Grundfos ML Series User manual

GRUNDFOS INSTRUCTIONS
ML Motors
Installation and operating instructions

English (US)
2
English (US) Installation and operating instructions
Original installation and operating instructions
These installation and operating instructions describe Grundfos
ML. Sections 1-9 give the information necessary to be able to
unpack, install and start up the product in a safe way.
Sections 10-17 give important information about the product, as
well as information on service, fault finding and disposal of the
product.
CONTENTS
Page
1. General information
1.1 Symbols used in this document
1.2 Hazard statements
The symbols and hazard statements below may appear in
Grundfos installation and operating instructions, safety
instructions and service instructions.
The hazard statements are structured in the following way:
1. General information 2
1.1 Symbols used in this document 2
1.2 Hazard statements 2
1.3 Notes 3
2. Limited warranty 3
3. Safety 4
4. Introduction 4
5. Delivery and handling 4
5.1 Delivery 4
5.2 Unpacking 4
5.3 Handling 4
6. Operating conditions 5
6.1 Ambient temperature and installation altitude 5
6.2 Frequency converter operation 5
7. Mechanical installation 6
7.1 Clearance 6
7.2 Terminal box positions 6
7.3 Outdoor installation 6
7.4 Foundation 7
7.5 Alignment 7
7.6 Fitting of coupling parts and pulleys 7
8. Electrical installation 7
8.1 Electrical connection 7
8.2 Circuit breaker 7
9. Start-up 8
9.1 Measuring the insulation resistance 8
9.2 Direction of rotation 8
10. Identification 8
10.1 Nameplate 8
10.2 Type key 8
11. Construction 9
11.1 Drain holes 9
11.2 Motor bearings 9
11.3 Balancing 9
11.4 Cable entry/screwed connection 9
12. Operation 9
12.1 Maximum number of starts per hour 9
13. Maintenance 10
13.1 General maintenance 10
13.2 Motor bearings 10
14. Technical data 11
14.1 Weight, winding resistance, sound pressure level 11
14.2 Enclosure class 11
14.3 Dimensional sketches 11
15. Fault finding 11
16. Service 11
17. Disposal 11
Read this document before installing the product.
Installation and operation must comply with local
regulations and accepted codes of good practice.
DANGER
Indicates a hazardous situation which, if not avoided,
will result in death or serious personal injury.
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious personal injury.
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate personal injury.
SIGNAL WORD
Description of hazard
Consequence of ignoring the warning.
- Action to avoid the hazard.

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English (US)
1.3 Notes
The symbols and notes below may appear in Grundfos
installation and operating instructions, safety instructions and
service instructions.
The symbols and hazard statements below may appear in
Grundfos installation and operating instructions, safety
instructions and service instructions.
2. Limited warranty
Products manufactured by Grundfos Pumps Corporation
(Grundfos) are warranted to the original user only to be free of
defects in material and workmanship for a period of 24 months
from date of installation, but not more than 30 months from date
of manufacture. Grundfos' liability under this warranty shall be
limited to repairing or replacing at Grundfos' option, without
charge, F.O.B. Grundfos' factory or authorized service station,
any product of Grundfos manufacture. Grundfos will not be liable
for any costs of removal, installation, transportation, or any other
charges that may arise in connection with a warranty claim.
Products which are sold, but not manufactured by Grundfos, are
subject to the warranty provided by the manufacturer of said
products and not by Grundfos' warranty.
Grundfos will not be liable for damage or wear to products caused
by abnormal operating conditions, accident, abuse, misuse,
unauthorized alteration or repair, or if the product was not
installed in accordance with Grundfos' printed installation and
operating instructions and accepted codes of good practice. The
warranty does not cover normal wear and tear.
To obtain service under this warranty, the defective product must
be returned to the distributor or dealer of Grundfos' products from
which it was purchased together with proof of purchase and
installation date, failure date and supporting installation data.
Unless otherwise provided, the distributor or dealer will contact
Grundfos or an authorized service station for instructions. Any
defective product to be returned to Grundfos or a service station
must be sent freight prepaid; documentation supporting the
warranty claim and/or a Return Material Authorization must be
included if so instructed.
