Grundfos CUE User manual

GRUNDFOS INSTRUCTIONS
CUE, 0.75 - 125 Hp
Installation and operating instructions

English (US)
2
English (US) Installation and operating instructions
Original installation and operating instructions.
CONTENTS
Page
1. 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 which 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.
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 limit
actions 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.
1. Limited warranty 2
2. Symbols used in this document 3
3. Introduction 3
3.1 General description 3
3.2 Applications 3
3.3 References 3
4. Safety and warnings 3
4.1 Warning 3
4.2 Safety regulations 3
4.3 Installation requirements 3
4.4 Reduced performance under certain conditions 3
5. Identification 4
5.1 Nameplate 4
5.2 Packaging label 4
6. Mechanical installation 4
6.1 Receipt and storage 4
6.2 Transportation and unpacking 4
6.3 Space requirements and air circulation 5
6.4 Mounting 5
7. Electrical connection 5
7.1 Electrical protection 5
7.2 Mains and motor connection 6
7.3 Connecting the signal terminals 10
7.4 Connecting the signal relays 13
7.5 Connecting the MCB 114 sensor input module 14
7.6 EMC-correct installation 14
7.7 RFI filters 15
7.8 Output filters 15
7.9 Motor cable 15
8. Operating modes 16
9. Control modes 16
9.1 Uncontrolled operation (open loop) 16
9.2 Controlled operation (closed loop) 16
10. Menu overview 17
11. Setting by means of the control panel 19
11.1 Control panel 19
11.2 Back to factory settings 20
11.3 Start-up guide 20
11.4 GENERAL 24
11.5 OPERATION 25
11.6 Menu STATUS 26
11.7 Menu INSTALLATION 28
12. Setting by means of PC Tool E-products 36
13. Priority of settings 36
13.1 Control without bus signal, local operating mode 36
13.2 Control with bus signal, remote-controlled operating
mode 36
14. External control signals 36
14.1 Digital inputs 36
14.2 External setpoint 37
14.3 GENIbus signal 37
14.4 Other bus standards 37
15. Maintenance and service 37
15.1 Cleaning the CUE 37
15.2 Service parts and service kits 37
16. Troubleshooting 38
16.1 Warning and alarm list 38
16.2 Resetting of alarms 38
16.3 Indicator lights 38
16.4 Signal relays 38
17. Technical data 39
17.1 Enclosure 39
17.2 Main dimensions and weights 40
17.3 Surroundings 40
17.4 Terminal tightening torques 41
17.5 Cable length 41
17.6 Fuses and cable gauge size 41
17.7 Inputs and outputs 43
17.8 Sound pressure level 43
18. Disposal 43
Warning
Prior to installation, read these installation and
operating instructions. Installation and operation
must comply with local regulations and accepted
codes of good practice.

