Grundfos UPE 2000 FZ Series User manual

GRUNDFOS INSTRUCTIONS
UPE Series 2000 FZ
Service parts

Table of contents
3
UPE Series 2000 FZ
English (GB) Installation and operating instructions . . . . . . . . . . . . . . . . .4
Dansk (DK) Monterings- og driftsinstruktion. . . . . . . . . . . . . . . . . . . . . .16
Deutsch (DE) Montage- und Betriebsanleitung. . . . . . . . . . . . . . . . . . . . .28
Ελληνικά (GR) Οδηγίες εγκατάστασης και λειτουργίας. . . . . . . . . . . . . . . .40
Español (ES) Instrucciones de instalación y funcionamiento . . . . . . . . . .52
Français (FR) Notice d'installation et de fonctionnement . . . . . . . . . . . . .64
Italiano (IT) Istruzioni di installazione e funzionamento . . . . . . . . . . . . .76
Nederlands (NL) Installatie- en bedieningsinstructies . . . . . . . . . . . . . . . . . .88
Português (PT) Instruções de instalação e funcionamento . . . . . . . . . . . .100
Русский (RU) Руководство по монтажу иэксплуатации . . . . . . . . . . .112
Suomi (FI) Asennus- ja käyttöohjeet . . . . . . . . . . . . . . . . . . . . . . . . .125
Svenska (SE) Monterings- och driftsinstruktion. . . . . . . . . . . . . . . . . . . .137
Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149

English (GB)
4
English (GB) Installation and operating instructions
Original installation and operating instructions.
CONTENTS Page
1. Symbols used in this document 5
2. General introduction 5
3. Replacement of control box 6
4. Replacement of power head 8
5. Replacement of differential-pressure sensor 10
6. Replacement of control box fan 11
7. Replacement of connecting cable (UPED 80-120 FZ) 12
8. Configuration of twin-head pumps 13
9. Start-up 14
9.1 Venting the pump 14
10. Disposal 15
Warning
Prior to installation, read these installation and operating
instructions. Installation and operation must comply with
local regulations and accepted codes of good practice.
Warning
The use of this product requires experience with and
knowledge of the product.
Persons with reduced physical, sensory or mental capabilities
must not use this product, unless they are under supervision
or have been instructed in the use of the product by a person
responsible for their safety.
Children must not use or play with this product.

English (GB)
5
1. Symbols used in this document
2. General introduction
These instructions relate to UPE Series 2000 circulator pumps, types UPE,
UPED 80-120 FZ and UPE 100-120 FZ and describe how to replace the
following components:
• control box
• power head
• differential-pressure sensor
• control box fan
• connecting cable (UPED 80-120 FZ).
See also the general installation and operating instructions and the
document "Supplement to installation and operating instructions" included.
All figures referred to can be found in the fold-out page at the end of this
booklet. In most figures only a single-head pump is shown, but all
dismantling and assembly instructions apply to both single-head and twin-
head pumps.
Warning
If these safety instructions are not observed, it may result in
personal injury!
Warning
The surface of the product may be so hot that it may cause
burns or personal injury.
Caution
If these safety instructions are not observed, it may result in
malfunction or damage to the equipment!
Note
Notes or instructions that make the job easier and ensure safe
operation.

English (GB)
6
3. Replacement of control box
Dismantling
1. Check that the "Reorder No." of the new control box is identical to that of
the existing control box. See fig. 1.
2. Switch off the power supply to the pump, and make sure that it cannot be
accidentally switched on again during replacement.
3. Remove the four screws securing the control box cover. Remove the
cover. See fig. 2.
4. Before disconnecting any leads, carefully note their position.
5. Disconnect all leads from the control box.
6. Unscrew the five screws securing the printed circuit board (PCB) to the
control box bottom and remove the PCB from the control box. See fig. 4.
7. Remove the two rubber plugs. See fig. 6.
8. Remove the two screws securing the terminal box to the power head.
See fig. 5.
9. Remove the control box bottom from the power head. See fig. 6.
10.Dismantle the new control box for easy mounting. See fig. 2 and fig. 4.
Warning
Never make any connections in the pump control box unless
the power supply has been switched off for at least 5 minutes.
Make sure that voltage supplies from other external systems
have been switched off as well.
Caution
Always use an antistatic service kit (Grundfos ESD,
protection set prod. no. 96884939) when dismantling and
assembling the terminal box as the electronics are sensitive
to static electricity. Connect the antistatic service kit to the
connection terminal of the protective earth lead (PE terminal).