Grundfos will not be liable for any incidental or consequential
damages, losses, or expenses arising from installation, use, or
any other causes. There are no express or implied warranties,
including merchantability or fitness for a particular purpose, which
extend beyond those warranties described or referred to above.
Some jurisdictions do not allow the exclusion or limitation of
incidental or consequential damages and some jurisdictions do
not allow limitations on how long implied warranties may last.
Therefore the above limitations or exclusions may not apply to
you. This warranty gives you specific legal rights and you may
also have other rights which vary from jurisdiction to jurisdiction.
Products which are repaired or replaced by Grundfos or
authorized service center under the provisions of these limited
warranty terms will continue to be covered by Grundfos warranty
only through the remainder of the original warranty period set
forth by the original purchase date.
Observe these instructions for explosion-proof
products.
A blue or grey circle with a white graphical symbol
indicates that an action must be taken.
A red or grey circle with a diagonal bar, possibly with
a black graphical symbol, indicates that an action
must not be taken or must be stopped.
If these instructions are not observed, it may result in
malfunction or damage to the equipment.
Tips and advice that make the work easier.

English (US)
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3. Safety
Observe the safety instructions to ensure correct installation,
operation and maintenance of the motor. The instructions must
be known by any person installing, using or maintaining the
motor. Failure to observe the instructions may invalidate the
warranty.
Safety equipment required to prevent accidents must be made
available according to local safety instructions.
The electrical installation of the motor must be carried out
according to local regulations. In the USA, the National Electrical
Code, NEMA Standard MG 2, must be followed.
4. Introduction
These installation and operating instructions apply to the
following 2-pole Grundfos ML motors:
For model designation, see section 10.2 Type key.
5. Delivery and handling
5.1 Delivery
Immediately after the receipt, check the motor for external
damage. If this is the case, contact the shipping agent
immediately. Check whether all nameplate data are according to
specifications, especially as regards the voltage and check also
whether the winding has been connected correctly according to
the wiring diagram in the terminal box cover and the nameplate
data.
5.2 Unpacking
The motor should not be exposed to unnecessary impact and
shocks.
Remove transport protectors, if any. Turn the shaft by hand to
check that it rotates freely.
5.3 Handling
5.3.1 Lifting the motor
Take care not to damage additional equipment and cables.
The table shows the number of eyebolts and the maximum
permissible weight.
5.3.2 Storage
Until installation, Grundfos motors should be stored in the
packaging in which they were delivered.
Store the motors in an enclosed, dry and well-ventilated room.
For protection, treat unprotected machine surfaces (shaft ends
and flanges) with a corrosion inhibitor.
Storage temperature
-4 °F to 140 °F (-20 °C to +60 °C).
Power
[hp] NEMA frame size Efficiency class
1/3 56C
Premium
1/2 56C
3/4 56C
1 56C
1 1/2 56C
2 56C
3182TC
5182TC
7 1/2 213TC
10 215TC
15 254TC
20 256TC
25 284TSC
30 286TSC
Do not use sharp tools when unpacking the motor.
WARNING
Crushing of feet
Death or serious personal injury
- Wear personal protective equipment and attach
lifting equipment to the motor eyebolts when
handling the product.
- Keep other persons at a safe distance when
handling the product.
CAUTION
Crushing of feet
Minor or moderate personal injury
- Make sure that the eyebolts are secured in
position.
Frame size Power
[hp]
Number of eyebolts/max.
permissible weight
56C 1/3 - 3 2 x M8/310 lbs
(140 kg/1.4 kN)
182TC, 213TC,
215TC 5-10 2 x M10/510 lbs
(230 kg/2.3 kN)
254TC, 256TC,
284TC, 286TC 15-30 2 x M12/750 lbs
(340 kg/3.4 kN)
If ML motors are stored, the shaft must be turned by
hand at least once a month to prevent it from getting
stuck and to distribute the bearing grease.
If the motor has been stored for more than two years
before installation, the rotating parts must be
dismantled and checked. Relubricate motors with
lubricating nipples. Replace the greased-for-life
bearings.

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English (US)
6. Operating conditions
6.1 Ambient temperature and installation altitude
Grundfos motors are designed for operation at temperatures up
to 104 °F (40 °C). Grundfos ML motors are capable of continuous
operation at ambient temperatures up to 140 °F (60 °C), however
subject to a shorter bearing life. See section 13.2 Motor bearings.