3
English (US)
2. Symbols used in this document
3. Introduction
This manual introduces all aspects of your Grundfos CUE
frequency converter in the power range of 1.8 to 177 A
(0.55 to 90 kW).
Always keep this manual close to the CUE.
3.1 General description
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.
3.2 Applications
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 cases:
• in the supply voltage or power ranges not covered by the
E-pump range
• in applications where an integrated variable frequency drive is
not desirable or permissible.
3.3 References
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.
• The service instructions contain all required instructions for
dismantling and repairing the variable frequency drive.
Technical documentation is available at www.grundfos.com >
Grundfos Product Center.
If you have any questions, please contact the nearest Grundfos
company or service workshop.
4. Safety and warnings
4.1 Warning
Wait only for shorter time if stated so on the nameplate of the
CUE in question.
4.2 Safety regulations
• 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 grounded correctly and protected against
indirect contact according to local regulations.
• The leakage current to ground exceeds 3.5 mA.
• Enclosure class NEMA 1 must not be installed freely
accessible, but only in a panel.
• Enclosure class NEMA 12 must not be installed outdoors
without additional protection against weather conditions and
the sun.
• Always observe national and local regulations as to cable
gauge size, short-circuit protection and overcurrent protection.
4.3 Installation requirements
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, grounding)
• safety on connecting inputs and outputs (PELV).
4.3.1 IT mains
In connection with IT mains and grounded delta mains, the mains
voltage may exceed 440 V between phase and ground.
4.3.2 Aggressive environment
The CUE contains a large number of mechanical and electronic
components. They are all vulnerable to environmental impact.
4.4 Reduced performance under certain conditions
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.
Warning
If these safety instructions are not observed,
it may result in personal injury.
Caution
If these safety instructions are not observed,
it may result in malfunction or damage to the
equipment.
Note
Note
Notes or instructions that make the job easier
and ensure safe operation.
Warning
Any installation, maintenance and inspection
must be carried out by trained personnel.
Warning
Touching the electrical parts may be fatal, even
after the CUE has been switched off.
Before performing any work on the CUE, the
mains supply and other input voltages must be
switched off at least for as long as stated below.
Voltage Min. waiting time
4 minutes 15 minutes 20 minutes
200-240 V 1-5 Hp
(0.75 - 3.7 kW)
7.5 - 60 Hp
(5.5 - 45 kW)
380-500 V 0.75 - 10 Hp
(0.55 - 7.5 kW)
15-125 Hp
(11-90 kW)
525-600 V 1-10 Hp
(0.75 - 7.5 kW)
525-690 V 15-125 Hp
(11-90 kW)
Warning
Do not connect 380-500 V CUE variable frequency
drive to mains supplies with a voltage between
phase and ground of more than 440 V.
Caution
The CUE should not be installed in an
environment where the air contains liquids,
particles or gases which may affect and damage
the electronic components.

English (US)
4
4.4.1 Reduction at low air pressure
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.
4.4.2 Reduction in connection with long motor cables
The maximum cable length for the CUE is 1000 ft. (300 m) for
unscreened and 500 ft. (150 m) for screened cables. In case of
longer cables, contact Grundfos.
The CUE is designed for a motor cable with a maximum gauge
size as stated in section 17.6 Fuses and cable gauge size.
5. Identification
5.1 Nameplate
The CUE can be identified by means of the nameplate.
An example is shown below.
Fig. 1 Example of nameplate
5.2 Packaging label
The CUE can also be identified by means of the label on the
packaging.
6. Mechanical installation
The individual CUE cabinet sizes are characterized by their
enclosures. The table in section 17.1 Enclosure shows the
relationship between enclosure class and enclosure type.
6.1 Receipt and storage
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 packaging which is not suitable
for outdoor storage.
6.2 Transportation and unpacking
To prevent damage during the transport to the site, the CUE must
only be unpacked at the installation site.
The packaging contains accessory bag(s), documentation and
the unit itself. See fig. 2.
Fig. 2 CUE packaging
Warning
At altitudes above 6600 ft. (2000 m), the PELV
requirements cannot be met.
TM04 3272 3808
Text Description
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.
2 Hp (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)
TM03 8857 2607
Accessory
bag(s)
Documentation

