Grundfos BoosterpaQ PFU 2000 User manual

GRUNDFOS INSTRUCTIONS
BoosterpaQ®
Grundfos CR-Booster Systems
60 Hz
Installation and operating instructions
Factory settings are documented in this manual.
Please leave these instructions with the BoosterpaQ
for future reference.
For technical support, call your supplier or contact
Grundfos Pumps Corporation at 913 227 3400 (USA).
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Model:
Part Number:
PFU 2000 Eprom P/N:
PMU 2000 Eprom P/N:
Serial Number:
Production Date:
Your BoosterpaQ was factory assembled and tested with the factory set control parameters
listed at the beginning of one of the following sections as marked.
Standard PFU 2000 System Controller
(See pages 6 and 7 for Installation and Start-up)
Standard PMU 2000 System Controller
(See pages 6 and 8 for Installation and Start-up)
Name
Date
2
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CONTENTS
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
System types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Control modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Factory settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
PMU 2000 display overview WITH
pre-pressure measuring . . . . . . . . . . . . . . . . . . . . . . . . 22
PMU 2000 LCD display notes . . . . . . . . . . . . . . . . . . . 24
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . 34
BoosterpaQ System Types
System System
Type Function
ME All pumps are fitted with variable frequency
driven motors. All pumps in operation are speed-
controlled (same speed) and are full-size.
MEH Two half-size pumps are fitted with variable
frequency driven motors (same speed if both
pumps are operating). Full-size pumps are mains
operated (on/off). The variable speed pump(s)
always start first.
MES One pump is fitted with a variable frequency
drive motor. The other pumps are start/stop
operated (on/off). All pumps are full-size pumps.
The variable speed pump(s) always start first.
MF All pumps are full-size pumps. One pump is
operated via a variable frequency drive. The
other pumps are start/stop operated (on/off).
All pumps will be controlled by the variable
frequency drive in rotation. The variable speed
pump(s) always start first.
MFH Two pumps are half-size pumps. The other
pumps are full-size pumps. The two half-size
pumps are controlled by a variable frequency
drive in rotation, and the full-size pumps are
start/stop operated (on/off) and alternated. The
variable speed pump(s) always start first.
MS All pumps are equal size and are start/stop oper-
ated (on/off).
MSH One half-size pump. The other pumps are full-
size pumps. All pumps are start/stop (on/off).
3
Application
Grundfos BoosterpaQ systems are designed for transfer
and boosting of clean water in commercial buildings,
commercial landscape, industrial, and municipal applica-
tions. The BoosterpaQ range consists of three main groups:
S, F, and E. The main groups are divided into subgroups as
shown in the next column on this page.
Related Documents
For some BoosterpaQs, detailed information can be found
in the following related documents:
• Wiring Diagram
• Bill of Materials
• CR Pump Installation and Operating Instructions
• CRE Pump Installation and Operating Instructions
• Variable Frequency Drive Installation and Operating
Instructions
• BoosterpaQ Product Guide
SAFETY WARNING
Before beginning installation procedures,
these Installation and Operating Instruc-
tions should be studied carefully. Install-
ation and operation must be in accordance
with the National Electrical Code and local regula-
tions and accepted codes of good practice.
SHOCK HAZARD
A faulty motor or wiring can cause electrical shock
that could be fatal, whether touched directly or
conducted through standing water. For this reason,
proper grounding of the pump and system electri-
cal panel to the power supply’s grounding terminal
is required for safe installation and operation (see
“Electrical Connection,” page 6).
In all installations, the above-ground metal plumb-
ing should be connected to the power supply ground
as described in Article 250-80 of the National
Electrical Code.
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Construction
Grundfos BoosterpaQ systems consist of 1-8 pumps
with all necessary fittings and a Grundfos Control 2000
mounted on a common base frame, ready for installation.
The Control 2000 has its own base for large BoosterpaQs.
In most cases a diaphragm tank must be included in the
installation.
BoosterpaQ Control Modes
BoosterpaQs always include the Grundfos PFU 2000
Controller, but a PMU 2000 can be added. The optional
PMU 2000 provides additional functions and detailed sys-
tem information via a LCD (Liquid Crystal Display).
If the BoosterpaQ includes the PFU 2000 only, its faceplate
will be located on the control panel door (see below). If
the BoosterpaQ includes the optional PMU 2000, the PMU
2000 replaces the PFU 2000 faceplate (see below).
4
BoosterpaQs offer the following functions:
• Closed-loop control
• Automatic shut-off at zero flow
• Automatic cascade control of pumps
• Automatic pump rotation to equalize operation time
among the pumps; and with PMU 2000, selectable
pump priority, minimum pump operation, and selec-
table pump sequencing
• Manual operation of each pump
• Possibility of various analog set-point influences:
– friction loss compensation (flow-dependent set-point
control with or without flow measurement), PMU
2000 only
– external set-point adjustment
• Possibility of various digital remote-control functions:
– system on/off
– reduced capacity during emergency power situations
(PMU 2000)
– alternative set-points (PMU 2000)
– switching off individual pumps
• Pump and system monitoring functions:
– minimum and maximum limits of actual value
(high and low system pressure)
– pre-pressure (out of water or low inlet pressure)
– motor protection
– BUS communication (GeniBUS Protocol)
• LCD Display and indication functions:
– 2 x 24 character LCD display (PMU 2000)
– green indicator light for operating indications and red
indicator light for fault indications
– potential-free relay contacts for operation and fault
• Multiple set-points (PMU 2000)
• Grundfos BUS communication (GeniBUS Protocol)
PRESSURE
TRANSMITTER
VALVE
PFU 2000
PRESSURE GAUGE
CHECK
VALVE
ISOLATING
PUMP
Control 2000
DIAPHRAGM
TANK
Figure 1: System construction
PFU 2000
PMU 2000
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Grundfos BoosterpaQ ME Grundfos BoosterpaQ MEH Grundfos BoosterpaQ MES
Example:
Three pumps of equal
size with MLE motors
and a diaphragm tank.