English (GB)
7
Assembly
1. Mount the new control box bottom on the power head. See fig. 6.
Check that the gasket is positioned correctly. See fig. 7.
Be careful not to damage the motor cable.
Refer to section Wiring diagram in the general installation and operating
instructions.
2. Remove the two rubber plugs. See fig. 6.
3. Fit and tighten the two screws. See fig. 5.
4. Mount the PCB, fit and tighten the five screws. See fig. 4.
5. Connect the motor cable including screen and PE lead. See fig. 8.
6. Enter the leads into the control box bottom via the cable entries.
7. Connect all the leads in the same positions as before dismantling.
8. Mount the cover, fit and tighten the four screws. See fig. 2.
9. Twin-head pumps:
Follow the instructions given in section 8. Configuration of twin-head
pumps in order to obtain the right configuration.
The pump is now ready for operation.
See section 9. Start-up.

English (GB)
8
4. Replacement of power head
Dismantling
1. Note the pump type of the faulty power head and find the corresponding
service nameplate delivered together with the new power head. Fit the
service nameplate on the new power head. See fig. 9.
2. Switch off the power supply to the pump, and make sure that it cannot be
accidentally switched on again during replacement.
3. Close the isolating valves on either side of the pump or empty pipe
system for water.
4. Remove the four screws securing the control box cover. Remove the
cover. See fig. 2.
5. Before disconnecting any leads, carefully note their position.
6. Disconnect all leads from the control box.
7. Unscrew the five screws securing the PCB to the control box bottom and
remove the PCB from the control box. See fig. 4.
8. Remove the two rubber plugs. See fig. 6.
9. Remove the two screws securing the terminal box to the power head.
See fig. 5.
Warning
Please note that the pump may be hot for a while after being
switched off and that hot liquid may escape from the pump
during dismantling.
Warning
Never make any connections in the pump control box unless
the power supply has been switched off for at least 5 minutes.
Make sure that voltage supplies from other external systems
have been switched off as well.
Caution
Always use an antistatic service kit (Grundfos ESD,
protection set prod. no. 96884939) when dismantling and
assembling the terminal box as the electronics are sensitive
to static electricity. Connect the antistatic service kit to the
connection terminal of the protective earth lead (PE terminal).

English (GB)
9
10.Remove the control box bottom from the power head. See fig. 6.
11. Hold the power head, and remove the four screws securing the power
head to the pump housing. See fig. 10.
12.Pull off the power head. See fig. 11.
Assembly
1. Check that the O-ring is in place. See fig. 12.
2. Fit the new power head in the same position as old power head.
See fig. 11.
3. Fit and tighten the four screws diagonally (20 Nm). See fig. 10.
4. Mount the control box bottom on the power head. See fig. 6.
Check that the gasket is positioned correctly. See fig. 7.
Be careful not to damage the motor cable.
5. Fit and tighten the two screws. See fig. 5.
6. Mount the PCB, fit and tighten the five screws. See fig. 4.
7. Connect the motor cable including screen and PE lead. See fig. 8.
8. Enter the leads into the control box bottom via the cable entries.
9. Connect all the leads in the same positions as before dismantling.
10.Mount the cover, fit and tighten the four screws. See fig. 2.
11. Open the isolating valves on either side of the pump.
12.Twin-head pumps:
Follow the instructions given in 8. Configuration of twin-head pumps in
order to obtain the right configuration.
The pump is now ready for operation.
See section 9. Start-up.
Warning
Take care that escaping liquid does not cause personal injury
or damage to components.

English (GB)
10
5. Replacement of differential-pressure sensor
Dismantling
1. Switch off the power supply to the pump, and make sure that it cannot be
accidentally switched on again during replacement.
2. Close the isolating valves on either side of the pump or empty pipe
system for water.
3. Remove the four screws securing the control box cover. Remove the
cover. See fig. 2.
4. Disconnect the plug from the terminal block (D). See fig. 13. Refer to
section Wiring diagram in the general installation and operating
instructions.
5. Unscrew the cable entry. See fig. 14.
6. Remove the two screws securing the metal block with the differential
pressure sensor to the pump housing. See fig. 15.
7. Remove the metal block with the sensor from the pump. See fig. 15.
8. Dispose of the faulty differential pressure sensor according to
section 10. Disposal.
Assembly
1. Place the O-ring from the sensor kit on the pump housing. See fig. 17.
1. Fit the metal block holding the sensor on the pump housing without
damaging the O-ring. See fig. 16.
2. Tighten the two screws. See fig. 15.
3. Enter the lead into the control box bottom.
4. Fit the plug into the terminal block (D). See fig. 13.
5. Tighten the cable entry. See fig. 14.
6. Mount the cover, fit and tighten the four screws. See fig. 2.
7. Open the isolating valves on either side of the pump.
The pump is now ready for operation. See section 9. Start-up.
Warning
Please note that the pump may be hot for a while after being
switched off and that hot liquid may escape from the pump
during dismantling.
Warning
Never make any connections in the pump control box unless
the power supply has been switched off for at least 5 minutes.
Make sure that voltage supplies from other external systems
have been switched off as well.