5
English (US)
6.3 Space requirements and air circulation
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 122 °F (50 °C).
• Hang the CUE directly on the wall, or fit it with a back plate.
See fig. 3.
Fig. 3 CUE hung directly on the wall or fitted with a back
plate
Required free space above and below the CUE
For information about enclosures, see table in section
17.1 Enclosure.
6.4 Mounting
1. Mark and drill holes. See the dimensions in section 17.2 Main
dimensions and weights.
2. Fit the screws, but leave loose. Mount the CUE, and tighten
the four screws.
Fig. 4 Drilling of holes
7. Electrical connection
Fig. 5 Example of three-phase mains connection of the CUE
with mains switch, back-up fuses and additional
protection
7.1 Electrical protection
7.1.1 Protection against electric shock, indirect contact
Protective conductors must always have a yellow/green (PE) or
yellow/green/blue (PEN) color marking.
Instructions according to EN IEC 61800-5-1:
• The CUE must be stationary, installed permanently and
connected permanently to the mains supply.
• The ground connection must be carried out with duplicate
protective conductors or with a single reinforced protective
conductor with a gauge size of minimum 8 AWG (10 mm2).
7.1.2 Protection against short-circuit, fuses
The CUE and the supply system must be protected against short-
circuit.
Grundfos demands that the back-up fuses mentioned in section
17.6 Fuses and cable gauge size are used for protection against
short-circuit.
The CUE offers complete short-circuit protection in case of a
short-circuit on the motor output.
7.1.3 Additional protection
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 type B.
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 17.7.1 Mains supply (L1, L2, L3).
During start-up and in asymmetrical supply systems, the leakage
current can be higher than normal and may cause the ELCB to
trip.
TM03 8859 2607
Enclosure Space [in. (mm)]
A2, A3, A4, A5 3.9 (100)
B1, B2, B3, B4, C1, C3 7.9 (200)
C2, C4 8.9 (225)
Caution
The user is responsible for mounting the CUE
securely on a firm surface.
TM03 8860 2607
Warning
The owner or installer is responsible for ensuring
correct grounding and protection according to
national and local standards.
b
a
a
b
Warning
Before making any work on the CUE, the mains
supply and other voltage inputs must be
switched off for at least as long as stated in
section 4. Safety and warnings.
TM03 8525 1807
Warning
The CUE must be grounded correctly and
protected against indirect contact according to
national regulations.
Caution
The leakage current to ground exceeds 3.5 mA,
and a reinforced ground connection is required.
Caution
The leakage current to ground exceeds 3.5 mA.
ELCB
ELCB

English (US)
6
7.1.4 Motor protection
The motor requires no external motor protection. The CUE
protects the motor against thermal overloading and blocking.
7.1.5 Protection against overcurrent
The CUE has an internal overcurrent protection for overload
protection on the motor output.
7.1.6 Protection against supply voltage transients
The CUE is protected against supply voltage transients according
to EN 61800-3, second environment.
7.2 Mains and motor connection
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.
7.2.1 Mains switch
A mains switch can be installed before the CUE according to local
regulations. See fig. 5.
7.2.2 Wiring diagram
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.
Fig. 6 Wiring diagram, three-phase mains connection
7.2.3 Mains connection, enclosures A2 and A3
For information about enclosures, see table in section
17.1 Enclosure.
1. Fit the mounting plate with two screws.
Fig. 7 Fitting the mounting plate
2. Connect the ground conductor to terminal 95 (PE) and the
mains conductors to terminals 91 (L1), 92 (L2), 93 (L3) of the
mains plug. Put the mains plug into the socket marked
MAINS.
Fig. 8 Connecting the ground conductor and mains
conductors
Note
Note
The maximum output voltage of the CUE is equal
to the input voltage.
Example: If the supply voltage is 208 V, choose a
208 V rated motor.
TM03 8799 2507
Terminal Function
91 (L1)
Three-phase supply92 (L2)
93 (L3)
95/99 (PE) Ground connection
96 (U)
Three-phase motor connection, 0-100 % of
mains voltage
97 (V)
98 (W)
Note
Note
For single-phase connection, use L1 and L2.
Cable sizing:
To determine the conductor gauge size for the
single-phase mains input cable, multiply the
CUE’s max. current output by 2, and choose the
gauge size based on that amperage.
For three-phase input, use the same conductor
gauge size as selected for the motor.
For CUE to motor, use standard published three-
phase wiring charts based on motor size.
Caution
Check that the mains voltage and frequency
correspond to the values on the nameplate of the
CUE and the motor.
TM03 9010 2807TM03 9011 2807
Note
Note
For single-phase connection, use L1 and L2.