One pump
in operation.
Three pumps
in operation.
Grundfos BoosterpaQ ME maintains a con-
stant pressure through continuous variable
adjustment of the speed of the pumps. The
system performance is adjusted to the demand
through cutting in/out the required number of
pumps and through parallel speed control of the
pumps in operation. Pump rotation is automatic
and depends on load, time and fault.
PFU 2000
MLE MLE MLE
Example:
Two half-size pumps
with MLE motors, one
mains-operated full-size
pump and a diaphragm
tank.
One half-size
pump with
MLE motor in
operation.
One full-size
pump and one
half-size pump
with MLE
motors in
operation.
Grundfos BoosterpaQ MEH maintains a con-
stant pressure through continuous variable
and parallel adjustment of the speed of the
two half-size pumps, while the full-size pump
is mains-operated. The half-size pumps always
start first. If the pressure cannot be maintained
by one half-size pump, the second half-size
pump and/or the full-size pump will be cut in.
Pump rotation is automatic and depends on
load, time and fault.
PFU 2000
MLE MLE
Q
H
set
H
Q
H
set
H
Product Description
Example:
One pump with MLE
motor, two mains-
operated pumps and
a diaphragm tank.
All pumps are of
equal size.
One pump
with MLE
motor in
operation.
One pump with
MLE motor in
operation and
two pumps
on mains-
operation.
Grundfos BoosterpaQ MES maintains a con-
stant pressure through continuous variable
adjustment of the speed of one pump. The
other pumps are cut in/out on mains opera-
tion according to demand thus achieving a
performance corresponding to consumption.
The pump with MLE motor will always start
first. Rotation among the pumps on mains
operation is automatic and depends on load,
time and fault.
PFU 2000
MLE
Q
H
set
H
Q
H
set
H
Q
H
set
H
Q
H
set
H
Grundfos BoosterpaQ MF Grundfos BoosterpaQ MFH Grundfos BoosterpaQ MS
Example:
Four pumps and a
diaphragm tank. All
pumps are of equal
size.
One pump
in operation
via variable
frequency
drive.
One pump
in operation
via variable
frequency
drive and
two pumps
on mains
operation.
Grundfos BoosterpaQ MF maintains a constant
pressure through continuous variable adjust-
ment of the speed of one pump. The other
pumps are mains-operated (on/off) according
to the demand thus achieving a system size
corresponding to the consumption. The pump
controlled by the variable frequency drive will
always start first. Pump rotation is automatic
and depends on load, time and fault. All pumps
are controlled by the variable frequency drive in
rotation.
PFU 2000
Example:
Two half-size pumps,
two full-size pumps,
and a diaphragm tank.
One half-size
pump in oper-
ation via variable
frequency drive.
One full-size
pump in oper-
ation via variable
frequency drive
and one full-
size pump on
mains operation.
Grundfos BoosterpaQ MFH maintains a con-
stant pressure through continuous variable
adjustment of the speed of the one half-size
pump. The rest of the pumps are mains-operat-
ed. A half-size pump controlled by the variable
frequency drive will always start first. If the
pressure cannot be maintained by one half-size
pump, the second half-size pump and/or the
full-size pump will be cut in on mains-opera-
tion. Rotation between the half-size pumps is
automatic and depends on load, time and fault.
The full-size pumps on mains power are auto-
matically rotated among themselves.
PFU 2000
Q
H
set
H
set
H
Q
H
Example:
Four pumps and
a diaphragm tank.
All pumps are of
equal size.
One pump
in opera-
tion.
Three
pumps in
operation.
Grundfos BoosterpaQ MS maintains a pressure
range by cutting in/out the required number
of pumps. The operating range of the pumps
will lie between the lines Hset and Hstop (cut-
out pressure). The cut-out pressure cannot be
set but is calculated automatically. Rotation
among the pumps is automatic and depends
on load, time, and fault.
PFU 2000
Q
stop
set
H
H
H
Q
stop
set
H
H
H
Q
set
H
H
Q
set
H
H
Q
H
set
H
set
H
Q
H
Example:
One half-size
pump, three full-
size pumps and a
diaphragm tank.
Grundfos BoosterpaQ MSH
PFU 2000
Q
stop
set
H
H
H
Q
stop
set
H
H
H
Example:
One half-size
pump in
operation.
Q
stop
set
H
H
H
Q
stop
set
H
H
H
Example:
One half-size
pump and
one full-size
pump in
operation.
Grundfos BoosterpaQ MSH maintains a pressure range by cutting in/out the half-size pump and the full-size pumps. The half-size pump will always
start first. The half-size pump will be cut out again when a full-size pump is cut in. The operating range of the pumps will lie between the lines Hset
and Hstop (cut-out pressure). The cut-out pressure cannot be set but is calculated automatically. Rotation among the full-size pumps is automatic and
depends on load, time and fault.
5
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6
Installation
Upon its arrival, check your BoosterpaQ system for ship-
ping damage and confirm that you have received the
correct system prior to installation.
Location
BoosterpaQ systems must be installed in a well-ventilated
area. When a BoosterpaQ is installed outdoors, it must
be protected from rain, cold, heat, and direct sunlight to
operate within the product humidity and temperature
limits. The BoosterpaQ should be placed with a 3-foot
clearance in front and on the two sides for ease of service.
