head losses in those parts of the system through with the total quantity of water flows (for example boiler, heat exchanger and distribution pipe up to the first branching) or low differential temperature. b) Underfloor heating systems and one-pipe heating systems with thermostatic valves and great head losses in the boiler circuit. c) Primary circuit pumps in systems with great head losses in the primary circuit. a) Two-pipe heating systems with thermostatic valves and with a dimensioned pump head lower than 2metres, dimensioned for natural circulation, small head losses in those parts of the system through with the total quantity of water flows (for example boiler, heat exchanger and distribution pipe up to the first branching) or modified to a high differential temperature (for example district heating). b) Underfloor heating systems with thermostatic valves. c) One-pipe heating systems with thermostatic valves or pipe balancing valves. d) Primary circuit pumps in systems with small head losses in the primary circuit. Select this control mode Proportional pressure Constant pressure 11

English (GB) 7.3.1 Setting in connection with pump replacement If an uncontrolled pump is to be replaced with a UPE(D) FZ pump, settings can be made according to the tables below. Existing pump Existing pump at maximum speed UPE(D) FZ Existing pump Existing pump at reduced speed UPE(D) FZ Maximum head [m] Setting of head [m] Setting of control mode Read the tables as follows: If the maximum head of the existing pump is 6 metres and the pump is running at maximum speed under normal operating conditions, it is recommended to set the pump to 3 metres and to select proportional pressure. If, however, the existing pump is running at a reduced speed, it is recommended to set the pump to 2 metres and to select constant pressure. 7.4 Max. or min. curve duty To be set on the control panel, with the R100 or a building management system via bus. It is not possible to set max. curve duty via the external input. The pump can be set to operate according to the max. or min. curve, like an uncontrolled pump. See fig. 10. Maximum head [m] The max. curve mode can be selected if an uncontrolled pump is required. See section 8.2 Control panel. In this operating mode, the pump will operate independently of an external controller, if installed. The min. curve mode can be used in periods in which a minimum flow is required. This operating mode is for instance suitable for night-time duty. 7.5 Constant-curve duty To be set with the R100. The pump can be set to operate according to a constant curve, like an uncontrolled pump. Select one of the curves between the max. and min. curves. See fig. 11. Fig. 11 Setting of head [m] Constant-curve duty Setting of control mode 3 2 Constant pressure 3 1.5 Constant pressure 4 2 Constant pressure 4 1.5 Constant pressure 5 2.5 Proportional pressure 5 2 Constant pressure 6 3 Proportional pressure 6 2 Constant pressure 7 3.5 Proportional pressure 7 2.5 Proportional pressure 8 4 Proportional pressure 8 3 Proportional pressure 9 4.5 Proportional pressure 9 3.5 Proportional pressure 10 5 Proportional pressure 10 3.5 Proportional pressure 11 5.5 Proportional pressure 11 4 Proportional pressure 12 6 Proportional pressure 12 4 Proportional pressure H Min. Max. Q TM00 5547 4596 H Min. Max. Q TM00 5548 4596 Fig. 10 Max. and min. curves 12

7.6 Temperature influence To be set with the R100. When temperature influence is activated in proportional- or constant-pressure control mode, the setpoint for head will be reduced according to the liquid temperature. It is possible to set temperature influence to function at liquid temperatures below 80 C or below 50 C. These temperature limits are called T max.. The setpoint is reduced in relation to the head set (= 100 %) according to the characteristics below. H 100 100% % H actual 3030% % 20 Fig. 12 Temperature influence In the above example, T max. = 80 C has been selected. The actual liquid temperature T actual causes the setpoint for head to be reduced from 100 % to H actual. The temperature influence function requires: Proportional- or constant-pressure control mode. The pump must be installed in the flow pipe. System with flow-pipe temperature control, for example according to outdoor temperature. Temperature influence is suitable in systems with variable flows (for example two-pipe heating systems) in which the activation of the temperature influence function will ensure a further reduction of the pump performance in periods with small heating demands and consequently a reduced flow-pipe temperature. systems with almost constant flows (for example one-pipe heating systems and underfloor heating systems) in which variable heating demands cannot be registered as changes in the head as is the case with two-pipe heating systems. In such systems, the pump performance can only be adjusted by activating the temperature influence function. Selection of T max. In systems with a flow-pipe temperature of up to and including 55 C, select T max. = 50 C. above 55 C, select T max. = 80 C. H 50 80 t [ C] T actual Q TM01 0626 1797 7.7 Indicator lights The two indicator lights are used for fault and operating indication. For position on pump (fig. 14), see section 8.2 Control panel. Note When the R100 remote control communicates with the pump, the red indicator light will flash rapidly. Functions of indicator lights Indicator lights Fault (red) Off Off Off Permanently on Permanently on Permanently on Operation (green) Off Permanently on Flashing Off Permanently on Flashing See also section 9. Fault finding. Description The power supply has been switched off. The pump is operating. The pump has been set to stop. The pump has stopped due to a fault. Restarting will be attempted. It may be necessary to restart the pump manually by resetting the fault indication. The pump is operating, but it has been stopped due to a fault. Note: If there is no differential-pressure or temperature sensor signal, the pump will continue operating according to the max. curve. The pump has been set to stop, but it has been stopped due to a fault. English (GB) 13