The ambient temperature and the installation altitude are
important factors for the motor life.
The table does not show combined maximum values, meaning
that the motor is not capable of operating at 140 °F (60 °C) at an
altitude of 11500 ft (3500 m) at the same time.
If these values are exceeded, the motor must not be fully loaded
due to the risk of overheating.
Overheating may result from excessive ambient temperatures or
low density and consequently low cooling effect of the air.
In such cases, it may be necessary to reduce the load or use a
motor with a higher rated output.
The curves below show the maximum motor load of the various
efficiency classes.
Fig. 1 Motor output in relation to temperature/installation
altitude
Example
The example shows a motor under these operating conditions:
• Ambient temperature: 215 °F (65 °C).
• Installation altitude above sea level: 15600 ft (4750 m).
Maximum load of the motor:
• Ambient temperature of 215 °F (65 °C): 95 %.
• 15600 ft (4750 m) above sea level: 88 %.
As both operating conditions apply, the motor must not be loaded
more than (0.95 x 0.88) = 83.6 %.
6.2 Frequency converter operation
All three-phase ML motors with phase insulation can be
connected to a frequency converter.
6.2.1 Phase insulation
ML, from 1/3 to 1 1/2 hp
ML motors, from 1/3 to 1 1/2 hp, do not have phase insulation as
standard. The motors are not suitable for frequency converter
operation as they are not protected against the voltage peaks
caused by frequency converter operation.
Only motors with a rated voltage equal to or above 460 V have
phase insulation.
ML, from 2 to 30 hp
ML motors, from 2 to 30 hp, have phase insulation. The motors
are suitable for frequency converter operation, subject to these
precautions:
Operating conditions for ML motors to be used for frequency
converter operation
• Check that the motor has phase insulation.
(Only motors with a rated voltage equal to or above 460 V
have phase insulation.)
• Fit a sine-wave filter between the motor and the frequency
converter.
Max. ambient temperature at
full load
[°F / °C]
Max. installation altitude
above sea level at full load
[ft / m]
140 / 60 11500 / 3500
TM07 0345 5017
If the motor load is not reduced in case the ambient
temperature or installation altitude is exceeded, the
motor life will be limited, and the warranty is void.
20 25 30 35 40 45 50 55 60 65 70 T [°C]
50
60
70
80
90
100
110
[%]
P2
70 80 90 100 110 120 130 140 150 160 T [°F]
3280 7382 11483 15584 [ft]
Frequency converter operation of ML motors without
phase insulation will cause damage to the motor.

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6.2.2 Acoustic noise and voltage peaks
Frequency converter operation may cause increased acoustic
noise from the motor and will often expose the motor insulation
system to a heavier load due to voltage peaks reducing motor life.
To prevent the voltage peaks from damaging the motor, make
sure to observe the limits of IEC 60034-17.
Increased acoustic noise and detrimental voltage peaks can be
eliminated by fitting an output filter between the frequency
converter and the motor. For further details, contact your
frequency converter supplier or Grundfos.
Figure 2 shows the maximum permissible voltage peaks
measured at the motor terminals for a specific rise time.
Fig. 2 Maximum values for voltage peaks
How to eliminate problems with noise
• Noise-critical applications:
Fit an output filter between the frequency converter and the
motor. This will reduce the voltage peaks and consequently
the noise.
• Particularly noise-critical applications:
Fit a sinusoidal filter. This will reduce the voltage peaks and
optimise the sinusoidal wave of the power supply to the motor.
6.2.3 Cable length
The length of the cable between motor and frequency converter
affects the motor load. Fit a cable that meets the specifications
laid down by the frequency converter supplier.
6.2.4 Speed
Basically, ML motors are not suitable for oversynchronous
operation. Contact Grundfos if oversynchronous operation is
required.
Oversynchronous operation means that the motor runs at a
frequency higher than 60 Hz. This can be achieved by using a
frequency converter.
7. Mechanical installation
The installation must be carried out by authorised personnel in
accordance with local regulations.
Check by hand that the shaft rotates freely.
7.1 Clearance
To ensure sufficient air circulation, a clearance of minimum 2
inches (50 mm) must be available over/around the motor.