Hydraulic installation
Arrows on the pump
base show the direc-
tion of flow of water
through the pump. The
pipes connected to the
BoosterpaQ must be of
adequate size. To avoid
resonance, expansion
joints may be connected
to the discharge and suc-
tion pipes (see drawing
at right).
The system pipes are
connected to the mani-
folds of the BoosterpaQ.
Either end of the mani-
folds can be used as long
as the pipe does not pass
in front of the control
panel (check building
codes). Apply approved
sealing compound to
the unused end of each
manifold and fit the
screw cap. For manifolds with flanges, blind flanges with
gaskets are included.
If the suction pressure periodically exceeds the discharge
pressure, installing a bypass check valve (see drawing
above) minimizes flow through the pumps when the sys-
tem shuts down.
If the discharge pressure could reach pressures above the
plumbing maximum rating due to VFD failure or other
system causes, a pressure relief device must be installed.
Another option is to install a pressure sustaining valve
to return discharged fluid back to the suction manifold.
Grundfos offers this option.
BoosterpaQ hardware should be checked for tightness
prior to startup to avoid leaks due to transportation vibra-
tion. When a BoosterpaQ is installed in a densely popu-
lated building or the first user on the line is close to the
BoosterpaQ, it is advisable to fit pipe hanger/supports on
the suction and discharge pipes to prevent vibration being
transmitted through the pipe work (see drawing at left
with pipe hanger/support).
The BoosterpaQ should be positioned on a flat, level, solid
surface; for example, a concrete floor or foundation. If the
BoosterpaQ is not fitted with vibration dampers, it must
be bolted to the floor or foundation. The pipes must be
fastened securely to ensure that they cannot move or be
twisted.
Expansion joints, pipe hangers and vibration dampers
shown in the illustration at left are not included with the
BoosterpaQ.
Install a diaphragm tank as specified in the “Technical
Information” section.
Electrical connection
The connection of the electrical supply, transmitters and
external monitoring equipment must be carried out by an
authorized electrician in accordance with the NEC, local
regulations and the BoosterpaQ wiring diagram.
Ensure that the Control 2000 and the pumps are suitable
for the electricity supply on which they will be used (see
Technical Data). Please read the wiring diagram carefully.
According to the NEC, if the motors cannot be seen from
the control panel, they must be fitted with a disconnect
switch.
Any BoosterpaQ that utilizes a variable frequency drive
(ME, MEH, MF, MFH, MES) should be connected to an
electrical supply that all phase lines are electrically
symmetrical with respect to ground. A “four wire wye”
electrical supply is recommended. If a variable frequency
drive is connected to a delta transformer, the drive may
not operate correctly and may not provide optimum per-
formance (excessive faults, erratic behavior, or complete
failure). Ask your power company or electrician to deter-
mine what type of electrical supply is present. Generator
supplied power must meet public utility power quality
standards.
2
2
11
2
Installation with bypass
check valve
Installation with expansion
joints
1. Expansion joint
2. Pipe hanger/support
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7
PFU 2000 Startup
1. Have a qualified person
check for proper power
supply and plumbing
connections. Make sure
the main power is off.
2. Check that the air pres-
sure in the diaphragm
tank is 0.7 times the required discharge pressure
set-point (0.9 times for MS and MSH systems). System
pressure must not be applied to the tank connection
during the tank pre-charge process. If water is supplied
to the tank from the system, close the tank valve dur-
ing the pressurizing process.
3. Prime the system as follows.
Suction Pressure System (pumps are flooded at least as
high as the highest part of the pumps)
a. Close all discharge manifold pump isolation valves
and open all inlet manifold pump isolation valves.
b. Open the vent plug on top of each pump. It is a small
hex head screw in a large vent plug. Air and water
will escape from the pump through a small hole in
the large vent plug. When the air is out and water is
flowing steadily, tighten the small hex head screw
on the vent plug to stop the flow.
Suction Lift System (the water source is below the
pumps or does not flood the pumps to the highest point
on the pumps)
a. Close all discharge manifold pump isolation valves
and open all inlet manifold pump isolation valves.
b. For suction lift applications, a foot valve must be
placed on the inlet piping at the water source (tank,
etc.). If there is a fill point above the highest point of
the pumps, you may fill the system from this point.
If there is no fill point above the highest point of the
pumps, remove the large vent plug on each pump.
Fill each pump until the water is up to the vent plug,
then replace the vent plugs.
4. Check the inlet manifold pressure gauge. The inlet
pressure must be at least 5% of the maximum pressure
transducer rating (if a transducer is used). If another
type of dry run protection is used, ensure that sufficient
suction pressure is available for safe operation of the
pumps.
5. Ensure all circuit breakers are in the “on” position. The
control panel door must be open at this time.
6. If an isolation valve has been installed on the discharge
manifold, close it. If not installed, make sure the dis-
charge pump isolation valves are closed. Switch on
main power (the pumps may start at this time).
7. Turn the Function
Selector (small knob
on the PFU Controller)
on the PFU 2000 to
“Max” (see drawing
at right) (full clock-
wise rotation).
If the pumps did not
start in Step 6, they
will start after approx-
imately 15 seconds.
8. Vent the system by opening the vent plug on each
pump (as in Step 3). Venting with the pumps running
ensures all air is removed from the suction. Do not run
the system with the discharge manifold pump isolation
valves closed for more than five minutes to prevent
overheating of the pump liquid.
9. Once the pumps have been fully vented, turn the PFU
2000 Function Selector to “Stop” (full counter-clock-
wise). As the pumps stop, check the pump rotation. If
the area is dark, a flashlight may be required, or remove
a coupling guard on each pump for better visibil-
ity. Disconnect main power when removing coupling
guards. Do not touch the couplings while the pumps
are turning as injury may result. Replace all coupling
guards after the rotation check. Disconnect main power
when removing and replacing coupling guards (or open
service disconnect switches if this option was supplied).
