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Grundfos CUE User manual

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12

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GRUNDFOS
                                   
'HFODUDWLRQRIFRQIRUPLW\
2
Declaration of conformity
We, Grundfos, declare under our sole responsibility that the products
CUE, to which this declaration relates, are in conformity with these
Council directives on the approximation of the laws of the EC member
states:
— Low Voltage Directive (2006/95/EC).
Standard used: EN 61800-5-1: 2003.
— EMC Directive (2004/108/EC).
Standard used: EN 61800-3: 2005.
Bjerringbro, 15th December 2010
Jan Strandgaard
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.
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3
          
Installation and operating instructions
         ! "   "  #    $ # % &   "      ! "  ' ( "  #  ! )
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; 1 <  9 = 58 6 :9  5
This manual introduces all aspects of your Grundfos CUE
frequency converter in the power range of 0.55 to 90 kW.
Always keep this manual close to the CUE.
> ? @ A B C B D E F G B H I D J K L J M C
CUE is a series of external frequency converters especially
designed for pumps.
Thanks to the start-up guide in the CUE, the installer can quickly
set central parameters and put the CUE into operation.
Connected to a sensor or an external control signal, the CUE will
quickly adapt the pump speed to the actual demand.
> ? > N K K F J I E L J M C H
The CUE series and Grundfos standard pumps are a supplement
to the Grundfos E-pumps range with integrated frequency
converter.
A CUE solution offers the same E-pump functionality
• in the mains voltage or power ranges not covered by the
E-pump range.
• in applications where an integrated frequency converter is not
desirable or permissible.
> ? O P B Q B D B C I B H
Technical documentation for Grundfos CUE:
• The manual contains all information required for putting the
CUE into operation.
• The data booklet contains all technical information about the
construction and applications of the CUE.
• Service instructions contain all required instructions for
dismantling and repairing the frequency converter.
Technical documentation is available on www.grundfos.com >
International website > WebCAPS.
If you have any questions, please contact the nearest Grundfos
company or service workshop.
R) S T U V # ! ' ! & $   " W  ! $ # ( ' U &  " X
Y) Z  "  # $ ' ( "  #  X
2.1 General description 3
2.2 Applications 3
2.3 References 3
X
) S  [ & " T   $ \       ! ]
3.1 Warning 4
3.2 Safety regulations 4
3.3 Installation requirements 4
3.4 Reduced performance under certain conditions 4
]
) Z $ &  "  [  (  "  #  ]
4.1 Nameplate 4
4.2 Packaging label 4
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) _ & ( W    (    ! "   "  # 
^
5.1 Reception and storage 5
5.2 Transportation and unpacking 5
5.3 Space requirements and air circulation 5
5.4 Mounting 5
`) a & ( "   (  ( #   & ( "  # 
`
6.1 Electrical protection 6
6.2 Mains and motor connection 6
6.3 Connecting the signal terminals 10
6.4 Connecting the signal relays 12
6.5 Connecting the MCB 114 sensor input module 14
6.6 EMC-correct installation 14
6.7 RFI filters 15
6.8 Output filters 15
6.9 Motor cable 15
b
)  % &   "    U # $ & !
R `
c) d #  "  # U # $ & !
R `
8.1 Uncontrolled operation (open loop) 16
8.2 Controlled operation (closed loop) 16
e) _ &  ' # f &  f  & \
Rb
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R e
10.1 Control panel 19
10.2 Back to factory setting 19
10.3 CUE settings 19
10.4 Start-up guide 20
10.5 Menu GENERAL 23
10.6 Menu OPERATION 24
10.7 Menu STATUS 25
10.8 Menu INSTALLATION 26