English (GB) 7.8 External fault indication The pump incorporates a signal output for a potential-free fault signal via terminals 7 and 8. Functions of signal output Signal output 7 8 7 8 7 8 Description The power supply has been switched off. The pump is operating. The pump has been set to stop. 7.9 External analog 0-10 V controller The pump has an input for an external 0-10 VDC analog signal transmitter (terminals 5 and 6). Via this input, the pump can be controlled by an external controller if the pump has been set to this control mode: Constant curve. The external analog signal will set the pump curve within the range from the min. curve to the constant curve selected according to the characteristic in fig. 13. At an input voltage lower than 0.5 V, the pump will operate according to the min. curve. The setpoint cannot be changed. The setpoint can only be changed when the input voltage is higher than 0.5 V. H m 1 2 7 8 7 8 7 8 The pump has stopped due to a fault. Restarting will be attempted. It may be necessary to restart the pump manually by resetting the fault indication. The pump is operating, but it has been stopped due to a fault. Note: If there is no differential-pressure or temperature sensor signal, the pump will continue operating according to the max. curve. The pump has been set to stop, but it has been stopped due to a fault. The fault signal output is activated when the pump registers a fault. The fault signal relay is activated together with the red indicator light on the pump. Resetting of fault indications A fault indication can be reset in one of the following ways: Briefly press or on the pump. This will not influence the pump performance set. Briefly switch off the power supply to the pump. With the R100. See section 8.3 R100. The fault indication cannot be reset until the cause of the fault has disappeared. 0 Fig. 13 Pos. Constant curve Description 1 Maximum head/constant curve 2 Head set/constant curve Note Min. curve 1 2 3 4 5 6 8 9 10 The min. curve input, terminals 3 and 4, must be short-circuited. 7 U V TM03 1648 2505 14

7.10 External forced control The pump incorporates inputs for external signals for the forced-control functions: start/stop of pump (terminals 1 and 2) min. curve duty (terminals 3 and 4). During forced control, the light fields or indicator lights on the pump will show which function is active. Functional diagram: Start/stop input H H Functional diagram: Min. curve input The min. curve input is only active if the start/stop input is short-circuited. H H Start/stop Q Q Min. curve Q Q Normal duty Stop Normal duty Min. curve (night-time duty) 7.11 Deactivating the control panel To be set with the R100. The buttons on the pump control panel can be deactivated to prevent unauthorised persons from operating the pump. 7.12 Bus communication The pump has a serial communication port which enables communication with the Grundfos Control MPC Series 2000, a CIM/CIU communication interface, a building management system or another type of external control system. If a CIU unit is installed in the system, it is possible to establish communication between the pump and a main network via one of the following protocols: LON Profibus DP Modbus RTU BACnet MS/TP. For further details, see the installation and operating instructions for the CIM and CIU. Via the bus signal, it is possible to remote-set pump operating parameters, such as desired head, temperature influence and operating mode. At the same time, the pump can provide status information about important parameters, such as actual head, actual flow, power input and fault indications. Note When the pump is controlled via a bus signal, the number of settings available on the pump control panel or via the R100 will be reduced. The pump head and control mode can only be set via the bus signal. The pump control panel or the R100 can only set the pump to max. curve and to stop. However, an R100 is required if a number is to be allocated to the pump. See sections 8.6.5 Pump number and 8.7 Priority of settings. 7.13 Remote control The pump is designed for wireless communication with the Grundfos R100 remote control. The R100 communicates with the pump via infrared light. During communication, the R100 must be pointed at the pump control panel. When the R100 is communicating with the pump, the red indicator light will flash rapidly. The R100 offers additional setting options and status displays for the pump. See section 8.3 R100. English (GB) 15