7.2 Terminal box positions
Fig. 3 Permissible terminal box positions
In case of vertically installed motors, the terminal box must not
fall more than 10 ° below the horizontal plane.
Make sure that the motor drain holes are positioned so that
condensed water can escape from the motor. See section
11.1 Drain holes.
7.3 Outdoor installation
If it is installed outdoors, protect the motor against rain, snow and
sunshine.
TM04 4556 1709
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6
t [mS]
800
900
1000
1100
1200
1300
1400
U [V]
WARNING
Crushing of feet
Death or serious personal injury
- Wear personal protective equipment and attach
lifting equipment to the motor eyebolts when
handling the product.
- Keep other persons at a safe distance when
handling the product.
CAUTION
Crushing of feet
Minor or moderate personal injury
- Make sure that the eyebolts are secured in
position.
TM04 5510 3309

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English (US)
7.4 Foundation
Grundfos recommends to install motor and pump on a foundation
which is heavy enough to provide permanent and rigid support.
The foundation must be capable of absorbing any vibration,
normal strain or shock.
7.5 Alignment
Correct alignment is important to avoid problems with bearings,
vibrations and possible fracture of shaft ends.
7.6 Fitting of coupling parts and pulleys
Fit coupling parts, pulleys and similar components using suitable
equipment and tools that do not damage the motor bearings.
Never knock a coupling part or pulley into position. Always carry
out removal without pressing against the motor.
8. Electrical installation
8.1 Electrical connection
The electrical installation of the motor must be carried out
according to local regulations. In the USA, the National Electrical
Code, NEMA Standard MG 2, must be followed.
The wiring diagram is located in the terminal box cover.
ML motors can be connected in star (Y), parallel star (YY), delta
(D) or parallel delta (DD). See the wiring diagram in the terminal
box cover.
Voltage and connection are stated on the nameplate.
Example: 208-230 YY/460 Y
• If the voltage supply is 208-230 V, the motor must be
connected in parallel star.
• If the voltage supply is 460 V, the motor must be connected in
star.
Operating voltage and operating frequency are stated on the
motor nameplate. Check that the motor is suitable for the power
supply available at the installation site.
The voltage quality for ML motors, measured at the motor
terminals, must fulfill the following requirements:
• At rated frequency, the voltage variation must not exceed ± 10
% of rated voltage.
• At rated voltage, the frequency variation must not exceed ± 5
% of rated frequency.
• The combined variation in voltage and frequency (sum of
absolute values) must not exceed ± 10 %, provided that the
frequency variation does not exceed ± 5 % of rated frequency
and that the voltage variation does not exceed ± 6 % of rated
voltage.
Performance within these voltage and frequency variations will
not necessarily be in accordance with the standards established
for operation at rated voltage and frequency.
8.2 Circuit breaker
ML motors must be used with the proper size and type of
motor-protective circuit breaker to ensure the motor is protected
against damage from low voltage, phase failure, current
unbalance and overloads.
Use a properly sized circuit breaker with manual reset and
ambient-temperature compensated extra-quick trip in all three
phases. The overload protection should be set and adjusted to
the full-load current rating of the motor. Under no circumstances
should the overload protection be set to a higher value than the
full-load current shown on the motor nameplate. This will void the
warranty.
Set overload protection for auto transformers and resistance
starters in accordance with the recommendations of the
manufacturer.
ML motors as from 4.0 hp (3.0 kW) are supplied with thermal
switches (PTC) as standard and protected against thermal
overload with both rapid and slow variation. The motor protection
is stated on the nameplate.
Non-compliance may result in functional faults which
will damage the motor components.
WARNING
Electric shock
Death or serious personal injury
- Before starting any work on the product, switch off
the power supply. Make sure that the power supply
cannot be accidentally switched on.
- Follow the wiring diagram located in the terminal
box cover.
- Do not remove nor move the insulation material, if
any, present inside the terminal box.
- Do not connect the motor to the voltage supply
until the connection to earth has been carried out
in accordance with local regulations.
WARNING
Body injury
Death or serious personal injury
- If you test the motor without any device fitted to it,
make sure that the key is secured in the shaft
keyway, so that it cannot be ejected when starting
the motor.

English (US)
8
9. Start-up
9.1 Measuring the insulation resistance
Measure the insulation resistance before start-up and in case of
any risk of moisture in the windings.