R R ) S & " "    V T U &   ! # [ /d h # # a i %  # $ ' ( " ! X
Y
R Y )/  #   " T # [ ! & " "    ! X X
12.1 Control without bus signal, local operating mode 33
12.2 Control with bus signal, remote-controlled operating
mode 33
R
X
) a j " &    ( #  "  # !     ! X X
13.1 Digital inputs 33
13.2 External setpoint 33
13.3 GENIbus signal 34
13.4 Other bus standards 34
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]
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14.1 Cleaning the CUE 34
14.2 Service parts and service kits 34
R^
) k  ' " [   $    X ]
15.1 Warning and alarm list 34
15.2 Resetting of alarms 35
15.3 Indicator lights 35
15.4 Signal relays 35
R ` ) h & ( W   (  $  "  X
`
16.1 Enclosure 36
16.2 Cable entry 36
16.3 Main dimensions and weight 37
16.4 Surroundings 37
16.5 Terminal tightening torques 37
16.6 Cable length 38
16.7 Fuses and cable cross-section 38
16.8 Inputs and outputs 40
16.9 Sound pressure level 40
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Wait only for shorter time if stated so on the nameplate of the
CUE in question.
O ? >  E Q B L  D B   F E L J M C H
• The on/off button of the control panel does not disconnect the
CUE from the power supply and must therefore not be used as
a safety switch.
• The CUE must be earthed correctly and protected against
indirect contact according to national regulations.
• The leakage current to earth exceeds 3.5 mA.
• Enclosure class IP20/21 must not be installed freely
accessible, but only in a panel.
• Enclosure class IP54/55 must not be installed outdoors
without additional protection against water and the sun.
• Always observe national and local regulations as to cable
cross-section, short-circuit protection and overcurrent
protection.
O ? O  C H L E F F E L J M C D B   J D B  B C L H
The general safety necessitates special considerations as to
these aspects:
• fuses and switches for overcurrent and short-circuit protection
• selection of cables (mains current, motor, load distribution and
relay)
• net configuration (IT, TN, earthing)
• safety on connecting inputs and outputs (PELV).
X
)
X
)RZ h U    !
In connection with IT mains and earthed delta mains, the mains
voltage may exceed 440 V between phase and earth.
X
)
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)Y     & ! !  f & &  f   #  U &  "
The CUE contains a large number of mechanical and electronic
components. They are all vulnerable to environmental effects.
O ?  P B G  I B G K B D Q M D  E C I B  C G B D I B D L E J C I M C G J L J M C H
The CUE will reduce its performance under these conditions:
• low air pressure (at high altitude)
• long motor cables.
The required measures are described in the next two sections.
X
)
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PELV = Protective Extra Low Voltage.
At low air pressure, the cooling capacity of air is reduced, and the
CUE automatically reduces the performance to prevent overload.
It may be necessary to select a CUE with a higher performance.
X
)
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)Y  & $ ' ( "  #    ( #   & ( "  #  \  " W #   U # " #  (  V & !
The maximum cable length for the CUE is 300 m for unscreened
and 150 m for screened cables. In case of longer cables, contact
Grundfos.
The CUE is designed for a motor cable with a maximum cross-
section as stated in section
     ¡ ¢ £ ¢ ¤ ¥ ¦ § ¤ ¨ © £ § ª « ¢ ¢ ¬ ¢ £ §  ® « ¥
.
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 ? @ ° E  B K F E L B
The CUE can be identified by means of the nameplate.
An example is shown below.
k   ) R
Example of nameplate
 ? > ± E I ² E  J C  F E ³ B F
The CUE can also be identified by means of the label on the
packaging.
m n o p q p r
´ p  q p v u n w w n u q t p x