English (GB) 8. Setting the pump For the setting of the pump, use control panel R100 remote control bus communication (not described in detail in these instructions. Contact Grundfos). The table below shows the application of the individual operating units and in which section the function has been described. Function Control panel R100 8.2 Control panel Warning At high liquid temperatures, the pump may be so hot that only the buttons should be touched to avoid burns. The control panel (fig. 14) incorporates buttons for setting, and. light fields, yellow, for indication of control mode and pump head. indicator lights, green and red, for operating and fault indication. See section 7.7 Indicator lights. Buttons Proportional-pressure control 8.2.1 8.6.1 Constant-pressure control 8.2.1 8.6.1 Setting of pump head 8.2.2 8.4.1 Max. curve duty 8.2.3 8.4.2 Min. curve duty 8.2.4 8.4.2 Constant-curve duty - 8.4.2 Temperature influence - 8.6.3 Resetting of fault indications 8.2.6 8.4.3 Activation/deactivation of pump buttons - 8.6.4 Allocation of pump number - 8.6.5 Reading of various data - 8.5.1-8.5.7 Start/stop 8.2.5 8.4.2 "-" = not available with this operating unit. 8.1 Factory settings Control mode Head Control of twin-head pump UPE(D) 80-120 FZ Proportional pressure 6 m at max. flow. See fig. 14. Alternating operation UPE 100-120 FZ Proportional pressure 6 m at max. flow. See fig. 14. - Light fields Indicator lights Fig. 14 Control panel 8.2.1 Control mode setting Description of function, see section 7.1 Control modes. When and are pressed simultaneously, the light fields will indicate the selected control mode: Light fields Top + bottom light fields flashing Middle light fields flashing None of the light fields are on Control mode Proportional pressure Constant pressure Constant curve If the buttons are pressed for more than 5 sec., the control mode will change over to constant pressure and proportional pressure respectively. This means that constant-curve duty is deactivated if selected with the R100. TM04 4693 1809 16

8.2.2 Setting of pump head The desired pump head is set by pressing or. The light fields on the control panel will indicate the head set. The scaling is set to be approx. 1.2 metres per light field. The table below shows examples of pump head settings indicated by the light fields. English (GB) Constant-pressure control Proportional-pressure control H m H m UPE 100-120 FZ UPE(D) 80-120 FZ 12 0 Light fields 5 and 6 are activated, indicating a desired head of approx. 6.5 metres. Q TM04 5871 4209 12 0 Light fields 5 and 6 are activated, indicating a desired head of approx. 6.5 metres. Q TM04 5870 4209 17

English (GB) 8.2.3 Setting to max. curve duty Description of function, see section 7.4 Max. or min. curve duty. Press continuously to change over to the max. curve of the pump (top light field flashes). See fig. 15. To change back, press continuously until the desired head is indicated. H m 12 10 8 6 4 2 1 0 Fig. 15 Max. curve duty 8.2.4 Setting to min. curve duty Description of function, see section 7.4 Max. or min. curve duty. Press continuously to change over to the min. curve of the pump (bottom light field flashes). See fig. 16. To change back, press continuously until the desired head is indicated. H m 12 10 8 6 4 2 1 0 Fig. 16 Q Min. curve duty Q TM04 4695 1909 TM04 4696 1909 8.2.5 Start/stop of pump Stop the pump by continuously pressing until none of the light fields are activated. When the pump is stopped, the green indicator light will be flashing. Start the pump by continuously pressing until the desired head is indicated. If the pump is to be inoperative for a period, it is recommended to use the start/stop input, the R100 or to switch off the power supply. In this way, the pump head setting will remain unchanged when the pump is to be started again. 8.2.6 Resetting of fault indications To reset fault indications, briefly press or. This will not influence the pump performance set. If the fault has not disappeared, the fault indication will reappear. 8.3 R100 The pump is designed for wireless communication with the Grundfos R100 remote control. The R100 communicates with the pump via infrared light. During communication, the R100 must be pointed at the pump control panel. When the R100 is communicating with the pump, the red indicator light will flash rapidly. The R100 offers additional setting options and status displays for the pump. The R100 displays are divided into four parallel menus. See fig. 17: 0. GENERAL, see operating instructions for the R100 1. OPERATION 2. STATUS 3. INSTALLATION The number stated at each individual display in fig. 17 refers to the section in which the display is described. 18