If the rotation is incorrect on any 3 phase pumps, switch
any 2 of the 3 power main wires supplied to the control
panel (L1, L2, L3).
10. Open the discharge manifold isolation valve and the
isolation valves for each pump. Turn the PFU 2000
Function Selector clockwise approximately 50% of full
rotation, allow the system to come up to speed, then
slowly adjust the Function Selector until the system
maintains the desired set-point pressure as read on the
discharge pressure gauge.
NOTE: If you are filling an empty piping system, do not
allow the pumps to run with the valves wide open as
cavitation may occur.
NOTE: If the set-point is changed, readjust the dia-
phragm tank precharge pressure to 0.7 times the new
fluid pressure setting (0.9 times for MS and MSH sys-
tems). Check the diaphragm tank air pressure while no
fluid pressure is applied to the tank (see Step 4).
Your BoosterpaQ is now ready for operation.
Setpoint
100%0%
STOP MAX
Function Selector
in the PFU 2000
PFU 2000
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6. Ensure all circuit breakers are in the “on” position.
7. Make sure the discharge manifold pump isolation
valves are closed. Switch on main power. CAUTION:
The pumps may start at this time.
8. Turn the Function Selector on the PFU 2000 to “Max.”
(see drawing with Step 7 on previous page) (full clock-
wise rotation). If the pumps did not start in Step 7, they
will start after approximately 15 seconds.
9. Vent the system by opening the vent plug on each
pump (as in Step 4). Venting with the pumps running
ensures all air is removed from the suction. Do not run
the system with the discharge manifold pump isolation
valves closed more than five minutes to prevent over-
heating of the pump liquid.
10. Turn the PFU 2000 Function Selector to “Stop” (full
counter-clockwise). As the pumps stop, check the
pump rotation. If the area is dark, a flashlight may be
required, or remove a coupling guard on each pump
for better visibility. Disconnect the main power when
removing coupling guards. Do not touch the couplings
while the pumps are turning as injury may result.
Replace all coupling guards after the rotation check.
Disconnect main power when removing and replacing
coupling guards (or open service disconnect switches if
this option was supplied). If the rotation is incorrect on
any 3 phase pumps, switch any 2 of the 3 power main
wires supplied to the control panel (L1, L2, L3). If that
doesn’t correct the rotation, call your Grundfos repre-
sentative.
11. Open the discharge manifold isolation valves for each
pump. Turn the PFU 2000 Function Selector clockwise
approximately 50% of full rotation, allow the system
to come up to speed, then slowly adjust the Function
Selector until system maintains the desired set-point
pressure as read on the discharge pressure gauge.
This is done for two reasons. If the PMU 2000 (fol-
lowing set-up steps) should fail or get damaged, the
PFU 2000 will automatically operate the system. Also,
if the Function Selector is left in the “Stop” or “Max.”
positions, the PFU 2000 will not allow the PMU 2000 to
control the system. If there is a power outage, the PFU
will control the system for approximately 30 seconds
before the PMU settings are engaged. Therefore it is
important that the PFU is set correctly.
NOTE: If you are filling an empty piping system, do not
allow the pumps to run with the valves wide open as
cavitation may occur.
12. Turn off the main circuit breaker.
13. Replace the PMU 2000 plug which was removed in
Step 2.
PMU 2000 Startup
1. Have a qualified person
check for proper power
supply and plumbing con-
nections. Make sure the
main power is off.
2. Remove the PMU
2000 BUS plug
(see drawing at
right). Drawing
shows view of
the back of the
PMU 2000, which
is mounted on
the control cabi-
net door. Leave
the panel door
open until after
Step 13.
3. Check that the air pressure in the diaphragm tank is 0.7
times the required discharge pressure set-point (0.9
times for MS and MSH systems). System pressure must
not be applied to the tank connection during the tank
pre-charge process. If water is supplied to the tank
from the system, close the tank valve during the pres-
surizing process.
4. Prime the system as follows.
Suction Pressure System (pumps are flooded at least as
high as the highest part of the pumps)
a. Close all discharge manifold pump isolation valves
and open all inlet manifold pump isolation valves.
b. Open the vent plug on top of each pump. It is a small
hex head screw in a large vent plug. Air and water
will escape from the pump through a small hole in
the large vent plug. When the air is out and water is
flowing steadily, tighten the small hex head screw
on the vent plug to stop the flow.
Suction Lift System (the water source is below the
pumps or does not flood the pumps to the highest
point on the pumps)
a. Close all discharge manifold pump isolation valves
and open all inlet manifold pump isolation valves.
b. For suction lift applications, a foot valve must be
placed on the inlet piping at the water source (tank,
etc.). If there is a fill point above the highest point of
the pumps, you may fill the system from this point.
If there is no fill point above the highest point of the
pumps, remove the large vent plug on each pump.
Fill each pump until the water is up to the vent plug,
then replace the vent plugs.
5. Check the inlet manifold pressure gauge. There should
be positive pressure on the gauge (at least 5 - 10 psig if
a transducer is used). If another type of dry run protec-
tion is used, ensure that sufficient suction pressure is
available for safe operation of the pumps.
1. Electricity Supply
2. Operating Signal Output
3. Fault Signal Output
4. BUS (connection plug)
8
PMU 2000
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Troubleshooting —
Common Startup Problems
Before working with pumps, terminal boxes or
controllers, the electricity supply must be switched
off.
Most start-up problems occur for the following reasons:
1. Incorrect voltage or supply configuration — the system
will not start and lights may not illuminate. Alarms
may appear on variable frequency drives.