Calculate the minimum permissible insulation resistance, R, by
multiplying the rated voltage (in kV) of the motor with the constant
0.5 megohm/kV.
Stop using the motor immediately if the insulation resistance falls
below this value.
Example
If the rated voltage is 460 V, the measured resistance must be
higher than 0.46 kV x 0.5 megohm/kV = 0.23 megohm.
Measure the minimum permissible insulation resistance at a
winding temperature of 77 °F (25 °C) (± 15 °F/°C).
Procedure:
• Connect the megaohmmeter between phase and earth at a
measuring voltage of 500 V DC.
• Read the value on the megaohmmeter.
If the minimum insulation resistance is not attained, the windings
are too moist and must be oven-dried.
The oven temperature must be 194 °F (90 °C) for 12-16 hours
and then 221 °F (105 °C) for 6-8 hours.
9.2 Direction of rotation
The direction of rotation is clockwise, seen from the motor drive
end when the power conductors are connected in accordance
with the diagram located in the terminal box cover. The direction
of rotation can be changed by switching two random power
conductors.
10. Identification
10.1 Nameplate
The motor has one or two nameplates, depending on the frame
size. It is positioned on the side of the motor.
10.2 Type key
The type designation is stated on the nameplate.
WARNING
Electric shock
Death or serious personal injury
- When measuring the insulation resistance,
carefully follow the safety regulations of EN
50110-1 (operation of power plants) and the
instruction manual for measuring and test
equipment.
WARNING
Electric shock
Death or serious personal injury
- Do not touch the terminals until the windings are
de-energized.
During and immediately after the measurement,
there will be a risk of electric shock.
Remove any drain plugs before heating
Some ML motors have a properly directed fan. The
direction of rotation must be as stated on the motor.
60 Hz data are indicated on the nameplates for
three-phase motors.
Example ML 100 BC 2 182 TC -C
Motor Grundfos with cURus
approval
Frame size (centre line height of
motor shaft in mm, foot-mounted
motor, IEC)
The combination of letters indicates length of
stator core and motor output.
Number of poles:
2
Frame number
Frame letter:
T: Standard flange size for frame dimension
C: Type C face-mounting on drive end
Model designation:
C
D1
F1
H3

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English (US)
11. Construction
11.1 Drain holes
As standard, ML motors have drain holes in the drive end of the
stator housing.
If the motor is installed in a humid environment or in areas with
high air humidity, open the bottom drain hole. The drain holes
enable the escape of water which has entered the stator housing,
for instance through condensation.
Flange 56 C
The motor has three plugged drain holes.
Flange 182 TC
The motor has three plugged drain holes.
Flange 213 TC - 286 TSC
The motor has three plugged drain holes.
11.2 Motor bearings
The motor bearing type is stated on the nameplate.
Motors with lubricating nipples
Frame size 254TC and 286TC motors have lubricating nipples
both in the drive end and the non-drive end. The bearings are
lubricated from factory and should therefore not be lubricated
until commissioning.
The lubricating intervals are stated on the nameplate with
mechanical data. For information about lubrication and
maintenance of bearings, see section 13.2 Motor bearings.
11.3 Balancing
The rotor is dynamically balanced. As standard, the rotor has
been balanced with a half key inserted (cylindrical shaft).
11.4 Cable entry/screwed connection
Motors are supplied without screwed cable entries. The table
below shows the number and size of the cable entry holes of the
terminal box according to EN 50262.
12. Operation
12.1 Maximum number of starts per hour
If the drain plug is removed, the motor enclosure
class will change from IP55 to IP44.
TM03 1479 2205 TM03 1478 2205
ML 71 and ML 80 flanges
can be turned 180 ° and
90 ° to both sides.
ML 90 (CB and CC) flanges
can be turned 180 °
TM03 1478 2205
ML 90 (CB and FA), ML 100 and ML 112 flanges can be turned
180 °
TM03 1477 2205
ML 132-180 flanges can be turned 180 °
45º
30º
30º
Power
[hp] Frame size Number x
dimensions Description
1/3 - 1 1/2 56C 2 x 1/2" Two entries/holes
are closed with
blanking plugs,
and the two other
holes are closed
with knock-out
cable entries.