English (GB) 0. GENERAL 1. OPERATION 2. STATUS 3. INSTALLATION 8.4.1 8.5.1 8.6.1 8.4.2 8.5.2 8.6.2 8.4.3 8.5.3 8.6.3 8.5.4 8.6.4 8.5.5 8.6.5 8.5.6 8.6.6 8.5.7 Fig. 17 Menu overview 19

English (GB) 8.4 Menu OPERATION When the communication between the R100 and the pump has been established, "Contact with" appears in the display. When the "arrow down" on the R100 is pressed, the OPERATION menu appears. Note The display "Contact with" appears only once, i.e. when the R100 gets contact with the pump. 8.4.1 Setpoint This display depends on the control mode selected in the display "Control mode" in the INSTALLATION menu. If the pump is remote- or forced-controlled via external signals, the number of possible settings will be reduced. See section 8.7 Priority of settings. Attempts to change the settings will result in an indication in the display saying that the pump is remote-controlled and that changes therefore cannot be made. The following example of display will appear if the pump is in proportional-pressure control mode. 8.4.3 Fault indications If the pump is faulty, the cause will appear in this display. Possible causes: Phase failure Pump blocked Undervoltage Defective pressure/temperature sensor Internal fault. The fault indication can be reset in this display. If the fault cause has not disappeared when resetting is attempted, this will be indicated in the display. 8.5 Menu STATUS The displays appearing in this menu are status displays only. It is not possible to change or set values. The actual values in these displays are stated as a guide. 8.5.1 Actual setpoint Set the desired head. Furthermore, it is possible to select one of these operating modes: Stop Min. (min. curve) Max. (max. curve). This display will be a little different in the case of constant-pressure control or constant-curve duty. The actual duty point of the pump is indicated by a square in the Q/H field. No indication at low flow. 8.4.2 Operating mode Field "Actual setpoint": Actual setpoint of pump. Field "corresponding to": Actual setpoint in % of the setpoint set if the pump is connected to an external analog 0-10 V signal transmitter or if temperature influence or proportional-pressure control is activated. 8.5.2 Operating mode Select an operating mode: Stop Min. (min. curve) Normal (proportional pressure, constant pressure or constant curve) Max. (max. curve). This display shows the actual operating mode (Stop, Min., Normal or Max.) and where this was selected (Pump, R100, Bus or External). 20

8.5.3 Head and flow 8.6 Menu INSTALLATION In this menu, the settings are chosen that should be considered when installing the pump. 8.6.1 Control mode Description of function, see section 7.1 Control modes or 7.5 Constant-curve duty. English (GB) Very low flows cannot be registered, and the R100 will show "<" in front of the lowest possible flow value of the pump in question. 8.5.4 Speed The actual pump speed. 8.5.5 Liquid temperature Select a control mode: Prop. pressure (proportional pressure), Const. pressure (constant pressure), Const. curve (constant curve). Setting of setpoint and curve is carried out in display 8.4.1 Setpoint in the OPERATION menu. 8.6.2 Min. curve This display does not apply to UPE(D) 80-120 FZ and UPE 100-120 FZ. Description of function, see section 7.4 Max. or min. curve duty. The actual temperature of the pumped liquid. 8.5.6 Power input and power consumption This display does not apply to UPE(D) 80-120 FZ and UPE 100-120 FZ. Actual power input and power consumption of the pump. Power consumption is not calculated in UPE(D) 80-120 FZ and UPE 100-120 FZ. 8.5.7 Operating hours In this display, it is possible to choose between two min. curves. The curve is used when the operating mode "Min. curve" is selected. When controlling UPE(D) 80-120 FZ and UPE 100-120 FZ, only one min. curve is available. 8.6.3 Temperature influence Description of function, see section 7.6 Temperature influence. Number of operating hours of the pump. The value of operating hours is an accumulated value and cannot be set to zero. The temperature influence function can be activated in this display. In the case of temperature influence, the pump must be installed in the flow pipe. It is possible to choose between maximum temperatures of 50 C and 80 C. The temperature influence function will be active only in proportional- or constant-pressure control mode. When the temperature influence is active, a small thermometer is shown in the display "Setpoint" in the OPERATION menu. See section 8.4.1 Setpoint. 21