2. Wires and cables loosened during rough shipment
— this can cause faults and erratic operation. The lights
on the PFU 2000 or PMU 2000 panel and the lights
on or inside the motor terminal boxes may indicate
everything is operating properly, even when it is not, if
certain connections are loose. Most loose connections
will indicate a fault or cause erratic system operation.
Check to make sure all wires and cables are well con-
nected. DO NOT move wires to other terminals or
remove wires even if it appears that they don’t match
the electrical schematic. Every BoosterpaQ is factory
tested and proper operation is verified with the wires
connected as you receive them. Call your Grundfos dis-
tributor or the Grundfos factory if you believe you have
discovered incorrect wiring or documentation.
3. PMU 2000 LCD Display Settings are different than the
factory listed settings in this Installation and Operating
Manual — check them against the factory settings
(only applies if a PMU 2000 is installed). To check or
change the PMU 2000 settings, refer to the “PMU
2000 LCD Display Overview,” (pages 22 - 23). To find
out which way your system is set up, check the factory
settings list on page 12. Step through each menu of the
PMU 2000, but DO NOT make changes without care-
fully checking the factory settings. If the settings in the
PMU 2000 are different than the values recorded under
PMU 2000 factory setting, change them to match the
factory settings. If you believe the factory settings are
incorrect, check the explanations in the section begin-
ning on page 24, “PMU 2000 Display Notes,” to see if
the settings still seem incorrect. If you still feel they are
incorrect, please call your Grundfos distributor or the
Grundfos factory.
4. Inlet pressure is too low or no water is present at the
inlet manifold — check the inlet pressure gauge. The
pressure must be at least 5% of the maximum pres-
sure transducer rating (if a transducer is used), higher
than “min. pre-pressure”-Display 231 (if PMU 2000
installed), higher than the setting of the inlet pressure
switch (if used), or the level control switch must be
closed (if used). A closed valve(s) leading to the inlet
manifold could be the problem.
5. MLE motor (or Baldor SmartMotor) tripped on fault
— if an MLE motor trips on overload, allow 15 seconds
to reset itself. If motor does not reset, check motor
settings.
14. Turn on the main circuit breaker. After approximately
15 seconds, the pumps will start. If the system does not
start, press the “On/Off” button on the PMU 2000 (see
page 22 - 23). If the display reads “Off,” press “+” to
set the Zone to “On.” If the display already reads “On,”
do NOT press “+.” Instead, press “Esc” twice to return
to the main menu. If the system still fails to start, the
minimum inlet pressure may be set too low (only on
systems WITH pre-pressure measuring, see pages 22
- 23). If your system does not start and is set up WITH
pre-pressure measurement, press the “Set” button on
the PMU 2000, then “Enter,” then press the down arrow
repeatedly until you get to “Zone Configuration,” then
press “Enter,” then press the “down arrow” repeatedly
until you come to “min. pre-pressure.” At this display,
set the value below the available inlet pressure, then
press “Enter” and “Esc” repeatedly until you return to
the main menu, “Status.”
15. After the system starts, the PMU 2000 will indicate a
fault. This is normal. To reset the fault, press the “Fault
Indication” button (see page 12). The LCD should read
“Alarm System Mains Drop.” Press the “Enter” button.
This fault will clear.
16. There should be no more faults. If there are, you will
need to review the Troubleshooting section beginning
on this page. See page 12, section “Fault Indication
Menu” for a fault indication reading guide.
17. If there are no more faults, press the “Esc” button twice
to return to the main menu.
18. If your system is maintaining correct pressure, you
are finished with the set-up. If your system pressure
is incorrect, press the “Set” button on the PMU 2000
(see the graphic on pages 22-23), then press the “Enter”
button on the PMU 2000. Next, press the “+” or “-”
buttons on the PMU 2000 until the desired pressure
in psi is indicated in the PMU 2000 LCD readout. Press
“Enter,” then “Esc” twice.
19. When your system is operating properly, reduce
the system demand to 0 gpm by closing the system
discharge valve. Your BoosterpaQ will slow
down and stop within one to three min-
utes. If it does not do so, check the Trouble-
shooting section. If the system functions properly,
reopen discharge valve.
20. The BoosterpaQ should now be running. If not, recheck
Steps 18-19 and/or the Troubleshooting section begin-
ning on page 9. The system pressure should build to
the set-point pressure which you entered in Display
200 and remain there as flow demand rises and falls.
21. If your BoosterpaQ does not start, press the PMU 2000
panel alarm button which looks like an alarm horn
and is next to the LED lights. If there are any fault
indications, press the “Enter” button repeatedly until
all faults clear. If all faults clear, press “Esc” until the
“Status” screen appears (Display 100). The system
should start and maintain the set-point pressure. If it
still is not operating properly, recheck Steps 18-19 or
review the next section (Common Startup Problems).
9
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6. Tank pre-charge pressure is too low or too high — when
the system drops to low flow demand, the BoosterpaQ
will stop at a pressure slightly higher than the set-
point. It will restart when the pressure drops again
below the set-point. If the system stops and starts
frequently the tank pre-pressure may be too low or too
high. Stop the system, close the valve to the tank, bleed
the tank, and check the pre-charge air pressure. It must
be 0.7 times the set-point of the system (0.9 times for
MS and MSH systems). If the system continues to stop
and start frequently, consider a larger size tank.
7. Suction and discharge piping reversed.
8. Pump, manifold, or system piping is plugged with
debris.
9. Pumps rotate clockwise (must be counter-clockwise
looking from the top). On 3 phase systems, switch any
2 of the 3 power mains wires supplied to the control
panel. Do NOT switch other wires until this has been
tried.
10. Voltage monitor is triggered. Check voltage (loss of
phase, large imbalance).