English (GB)
11
6. Replacement of control box fan
Dismantling
1. Switch off the power supply to the pump, and make sure that it cannot be
accidentally switched on again during replacement.
2. Remove the four screws securing the control box cover. Remove the
cover. See fig. 2.
3. Remove the fan from the heat sink in the control box. See fig. 19.
4. Disconnect the fan plug from the fan socket in the PCB. See fig. 19.
5. Dispose of the faulty fan according to section 10. Disposal.
Assembly
1. Fit the plug of the new fan into the socket in the PCB. See fig. 19.
2. Mount the new fan. See fig. 19.
3. Mount the cover, fit and tighten the four screws. See fig. 2.
The pump is now ready for operation. See section 9. Start-up.
Warning
Never make any connections in the pump control box unless
the power supply has been switched off for at least 5 minutes.
Make sure that voltage supplies from other external systems
have been switched off as well.
Caution
Always use an antistatic service kit (Grundfos ESD,
protection set prod. no. 96884939) when dismantling and
assembling the terminal box as the electronics are sensitive
to static electricity. Connect the antistatic service kit to the
connection terminal of the protective earth lead (PE terminal).
Note
The arrows marked on the side of the fan shows the direction
of rotation and the direction of the cooling air. See fig. 20.

English (GB)
12
7. Replacement of connecting cable (UPED 80-120 FZ)
Dismantling
1. Switch off the power supply to the pump, and make sure that it cannot be
accidentally switched on again during replacement.
2. Remove the 2 x 4 screws securing the control box covers on the two
control boxes. Remove the covers. See fig. 2.
3. Disconnect the connecting cable from the sockets. See fig. 21.
4. Unscrew the two cable entries on the two control boxes.
5. Remove the connecting cable.
Assembly
1. Enter the connecting cable into the control box bottoms.
2. Mount plugs of the new connecting cable in the sockets of the two control
boxes. See fig. 21.
3. Fit and tighten the two cable entries.
4. Mount the covers, fit and tighten the 2 x 4 screws. See fig. 2.
The pump is now ready for operation. See section 9. Start-up.
Warning
Please note that the pump may be hot for a while after being
switched off and that hot liquid may escape from the pump
during dismantling.
Warning
Never make any connections in the pump control box unless
the power supply has been switched off for at least 5 minutes.
Make sure that voltage supplies from other external systems
have been switched off as well.

English (GB)
13
8. Configuration of twin-head pumps
Use the procedure below to establish the correct master/slave configuration
in case one of the control boxes or both have been replaced.
Configuration
1. Switch off the power supply to the pump.
2. Switch on the power supply and press the two arrow buttons on the front
simultaneously for 15 seconds (two flashing light fields indicate that the
pump is in configuration mode).
3. Keep the buttons depressed, and the flashing light fields will change.
See the meaning of the different settings in the table below.
4. Release the buttons when the control box is in the appropriate mode.
Refer to the general installation and operating instructions and the document
Supplement to installation and operating instructions for further information
about setting of the pump.
Configuration Light fields
Single pump
TM04 6834 1010
Master pump, marked (1)
TM04 6835 1010
Slave pump, marked (2)
TM04 6833 1010

English (GB)
14
9. Start-up
Do not start the pump until the system has been filled with liquid and vented.
Furthermore, the required minimum inlet pressure must be available at the
pump inlet. See the general installation and operating instructions.
9.1 Venting the pump
Vent the pump before start-up. See figure below.
Due to air remaining in the pump, the pump may be noisy when first switched
on. This noise should cease after a few minutes of operation.
After start-up, set the desired operating mode and head.
Note
The system cannot be vented through the pump.
Warning
When the air vent screw is loosened, scalding hot liquid
under high pressure may escape. Take care that escaping
liquid does not cause personal injury or damage to
components.
TM04 4635 1809 - TM04 4636 1809
Air vent screw
Venting the pump

English (GB)
15
10. Disposal
This product or parts of it must be disposed of in an environmentally sound
way:
1. Use the public or private waste collection service.
2. If this is not possible, contact the nearest Grundfos company or service
workshop.
Subject to alterations.

Appendix
149
Appendix
Fig. 1
TM04 6856 1010

Appendix
150
Fig. 2
Fig. 3
TM04 6857 1010TM04 6858 1010

Appendix
151
Fig. 4
Fig. 5
TM04 6859 1010TM04 6860 1010

Appendix
152
Fig. 6
Fig. 7
TM04 6861 1010TM04 6862 1010

Appendix
153
Fig. 8
Fig. 9
TM04 6863 1010TM04 6864 1010