English (GB) Note If the pump is controlled via bus, temperature influence cannot be set with the R100. 8.6.4 Buttons on pump 8.7 Priority of settings The external forced-control signals will influence the settings available on the pump and with the R100. The pump can always be set to max. curve duty or to stop on the pump control panel or with the R100. If two or more functions are activated at the same time, the pump will operate according to the function with the highest priority. The priority of the settings is as shown in the tables below. Without bus signal To prevent unauthorised persons from operating the pump, the function of the buttons and can be deactivated in this display. The buttons can be reactivated only with the R100. The buttons can be set to: Active Not active. 8.6.5 Pump number Possible settings Priority Pump control panel or R100 External signals 1 Stop 2 Max. curve 3 Stop 4 Min. curve Min. curve 5 Setting of head Setting of head With bus signal A number between 1 and 64 can be allocated to a pump or changed so that the R100 or a unit connected to the bus network can distinguish between two or more pumps. The Grundfos Pump Management System 2000 can, however, only accept the numbers 1 to 8. For further details, see the installation and operating instructions for the management system in question. 8.6.6 Twin-head pump Priority Pump control panel or R100 Possible settings External signals Bus signal 1 Stop 2 Max. curve 3 Stop Stop 4 Max. curve 5 Min. curve Min. curve 6 Setting of head This display can only be used in connection with twin-head pumps. See also the document "Supplement to installation instructions". 22

9. Fault finding Warning Before removing the control box cover, make sure that the power supply has been switched off for at least 5 minutes. The pumped liquid may be scalding hot and under high pressure. Before any removal or dismantling of the pump, the system must therefore be drained, or the isolating valves on either side of the pump must be closed. See also section 7.7 Indicator lights. English (GB) Fault Cause Remedy 1. The pump is not running. None of the indicator lights are on. 2. The pump is not running. The green indicator light is flashing. 3. The pump has stopped due to a fault. The red indicator light is on, and the green indicator light is off. 4. The pump is operating, but has been stopped due to a fault. The red and green indicator lights are on. 5. The pump has been set to stop, but it has been stopped due to a fault. The red indicator light is on, and the green indicator light is flashing. 6. Noise in the system. The green indicator light is on. 7. Noise in the pump. The green indicator light is on. a) One fuse in the installation is blown. b) The current-operated or voltage-operated circuit breaker has tripped out. Replace the fuse. Cut in the circuit breaker. c) The pump is defective. Repair or replace the pump. The pump has been stopped in one of the following ways: 1. With the button. 2. With the R100. 3. External on/off switch in position off.* 4. Via bus signal.* 1. Start the pump by pressing. 2. Start the pump with the R100 or by pressing. 3. Switch on the on/off switch.* 4. Start the pump via bus signal.* *The fault can be temporarily corrected by selecting max. curve duty on the pump or with the R100 as external forced-control signals will be ignored. a) Power supply failure (for example undervoltage). b) Pump blocked and/or impurities in the pump. Check that the power supply falls within the specified range. Remove the vent screw, turn the rotor with a screwdriver inserted into the slot in the shaft end, and/or dismantle and clean the pump. c) Fault in electronics. Contact Grundfos. a) The pressure and temperature sensor is defective. b) The pump has restarted automatically after a temporary fault. a) The pressure and temperature sensor is defective. b) The pump has restarted automatically after a temporary fault. Check sensor connection. Replace if necessary. Reset the fault indication. Check sensor connection. Replace, if necessary. Reset the fault indication. a) Air in the system. Vent the system. b) The flow is too high. Reduce the head (setpoint), and possibly change over to constant pressure. c) The pressure is too high. Reduce the head (setpoint), and possibly change over to proportional pressure. a) Air in the pump. Vent the pump. b) The inlet pressure is too low. Increase the inlet pressure, and/or check air volume in the expansion tank (if installed). 23