n q p u y p n p ~ y n p z q p v | y ~ u q t p

} v u  y ~ n o o q y z t } u   u o n q p y z | y o v t p p y w 
m n o p q p r
µ t } ~ { q p r u { y y w y ~ u o q ~ n w | n o u v

n   y  n u n w x y  y p
n  u y o u { y ¶ · ¸ { n v  y y p v  q u ~ { y z t   
¹ y  t o y

n  q p r n p   t o  t p u { y ¶ · ¸ x u { y

n q p v
v } | | w  n p z t u { y o q p | } u  t w u n r y v

} v u  y
v  q u ~ { y z t   n u w y n v u  t o n v w t p r n v v u n u y z  y w t  
º# "   & _   ) \   "    "  U &
4 minutes 15 minutes 20 minutes
200-240 V 0.75 - 3.7 kW 5.5 - 45 kW
380-500 V 0.55 - 7.5 kW 11 - 90 kW
525-600 V 0.75 - 7.5 kW
525-690 V 11 - 90 kW
m n o p q p r
» t p t u ~ t p p y ~ u ¼ ½ ¾ ¿ À ¾ ¾ Á ¶ · ¸  o y  } y p ~ 
~ t p  y o u y o v u t

n q p v v } | | w q y v  q u { n  t w u n r y
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| n o u q ~ w y v t o r n v y v  { q ~ {
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n  n   y ~ u n p z z n
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m n o p q p r
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TM04 3272 3808
h & j " l & ! (   % "  # 
T/C: CUE (product name)
202P1M2... (internal code)
Prod.no: Product number: 12345678
S/N:
Serial number: 123456G234
The last three digits indicate the production date:
23 is the week, and 4 is the year 2004.
1.5 kW Typical shaft power on the motor
IN: Supply voltage, frequency and maximum input
current
OUT:
Motor voltage, frequency and maximum output
current. The maximum output frequency usually
depends on the pump type.
CHASSIS/
IP20 Enclosure class
Tamb. Maximum ambient temperature
T/C: CUE202P1M2T5E20H1BXCXXXSXXXXAXBXCXXXXDX
Prod. no: 12345678 S
/
N: 123456G234
IN: 3x380-500 V 50/60Hz 3.7A
OUT: 3x0-Vin 0-100Hz 4.1 A 2.8 kV
A
CHASSIS/IP20 Tamb. 45C/122F
IIIIIIIIIIIBAR CODEIIIIIIIIIII MADE IN DENMARK
Listed 76X1 E134261 Ind. Contr. Eq.
See manual for prefuse
CAUTION:
SEE MANUAL
/
VOIR MANUEL
WARNING:
STORED CHARGE DO NOT TOUCH UNTIL
4 MIN AFTER DISCONNECTION
CHARGE RESIDUELLE, ATTENDRE
4 MIN APRES DECONNEXION
1.5 kW (400V)
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The individual CUE cabinet sizes are characterised by their
enclosures. The table in section
   
shows the relationship of
enclosure class and enclosure type.
Ç? @ P B I B K L J M C E C G H L M D E  B
Check on receipt that the packaging is intact, and the unit is
complete. In case of damage during transport, contact the
transport company to complain.
Note that the CUE is delivered in a packaging which is not
suitable for outdoor storage.
Ç? > È D E C H K M D L E L J M C E C G  C K E I ² J C 
The CUE must only be unpacked at the installation site to prevent
damage during the transport to the site.
The packaging contains accessory bag(s), documentation and
the unit itself. See fig 2.
k   ) Y
CUE packaging
Ç? O  K E I B D B   J D B  B C L H E C G E J D I J D I  F E L J M C
CUE units can be mounted side by side, but as a sufficient air
circulation is required for cooling these requirements must be
met:
• Sufficient free space above and below the CUE.
See table below.
• Ambient temperature up to 50 °C.
• Hang the CUE directly on the wall, or fit it with a back plate.
See fig. 3.
k   )
X
CUE hung directly on the wall or fitted with a back
plate
& É '   & $ [  & & ! %  ( &  V # f &   $ V & # \ " W & d Ê a
For information about enclosure, see table in section
   