INDICATOR LIGHTS OUTPUTS PFU 2000 OUTPUTS PMU 2000
Fault (red) Operation (green) Fault Operation Fault Operation Description
Electricity supply switched off or
Off Off supply failure.
At least one pump in each zone is
Off in operation.
All pumps in at least one zone have
been stopped:
• via external on/off switch or
• via function selector in
PFU 2000 (pos. STOP),
• via PFU 2000/PMU 2000.
At least one pump is stopped due
to fault.
At least one pump is or has been
stopped due to fault. At least one
pump in each zone is in operation.
All pumps in at least one zone have
been stopped:
• via external on/off switch or via
function selector in PFU 2000
Flashing • via PFU 2000/PMU 2000. At least
one pump is or has been stopped
due to fault.
FlashingOff
Permanently
on
Permanently
on
Permanently
on
Permanently
on
Permanently
on
Off
11. PFU 2000 DIP Switch Settings are different than the
factory listed settings in this Installation and Operating
Manual — check them against the factory settings on
page 12 depending or whether your system has only a
PFU 2000 or a PMU 2000. Call your Grundfos distribu-
tor or the Grundfos factory if you believe you have
discovered incorrect settings.
Operating and fault indications
The two indicator lights (LED) on the front cover of PFU
2000/PMU 2000 indicate pump operation (green) and/or
fault (red). Two external indicator lights (LED) can be con-
nected instead of the two indicator lights (LED) on the
front cover (see page 38, Terminals 7 and 8). The function
of the indicator lights (LED) and the operating and fault
signal outputs are listed in the table below.
10
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11
Fault Cause Remedy
1. Motor does not run when
started.
a) Electricity supply disconnected or loose
wires.
Connect the electricity supply. Check for loose
wires. DO NOT over tighten terminal screws.
b) Automatic circuit breakers cut out. Correct the fault and cut in the automatic
circuit breakers.
c) Motor protection activated. Correct the fault and reactivate the motor
protection.
d) Fuse in the PFU 2000 defective. Replace the fuse.
e) Motor defective. Repair/replace the motor.
2. Motor starts, but stops
immediately afterwards.
a) Fault in pressure transmitter. Check transmitter/wiring. If necessary replace
the pressure transmitter. Transmitters with
0-20 mA or 4-20 mA output signals are moni-
tored by the PFU 2000.
b) Dry running or no pre-pressure.
The operating pressure is not reached.
Check the supply of water to the pump. When
the pressure has been reestablished, the
pump will restart after 15 seconds and the
fault indication will remain.
3. Unstable water delivery
from BoosterpaQ MS
(applies only to very low
consumption)
a) Pre-pressure too low. Check the suction pipe and possible suction
strainer.
b) On/Off band set too low Increase On/Off band
c) Suction pipe/pumps partly blocked by
impurities.
Clean the suction pipe/pumps.
d) Pumps suck air. Check the suction pipe for leakages.
e) Pressure transmitter defective. Replace the transmitter.
f) Max. Limit set too low. Increase Max. limit.
4. Pumps are running, but
deliver no water or reduced
output
a) Suction pipe/pumps blocked by impurities. Clean the suction pipe/pumps.
b) Check valve blocked in closed position. Clean the check valve. The check valve must
move freely.
c) Suction pipe leaky. Check the suction pipe for leakages.
d) Air in suction pipe/pumps. Vent the pumps. Check the suction pipe for
leakages.
e) Motors running with the wrong direction
of rotation.
Change the direction of rotation.
5. Leakages from the shaft
seal
a) Shaft seal defective. Replace the shaft seal.
b) Height adjustment of pump shaft is
inaccurate.
Readjust the shaft height.
6. Noise a) The pumps are cavitating. Clean the suction pipe/pumps and possibly
the suction strainer.
b) The pumps do not rotate freely (frictional
resistance) due to inaccurate height adjust-
ment of the pump shaft.
Readjust the shaft height.
7. Very frequent starts and
stops
a) Wrong diaphragm tank precharge pressure. Check the diaphragm tank precharge pres-
sure.
b) Incorrect voltage. Check voltage during motor operation.
c) PMU settings other than factory. Review documentation and restore PMU to
original factory settings.
8. System only runs at max.
or “Off” (no regulation)
a) Fault in transmitter or signal. Check wire connections. Ensure bare wire,
NOT insulation, is compressed in termination
fitting. If connection is good replace pressure
transmitter.
Troubleshooting/Fault-finding chart
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PMU fault indication menu
Press the button on the PMU to see the following faults.
The PMU will keep the last 10 faults in memory.
PMU alarm examples
Alarm type: Zone, Pump,
PFU, System.
Time alarm occurred (hh-mm)
24-hour clock.
Detail of alarm: See chart
below.
Time & date alarm cleared. If
“Actual” then alarm still exists.
Date alarm occurred (dd-mm)
Alarm zone A min. limit
10:12 03-11 10:22 03-11
12
PMU alarm display Condition Possible remedy
Alarm System mains drop
10:12 03-11 11:43 29-10
There was a power failure to the system. This is normal during shipping as there was
a power failure to the system. Simply reset
the alarm.
Alarm Zone A max. limit
10:12 03-11 Actual
High System Pressure on discharge.
Possible VFD failure or max. limit set too low.
Solve VFD problem. Adjust max. limit to higher
value (may be too close to set-point (system
pressure).
Alarm Zone A min. limit
10:12 03-11 Actual
Low System Pressure on discharge. Possible
pipe breakage in system or pipes are not yet
filled.
Repair piping. Adjust Min. Limit to a lower
value as it may be set too high (too close to
system pressure).
Alarm Zone A Watershort
10:12 03-11 Actual
Low Suction Pressure. Check suction condi-
tions.