English (GB) Fault Cause Remedy 8. Insufficient heat in some places in the heating system. Note a) The flow is too low. Increase the head (setpoint) and/or change over to constant pressure. The R100 can also be used for fault finding. 10. Megging Megging of an installation incorporating an UPE pump is not allowed, as the built-in electronics may be damaged. If megging of the pump is necessary, the pump should be electrically separated from the installation. Twin head pumps: The master and slave pumps must be megged separately. Megging of the pump can be carried out as described below. 10.1 Megging of UPE pumps See also section 5.2 Wiring diagram. 1. Switch off the power supply. 2. Remove the conductors from terminals L, N and earth (terminals 9, 10 and 11). 3. Short-circuit terminals L and N using a short wire. 4. Test between terminals L/N and earth. Maximum test voltage: 1000 VAC or 1500 VDC. Note: Never test between supply terminals (L and N). Maximum permissible leakage current: <20mA. 5. Remove the short wire between terminals L and N. 6. Fit the supply wires to terminals L and N and the earth terminal. 7. Switch on the power supply. 10.2 High-voltage test If it is necessary to high-voltage test the UPE pump, the megging instructions must be followed. See section 10. Megging. 24

11. Service kits Warning Before starting work on the pump, make sure that the mains switch has been switched off. It must be ensured that the power supply cannot be accidentally switched on. The service kits can be ordered as required: English (GB) Service kit Pump type Product number Pump head UPE(D) 80/100-120 FZ 97529251 Control box, complete UPE(D) 80/100-120 FZ 97529279 Sensor, complete UPE(D) 80/100-120 FZ 97529255 Connection cable UPED 80-120 FZ 97529293 Gasket kit UPE(D) 80/100-120 FZ 97529296 Fan UPE(D) 80/100-120 FZ 97564038 Air vent plug UPE(D) 80/100-120 FZ 97529299 Flap valve kit UPED 80-120 FZ 97822546 25

English (GB) 12. Technical data Supply voltage 1 x 230 V - 10 %/+ 6 %, 50/60 Hz. Motor protection The pump requires no external motor protection. Enclosure class IPX4D. Relative air humidity Maximum 95 %. Ambient temperature 0 C to +40 C. Temperature class TF110 to EN 60335-2-51. Liquid temperature Maximum: +110 C. Continuously: +2 C to +95 C. Ambient temperature [ C] System pressure The system pressure is indicated on the nameplate. Pump type UPE(D) 80-120 FZ UPE 100-120 FZ Maximum liquid temperature [ C] 0 to 30 110 35 90 40 70 System pressure PN 6 PN 10 PN 16 [MPa] [MPa] [MPa] Number of bolt holes 0.6 4 1.0 1.6 8 0.6 4 1.0 1.6 8 Inlet pressure The following minimum pressures must be available at the pump inlet during operation: Liquid temperature EMC (electromagnetic compatibility) EN 61800-3. Electromagnetic disturbance, first environment (residential areas). Immunity to electromagnetic disturbance, second environment (industrial areas). Sound pressure level The sound pressure level of the pump is lower than 38 db(a). Leakage current The pump mains filter will cause a discharge current to earth during operation. I leakage < 3.5 ma. Inputs and outputs Start/stop input Min. curve input Input for analog 0-10 V signal Signal output Bus input 13. Disposal External potential-free switch. Contact load: 5 V, 0.5 ma. Screened cable. Loop resistance: Maximum 130 Ω/km. Logical levels: Logical zero: U < 1.5 V. Logical one: U > 4.0 V. External signal: 0-10 VDC. Maximum load: 1 ma. Screened cable. Internal potential-free change-over contact. Maximum load: 250 V, 2 A, AC1. Minimum load: 5 V, 1 ma. Screened cable. Grundfos bus protocol, GENIbus protocol, RS-485. Screened cable. Lead cross section: 0.25-1 mm 2. Cable length: Maximum 1200 m. This product or parts of it must be disposed of in an environmentally sound way: 1. Use the public or private waste collection service. 2. If this is not possible, contact the nearest Grundfos company or service workshop. Pump type UPE(D) 80-120 FZ UPE 100-120 FZ 75 C 90 C 110 C [bar]/[m Pa] 0.6/ 0.06 0.6/ 0.06 [bar]/[m Pa] 1.0/ 0.1 1.0/ 0.1 [bar]/[m Pa] 1.7/ 0.17 1.7/ 0.17 26 Subject to alterations.