2-3 56C - 182C 2 x M20
2 x 1/2 "
5-10 182C - 215TC 2 x M25
2 x 3/4"
15-30 254TC - 286TC 4 x M40
2 x M20
The holes are
closed with
knock-out cable
entries.
CAUTION
Hot surface
Minor or moderate personal injury
- Wear protection equipment.
Power
[hp] Frame size Maximum number
of starts per hour
1/3 56C
200
1/2 56C
3/4 56C
1 56C
1 1/2 56C
2 56C
3182TC
5182TC
7 1/2 213TC
10010 215TC
15 254TC
20 256TC
4025 284TSC
30 286TSC

English (US)
10
13. Maintenance
Maintenance must be carried out by qualified personnel.
13.1 General maintenance
Inspect the motor at regular intervals, determined by the
environment in which the motor is installed. To ensure adequate
ventilation, it is important to keep the motor clean. If the motor is
installed in a dusty environment, it must be cleaned and checked
more often than if it is installed in non-dusty environment.
In standard motors, condensed water cannot escape. The drain
hole at the lowest point of the motor can be opened and ensure
the escape of water entering the stator housing, for example in
connection with condensation.
13.2 Motor bearings
13.2.1 Motors without lubricating nipples
The bearings are greased for life. The expected life is at least
18000 operating hours at an ambient temperature of up to 104 °F
(40 °C). A higher ambient temperature reduces life. A
temperature increase of 50 °F (10 °C) reduces life by 50 %.
Bearing grease
The technical specifications of the grease must correspond to
DIN 51825, K3N or better.
•50 cSt (mm
2/s) at 104 °F (40 °C)
• 8 cSt (mm2/s) at 212 °F (100 °C).
Grease filling rate: 30-40 %.
13.2.2 Motors with lubricating nipples
Lubricate the bearings with high-temperature grease as specified
on the motor nameplate with mechanical data.
Lubricating intervals are stated on the lubricating plate for 104 °F
(40 °C) and 140 °F (60 °C).
We recommend to dismantle the motor when the bearings have
been relubricated five times. Clean and check the bearings for
damage; replace them if necessary.
In the case of seasonal operation (motor is idle for more than six
months of the year), we recommend to lubricate the motor
bearings when you take it out of operation.
It is important to relubricate the bearings as specified on the
motor nameplate with mechanical data. If this interval is not
observed, the bearing life will be reduced.
Reduced lubricating interval
The lubricating interval must be reduced in these situations:
• Dirty and dusty environments. Reduce the lubricating interval
by a factor 0.75.
• Very moist environments. Reduce the lubricating interval by a
factor 0.9.
If the environments are both dusty and moist, multiply the factors.
Grease type and quantity
See the motor nameplate with mechanical data.
WARNING
Electric shock
Death or serious personal injury
- Before starting any work on the product, switch off
the power supply. Make sure that the power supply
cannot be accidentally switched on.
- Follow the wiring diagram located in the terminal
box cover.
- Do not connect the motor to the voltage supply
until the connection to earth has been carried out
in accordance with local regulations.
- Do not remove nor move the insulation material, if
any, present inside the terminal box.
- Before repairing or replacing the thermal switch or
thermistor, if any, make sure that the motor cannot
restart automatically after cooling.
WARNING
Crushing of feet
Death or serious personal injury
- Wear personal protective equipment and attach
lifting equipment to the motor eyebolts when
handling the product.
- Keep other persons at a safe distance when
handling the product.
CAUTION
Crushing of feet
Minor or moderate personal injury
- Make sure that the eyebolts are secured in
position.
WARNING
Body injury
Death or serious personal injury
- After assembling the motor, make sure that there
are no loose objects, for example near the
ventilator or under the fan cover, which could be
ejected when starting the motor.
- After assembling the motor, if you test the motor
without any device fitted to it, make sure that the
key is secured in the shaft keyway, so that it
cannot be ejected when starting the motor.
CAUTION
Hot surface
Minor or moderate personal injury
- Wear protection equipment.
Keep grease free from dirt to avoid damage to motor
bearings. If the environment is extremely dirty,
contact Grundfos, the motor manufacturer, or an
authorized service center for additional information.
Do not mix dissimilar types of grease.
Never mix grease with thickeners, such as
lithium-based grease with polycarbamide-based
grease.