If inlet is pressurized, lower min. pre-pressure. If
flooded suction or suction lift, ensure water is in
suction piping.
Alarm Zone A speed cont.
10:12 03-11 10:16 03-11
Speed Control (Variable Frequency Drive)
Fault.
Check VFD fault log.
Alarm Zone A sensor AI1
10:12 03-11 Actual
Sensor fault on Analog Input 1 (discharge
pressure transducer)
Check transducer connections (may just be
loose wire). Check transducer. Replace if
necessary.
Alarm Zone A sensor AI2
10:12 03-11 Actual
Sensor fault on Analog Input 2 (normally suc-
tion pressure transducer).
Check transducer connections (may just be
loose wire). Check transducer. Replace if
necessary.
Alarm Zone A sensor AI3
10:12 03-11 Actual
Sensor fault on Analog Input 3 (normally
external set-point).
Check external set-point source. Check con-
nection (may be loose or not connected at
all).
Alarm pump: 1 fault
10:12 03-11 Actual
Fault on pump number 1. If pump is on/off pump (constant speed),
check manual motor protector (breaker). If
pump is MLE or Baldor Smartmotor, check
motor fault log or consult motor Installation
& Operating Instructions. Check voltage moni-
tor relay.
Alarm PFU 123
15:12 03-11 Actual
There is a communication error between
the PMU and the PFU that is connected to
pumps 1, 2 and 3.
Check BUS (RS485) connection between PMU
and
PFU. Check power supply to PFU and/
or PMU. Check fuse in PFU.
BpaQ IO INDD.indd 1/28/2005, 11:01 AM12

Faults, general
Fault conditions in the system are indicated by:
• Red indicator light (LED) on PFU or PMU
• Red indicator light(s) (LED) on control panel door
• PFU 2000 fault signal relay (if connected to alarm or
light)
• PMU 2000 fault signal relay (if connected to alarm or
light)
• PMU 2000 LCD display
In the PMU 2000, if installed, the last 10 “Fault” indications
are stored and sorted by time, occurrence and correction. If
more than 10 faults occur, the current faults and the latest
reset faults will be kept in the fault memory. “Warnings”
remain stored until they are reset on the PMU 2000. This
does not apply to the faults exceeding 10.
Manual resetting (restarting of PFU 2000)
A manual reset followed by an immediate restart is accom-
plished in one of the following ways:
• Press the “Reset” button on the PFU 2000
• Turn the function selector in the PFU 2000 to STOP,
then adjust back to the original settings
• Reset the fault indication(s) which caused the stop by
pressing “Enter” while in the “Fault Indication Menu”
of the PMU 2000 until all faults are reset
The PFU 2000 can be manually reset every fifth second.
Automatic resetting
(restarting of PFU 2000)
When a fault has been corrected, the system will attempt
to restart automatically at the following intervals:
• 1st time after 15 seconds
• 2nd time after five minutes
• 3rd - 4th time at 30 minute intervals
• 5th - ? time once every 24 hours until the fault has been
corrected
Your BoosterpaQ will not restart automatically until the
fault has been corrected. Each fault condition, except for
faults which do not shut down operation, increases the
restarting count attempts stored in memory. The number
of stored restarting attempts is reduced to zero by manual
resetting, allowing an immediate restarting attempt.
If not manually reset, the number of stored restarting
attempts will be reduced by one every three hours after
the alarm disappears. After a certain time without faults,
an automatic restarting attempt will be made 15 seconds
after the fault has been corrected (“1st time mode”).
13
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Factory settings with standard
PFU 2000 System Controller
(PMU 2000 NOT installed)
The following entries are the factory settings for the
BoosterpaQ with the serial number which is listed on
page 2 of this manual (if “Standard PFU 2000 System
Controller” was marked). The factory settings cover
most standard booster applications. Please contact your
Grundfos representative if you believe the settings should
be changed to match your application or the system is not
operating properly.
PFU 2000 front cover
PFU 2000: Example only - check factory settings
oWITH Pre-pressure Measuring
(has a pressure transducer on the inlet manifold)
oWITHOUT Pre-pressure Measuring
(pressure switch or level switch on the inlet manifold)
OFF ON
1
2
3
4
5
6
7
8
9
OFF
ON
1 2 3 4
DIP/Switch #1 DIP/Switch #2
PFU 2000 #1
(for systems with 1 to 4 pumps)
"X" indicates that each
switch was slid to that
position for this BoosterpaQ
at the factory.
OFF ON
1
2
3
4
5
6
7
8
9
OFF
ON
1 2 3 4
DIP/Switch #1
DIP/Switch #2DIP/Switch #2
Installed
Not installed
PFU 2000 #2
(for systems with 5 or more pumps)
"X" indicates that each
switch was slid to that
position for this BoosterpaQ
at the factory.
See PFU 2000 Dip Switch
Configuration, page 34.
14
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DISPLAY SETTINGS
Set Point 100% (Not “Max.”)
Operating Mode Normal
Control Mode Uncontrolled
External Set Point 0-10 V
Signal Relay Ready
Buttons on Motor Not Active
Stop Function Not Active
Operations Range min. 12% max 100%
R100 factory settings
If the MLE motors have an R100 Interface Keypad (shown)
the following are the mandatory settings: (See CRE
Installation & Operating Instructions
for further explanation if necessary).
With Optional PMU 2000 System
Controller Installed
The following entries are the factory settings for the
BoosterpaQ with the serial number which is listed on page
2 of this manual (if “Optional” PMU 2000 system control-
ler” was marked). The factory settings cover most standard
booster applications. Please contact your Grundfos repre-
sentative if you believe the settings should be changed
to match your application or the system is not operating
properly. PMU 2000, Display 200 may require adjustment
(see Step 18).