Appendix Appendix 1 TM04 5955 1011 UPE 80-120 FZ UPE 100-120 FZ PN 6 PN 10 PN 16 PN 6 PN 10 PN 16 L1 360 360 360 450 450 450 L3 180 180 180 225 225 225 B1 131 131 131 135 135 135 B4 100 100 100 100 100 100 B5 131 131 131 135 135 135 B7 115 115 115 115 115 115 H1 98 98 98 120 120 120 H2 402 402 402 410 410 410 H3 500 500 500 530 530 530 D1 80 80 80 100 100 100 D2 128 128 128 160 160 160 D3 150/160 160 160 170 180 180 D4 200 200 200 220 220 220 D5 4 x 18 8 x 18 8 x 18 4 x 18 8 x 18 8 x 18 M 2 x M12 2 x M12 2 x M12 2 x M12 2 x M12 2 x M12 52

TM04 5956 1011 Appendix UPED 80-120 FZ PN 6 PN 10 PN 16 L1 360 360 360 L2 150 150 150 L3 85 85 85 B2 125 125 125 B3 476 476 476 B4 235 235 235 B5 241 241 241 B6 120 120 120 B7 240 240 240 H1 98 98 98 H2 402 402 402 H3 500 500 500 D1 80 80 80 D2 128 128 128 D3 150 160 160 D4 200 200 200 D5 4 x 18 8 x 18 8 x 18 M 4 x M14 4 x M14 4 x M14 53

Appendix TM04 6038 4709 - TM04 6039 4709 - TM04 6040 4709 - TM04 6041 4709 - TM04 6042 4709 - TM04 6043 4709 - TM04 6044 4709 - TM04 6045 4709 Fig. 1 Possible pump positions and flow directions 54