.
Ç?  Ë M  C L J C 
1. Mark and drill holes. See the dimensions in section
   Ì
.
2. Fit the screws, but leave loose. Mount the CUE, and tighten
the four screws.
k   )
]
Drilling of holes
TM03 8857 2607
Accessory
bag(s)
Documentation
TM03 8859 2607
a  ( # ! '  & S %  ( & Í U U Î
A2, A3, A4, A5 100
B1, B2, B3, B4, C1, C3 200
C2, C4 225
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
v } o  n ~ y 
TM03 8860 2607
b
a
a
b
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^
Example of three-phase mains connection of the CUE
with mains switch, back-up fuses and additional
protection
Ð ? @ Ñ F B I L D J I E F K D M L B I L J M C
`)R)R /  # " & ( "  #       ! " & & ( "   ( ! W # ( Ò Ó   $   & ( " ( #  "  ( "
Protective conductors must always have a yellow/green (PE) or
yellow/green/blue (PEN) colour marking.
Instructions according to EN IEC 61800-5-1:
• The CUE must be stationary, installed permanently and
connected permanently to the mains supply.
• The earth connection must be carried out with duplicate
protective conductors or with a single reinforced protective
conductor with a cross-section of minimum 10 mm2.
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The CUE and the supply system must be protected against short-
circuit.
Grundfos demands that the back-up fuses mentioned in section
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are used for protection against short-circuit.
The CUE offers complete short-circuit protection in case of a
short-circuit on the motor output.
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If the CUE is connected to an electrical installation where an
earth leakage circuit breaker (ELCB) is used as additional
protection, the circuit breaker must be of a type marked with the
following symbols:
The circuit breaker is
" T % & Ô
.
The total leakage current of all the electrical equipment in the
installation must be taken into account.
The leakage current of the CUE in normal operation can be seen
in section
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.
During start and in asymmetrical supply systems, the leakage
current can be higher than normal and may cause the ELCB to
trip.
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The motor requires no external motor protection. The CUE
protects the motor against thermal overloading and blocking.
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The CUE has an internal overcurrent protection for overload
protection on the motor output.
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The CUE is protected against mains voltage transients according
to EN 61800-3, second environment.
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The supply voltage and frequency are marked on the CUE
nameplate. Make sure that the CUE is suitable for the power
supply of the installation site.
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A mains switch can be installed before the CUE according to local
regulations. See fig. 5.
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The wires in the terminal box must be as short as possible.
Excepted from this is the protective conductor which must be so
long that it is the last one to be disconnected in case the cable is
inadvertently pulled out of the cable entry.
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Wiring diagram, three-phase mains connection
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91 (L1)
Three-phase supply92 (L2)
93 (L3)
95/99 (PE) Earth connection
96 (U) Three-phase motor connection, 0-100 % of
mains voltage
97 (V)
98 (W)
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.
1. Fit the mounting plate with two screws.
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Fitting the mounting plate
2. Connect the earth conductor to terminal 95 (PE) and the mains
conductors to the terminals 91 (L1), 92 (L2), 93 (L3) of the
mains plug. Put the mains plug into the socket marked MAINS.
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Connecting the earth conductor and mains conductors
3. Fix the mains cable to the mounting plate.
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Fixing the mains cable
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1. Connect the earth conductor to terminal 99 (PE) on the
mounting plate. Connect the motor conductors to the terminals
96 (U), 97 (V), 98 (W) of the motor plug.
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Connecting the earth conductor and motor conductors
2. Put the motor plug into the socket marked MOTOR. Fix the
screened cable to the mounting plate with a cable clamp.
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Connecting the motor plug and fixing the screened
cable
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1. Connect the earth conductor to terminal 95 (PE). See fig. 12.
2. Connect the mains conductors to the terminals 91 (L1),
92 (L2), 93 (L3) of the mains plug.
3. Put the mains plug into the socket marked MAINS.
4. Fix the mains cable with a cable clamp.
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Mains connection, A4 and A5
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1. Connect the earth conductor to terminal 99 (PE). See fig. 13.
2. Connect the motor conductors to the terminals 96 (U), 97 (V),
98 (W) of the motor plug.
3. Put the motor plug into the socket marked MOTOR.
4. Fix the screened cable with a cable clamp.
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1. Connect the earth conductor to terminal 95 (PE). See fig. 14.
2. Connect the mains conductors to the terminals 91 (L1),
92 (L2), 93 (L3).
3. Fix the mains cable with a cable clamp.
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Mains connection, B1 and B2
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1. Connect the earth conductor to terminal 99 (PE). See fig. 15.
2. Connect the motor conductors to the terminals 96 (U), 97 (V),
98 (W).
3. Fix the screened cable with a cable clamp.
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1. Connect the earth conductor to terminal 95 (PE).
See figs 16 and 17.
2. Connect the mains conductors to the terminals 91 (L1),
92 (L2), 93 (L3).
3. Fix the mains cable with a cable clamp.
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1. Connect the earth conductor to terminal 99 (PE).
See figs 16 and 17.
2. Connect the motor conductors to the terminals 96 (U), 97 (V),
98 (W).
3. Fix the screened cable with a cable clamp.
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Mains and motor connection, B3
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Mains and motor connection, B4
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1. Connect the earth conductor to terminal 95 (PE). See fig. 18.
2. Connect the mains conductors to the terminals 91 (L1),
92 (L2), 93 (L3).
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1. Connect the earth conductor to terminal 99 (PE). See fig. 18.
2. Connect the motor conductors to the terminals 96 (U), 97 (V),
98 (W).
3. Fix the screened cable with a cable clamp.
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1. Connect the earth conductor to terminal 95 (PE).
See figs 19 and 20.
2. Connect the mains conductors to the terminals 91 (L1),
92 (L2), 93 (L3).
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1. Connect the earth conductor to terminal 99 (PE).
See figs 19 and 20.
2. Connect the motor conductors to the terminals 96 (U), 97 (V),
98 (W).
3. Fix the screened cable with a cable clamp.
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Mains and motor connection, C3
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Mains and motor connection, C4
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Connect the signal cables according to the guidelines for good
practice to ensure EMC-correct installation. See section
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.
• Use screened signal cables with a conductor cross-section of
min. 0.5 mm2and max. 1.5 mm2.
• Use a 3-conductor screened bus cable in new systems.
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Terminals 27, 29 and 37 are not used.
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12 +24 V out Supply to sensor
13 +24 V out Additional supply
18 DI 1 Digital input, start/stop
19 DI 2 Digital input, programmable
20 GND Common frame for digital inputs
32 DI 3 Digital input, programmable
33 DI 4 Digital input, programmable
39 GND Frame for analog output
42 AO 1 Analog output, 0-20 mA
50 +10 V out Supply to potentiometer
53 AI 1 External setpoint, 0-10 V/0/4-20 mA
54 AI 2 Sensor input, sensor 1, 0/4-20 mA
55 GND Common frame for analog inputs
61 RS-485 GND Y GENIbus, GND
68 RS-485 A GENIbus, signal A (+)
69 RS-485 B GENIbus, signal B (-)
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DI 3
DI 4
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Ext. setpoint
Sensor 1
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RS-485 B
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Start/stop
Terminals
53 and 54:
See section
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