PMU 2000 front cover
OFF ON
1
2
3
4
5
6
7
8
9
OFF
ON
1 2 3 4
DIP #1 DIP #2
PFU 2000 #1
(for systems with 1 to 4 pumps)
"X" indicates that each
switch was slid to that
position for this BoosterpaQ
at the factory.
OFF ON
1
2
3
4
5
6
7
8
9
OFF
ON
1 2 3 4
DIP #1
DIP #2
Installed
Not installed
PFU 2000 #2
(for systems with 5 or more pumps)
"X" indicates that each
switch was slid to that
position for this BoosterpaQ
at the factory.
OFF ON
1
2
3
4
5
6
7
8
9
OFF
ON
1 2 3 4
DIP #1 DIP #2
PFU 2000 #1
(for systems with 1 to 4 pumps)
"X" indicates that each
switch was slid to that
position for this BoosterpaQ
at the factory.
OFF ON
1
2
3
4
5
6
7
8
9
OFF
ON
1 2 3 4
DIP #1
DIP #2
Installed
Not installed
PFU 2000 #2
(for systems with 5 or more pumps)
"X" indicates that each
switch was slid to that
position for this BoosterpaQ
at the factory.
PFU 2000 DIP Switch Locations: Example only - check factory
settings
15
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101 All Pumps Set to o Zone A o Other ( )
104 Alarm Suppression o On o Off
105 Pump Communication o On o Off
111 Configuration Pre-Setting
o 8 With Pre-Pressure Monitoring o Other ( )
200 Set-point Max _______
201 Clock Program - See Below
202 Set-point Influence o On o Off
202 Set-point Influence ____%
204 System Time _____ seconds
205 Min Sequence _____seconds
206 Medium Sequence* ______seconds
207 On/Off Band _______
208 Pump Change o On o Off
209 Pump Change Time ________
212 Zone Name _________
213 Measuring Unit ________
214 Control Function o Normal o Inverse
219 Discharge Pressure Transducer (See Next Page)
216 Pre-Pressure Measuring o On o Off
220 Suction Pressure Transducer (See Next Page)
217 External Influence o Off o Ext. (See Below)
222 Input 4 o Off o Remote On/Off o Reduced Op. o Fire Fight
235 Hydraulic o Parallel o Series
226 Standby Pumps _____
227 Pump Priority (See Next Page)
228 Max. Limit (Discharge) _____
229 Min. Limit (Discharge) _____
230 Min. Limit Operation o On o Off
231 Min. Pre-Pressure ______
232 Maximum Pump Head (See Next Page)
300 Zone o On o Off o Local o Max
*Service Code Entry required
PMU factory settings
16
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Daily Sa-Su M-F
Time Set-point Time Set-point Time Set-point
201 clock program
219 discharge sensor
o 4-20mA o Other ( __________ )
o _____ to _____PSI o Other (________________)
220 suction sensor
o 4-20mA o Other ( __________ )
o _____to _____PSI o Other (________________)
227 pump priority
Pump 1 Pump 4
Pump 2 Pump 5
Pump 3 Pump 6
227 pump maximum head
Pump 1 Pump 4
Pump 2 Pump 5
Pump 3 Pump 6
17
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Danfoss VLT 2800 Factory Settings
Field changes
Parameter Description Factory setting New value Date
002 Local/Remote Operation 0
003 Local Reference Default
101 Torque Characteristics 2
102 Motor Power, kW
103 Motor Voltage
104 Motor Frequency, Hz
105 Motor Current, SFA
106 Rated Motor Speed, RPM
107 Automatic Motor Adaptation 2
128 Thermal Motor Protection 4
204 Minimum Reference
205 Maximum Reference
206 Ramp Type 2
207 Ramp Up Time
208 Ramp Down Time
214 Reference Function 2
215 Preset Reference 100
302 Digital Input 7
304 Digital Input 0
305 Digital Input 24
323 Relay Output 1
406 Automatic Restart Time 10
411 Switching Frequency 4500
018 Lock for Data Change 1
Additional settings
18
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Danfoss VLT 8000 Factory Settings
Factory Setting Field Changes
Item Number Parameter Value Value # New Value Date
1 001 Language English 0
2 102 Motor Power
3 103 Motor Voltage
4 104 Motor Frequency
5 105 Motor Current
6 106 Motor Speed
7 201 Minimum Freq.
8 202 Maximum Freq.
9 206 Ramp Up Time
10 207 Ramp Down Time
11 323 Relay 1 Function Ready Signal 1
12 326 Relay 2 Function Running 3
Additional Settings
19
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Danfoss VLT 8000 Factory Settings (continued)
Extended Menu Programming
Factory Setting Field Changes
Item Number Parameter Value Value # New Value Date
Level 0 007 Large Readout 3
008 Small Display Readout 16
009 Small Display Readout 5
010 Small Display Readout 6
Level 1 101 Torque Characteristics VT Low 2
112 Motor Preheater Disable 0
117 Motor Thermal Protection ETR Trip 1 4
Level 2 208 Automatic ramp-down Disable 0
210 Reference Type External/Preset 2
211 Preset Reference 1 100%
Level 3 302 Pin 18 Start 1
303 Pin 19 Reverse and Start 2
305 Pin 29 Preset Ref. On 6
308 Pin 53 Reference 1
309 Term. 53, Min. Scaling 0.0V
310 Term. 53, Max. Scaling 10V
325 Relay 01, Off Delay 2 sec
Level 4 400 Reset Function Automatic Reset x 10 6
401 Automatic Restart time 5 sec
407 Switching Frequency 4500
408 Interference Reduction Method Fixed Switching Freq. 0
Level 0 016 Lock for data change Locked 1
20
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