Grundfos companies Argentina Bombas GRUNDFOS de Argentina S.A. Ruta Panamericana km. 37.500 Lote 34A 1619 - Garin Pcia. de Buenos Aires Phone: +54-3327 414 444 Telefax: +54-3327 411 111 Australia GRUNDFOS Pumps Pty. Ltd. P.O. Box 2040 Regency Park South Australia 5942 Phone: +61-8-8461-4611 Telefax: +61-8-8340 0155 Austria GRUNDFOS Pumpen Vertrieb Ges.m.b.H. Grundfosstraße 2 A-5082 Grödig/Salzburg Tel.: +43-6246-883-0 Telefax: +43-6246-883-30 Belgium N.V. GRUNDFOS Bellux S.A. Boomsesteenweg 81-83 B-2630 Aartselaar Tél.: +32-3-870 7300 Télécopie: +32-3-870 7301 Belorussia Представительство ГРУНДФОС в Минске 220123, Минск, ул. В. Хоружей, 22, оф. 1105 Тел.: +(37517) 233 97 65, Факс: +(37517) 233 97 69 E-mail: grundfos_minsk@mail.ru Bosnia/Herzegovina GRUNDFOS Sarajevo Trg Heroja 16, BiH-71000 Sarajevo Phone: +387 33 713 290 Telefax: +387 33 659 079 e-mail: grundfos@bih.net.ba Brazil BOMBAS GRUNDFOS DO BRASIL Av. Humberto de Alencar Castelo Branco, 630 CEP 09850-300 São Bernardo do Campo - SP Phone: +55-11 4393 5533 Telefax: +55-11 4343 5015 Bulgaria Grundfos Bulgaria EOOD Slatina District Iztochna Tangenta street no. 100 BG - 1592 Sofia Tel. +359 2 49 22 200 Fax. +359 2 49 22 201 email: bulgaria@grundfos.bg Canada GRUNDFOS Canada Inc. 2941 Brighton Road Oakville, Ontario L6H 6C9 Phone: +1-905 829 9533 Telefax: +1-905 829 9512 China GRUNDFOS Pumps (Shanghai) Co. Ltd. 50/F Maxdo Center No. 8 XingYi Rd. Hongqiao development Zone Shanghai 200336 PRC Phone: +86-021-612 252 22 Telefax: +86-021-612 253 33 Croatia GRUNDFOS CROATIA d.o.o. Cebini 37, Buzin HR-10010 Zagreb Phone: +385 1 6595 400 Telefax: +385 1 6595 499 www.grundfos.hr Czech Republic GRUNDFOS s.r.o. Čajkovského 21 779 00 Olomouc Phone: +420-585-716 111 Telefax: +420-585-716 299 Denmark GRUNDFOS DK A/S Martin Bachs Vej 3 DK-8850 Bjerringbro Tlf.: +45-87 50 50 50 Telefax: +45-87 50 51 51 E-mail: info_gdk@grundfos.com www.grundfos.com/dk Estonia GRUNDFOS Pumps Eesti OÜ Peterburi tee 92G 11415 Tallinn Tel: + 372 606 1690 Fax: + 372 606 1691 Finland OY GRUNDFOS Pumput AB Mestarintie 11 FIN-01730 Vantaa Phone: +358-3066 5650 Telefax: +358-3066 56550 France Pompes GRUNDFOS Distribution S.A. Parc d Activités de Chesnes 57, rue de Malacombe F-38290 St. Quentin Fallavier (Lyon) Tél.: +33-4 74 82 15 15 Télécopie: +33-4 74 94 10 51 Germany GRUNDFOS GMBH Schlüterstr. 33 40699 Erkrath Tel.: +49-(0) 211 929 69-0 Telefax: +49-(0) 211 929 69-3799 e-mail: infoservice@grundfos.de Service in Deutschland: e-mail: kundendienst@grundfos.de Greece GRUNDFOS Hellas A.E.B.E. 20th km. Athinon-Markopoulou Av. P.O. Box 71 GR-19002 Peania Phone: +0030-210-66 83 400 Telefax: +0030-210-66 46 273 Hong Kong GRUNDFOS Pumps (Hong Kong) Ltd. Unit 1, Ground floor Siu Wai Industrial Centre 29-33 Wing Hong Street & 68 King Lam Street, Cheung Sha Wan Kowloon Phone: +852-27861706 / 27861741 Telefax: +852-27858664 Hungary GRUNDFOS Hungária Kft. Park u. 8 H-2045 Törökbálint, Phone: +36-23 511 110 Telefax: +36-23 511 111 India GRUNDFOS Pumps India Private Limited 118 Old Mahabalipuram Road Thoraipakkam Chennai 600 096 Phone: +91-44 2496 6800 Indonesia PT GRUNDFOS Pompa Jl. Rawa Sumur III, Blok III / CC-1 Kawasan Industri, Pulogadung Jakarta 13930 Phone: +62-21-460 6909 Telefax: +62-21-460 6910 / 460 6901 Ireland GRUNDFOS (Ireland) Ltd. Unit A, Merrywell Business Park Ballymount Road Lower Dublin 12 Phone: +353-1-4089 800 Telefax: +353-1-4089 830 Italy GRUNDFOS Pompe Italia S.r.l. Via Gran Sasso 4 I-20060 Truccazzano (Milano) Tel.: +39-02-95838112 Telefax: +39-02-95309290 / 95838461 Japan GRUNDFOS Pumps K.K. Gotanda Metalion Bldg., 5F, 5-21-15, Higashi-gotanda Shiagawa-ku, Tokyo 141-0022 Japan Phone: +81 35 448 1391 Telefax: +81 35 448 9619 Korea GRUNDFOS Pumps Korea Ltd. 6th Floor, Aju Building 679-5 Yeoksam-dong, Kangnam-ku, 135-916 Seoul, Korea Phone: +82-2-5317 600 Telefax: +82-2-5633 725 Latvia SIA GRUNDFOS Pumps Latvia Deglava biznesa centrs Augusta Deglava ielā 60, LV-1035, Rīga, Tālr.: + 371 714 9640, 7 149 641 Fakss: + 371 914 9646 Lithuania GRUNDFOS Pumps UAB Smolensko g. 6 LT-03201 Vilnius Tel: + 370 52 395 430 Fax: + 370 52 395 431