7
English (US)
3. Fix the mains cable to the mounting plate.
Fig. 9 Fixing the mains cable
7.2.4 Motor connection, enclosures A2 and A3
For information about enclosures, see table in section
17.1 Enclosure.
1. Connect the ground conductor to terminal 99 (PE) on the
mounting plate. Connect the motor conductors to
terminals 96 (U), 97 (V), 98 (W) of the motor plug.
Fig. 10 Connecting the ground 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.
Fig. 11 Connecting the motor plug and fixing the screened
cable
7.2.5 Enclosures A4 and A5
For information about enclosure, see table in section
17.1 Enclosure.
Mains connection
1. Connect the ground conductor to terminal 95 (PE).
See fig. 12.
2. Connect the mains conductors to 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.
Fig. 12 Mains connection, A4 and A5
Motor connection
TM03 9014 2807
Caution
The motor cable must be screened for the CUE to
meet EMC requirements.
TM03 9013 2807
TM03 9012 2807
Note
Note
Cable screens must be grounded at both ends.
Note
Note
The cable screen must be exposed and in
physical contact with the mounting plate and
clamp.
Caution
Check that mains voltage and frequency
correspond to the values on the nameplate of the
CUE and the motor.
TM03 9017 2807
Note
Note
For single-phase connection, use L1 and L2.
Caution
The motor cable must be screened for the CUE to
meet EMC requirements.

English (US)
8
1. Connect the ground conductor to terminal 99 (PE), see fig. 13.
2. Connect the motor conductors to 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.
Fig. 13 Motor connection, A5
7.2.6 Enclosures B1 and B2
For information about enclosure, see table in section
17.1 Enclosure.
Mains connection
1. Connect the ground conductor to terminal 95 (PE), see fig. 14.
2. Connect the mains conductors to terminals 91 (L1), 92 (L2),
93 (L3).
3. Fix the mains cable with a cable clamp.
Fig. 14 Mains connection, B1 and B2
Motor connection
1. Connect the ground conductor to terminal 99 (PE), see fig. 15.
2. Connect the motor conductors to terminals 96 (U), 97 (V),
98 (W).
3. Fix the screened cable with a cable clamp.
Fig. 15 Motor connection, B1 and B2
7.2.7 Enclosures B3 and B4
For information about enclosure, see table in section
17.1 Enclosure.
Mains connection
1. Connect the ground conductor to terminal 95 (PE).
See figs 16 and 17.
2. Connect the mains conductors to terminals 91 (L1), 92 (L2),
93 (L3).
3. Fix the mains cable with a cable clamp.
Motor connection
TM03 9018 2807
Note
Note
The cable screen must be exposed and in
physical contact with the mounting plate and
clamp.
Caution
Check that mains voltage and frequency
correspond to the values on the nameplate of the
CUE and the motor.
TM03 9019 2807
Note
Note
For single-phase connection, use L1 and L2.
Caution
The motor cable must be screened for the CUE to
meet EMC requirements.
TM03 9020 2807
Note
Note
The cable screen must be exposed and in
physical contact with the mounting plate and
clamp.
Caution
Check that mains voltage and frequency
correspond to the values on the nameplate of the
CUE and the motor.
Caution
The motor cable must be screened for the CUE to
meet EMC requirements.

9
English (US)
1. Connect the ground conductor to terminal 99 (PE).
See figs 16 and 17.
2. Connect the motor conductors to terminals 96 (U), 97 (V),
98 (W).
3. Fix the screened cable with a cable clamp.
Fig. 16 Mains and motor connection, B3
Fig. 17 Mains and motor connection, B4
7.2.8 Enclosures C1 and C2
For information about enclosure, see table in section
17.1 Enclosure.
Mains connection
1. Connect the ground conductor to terminal 95 (PE).
See fig. 18.
2. Connect the mains conductors to terminals 91 (L1), 92 (L2),
93 (L3).
Motor connection
1. Connect the ground conductor to terminal 99 (PE).
See fig. 18.
2. Connect the motor conductors to terminals 96 (U), 97 (V),
98 (W).
3. Fix the screened cable with a cable clamp.
Fig. 18 Mains and motor connection, C1 and C2
7.2.9 Enclosures C3 and C4
For information about enclosure, see table in section
17.1 Enclosure.
Mains connection
1. Connect the ground conductor to terminal 95 (PE).
See figs 19 and 20.
2. Connect the mains conductors to terminals 91 (L1), 92 (L2),
93 (L3).
TM03 9446 4007
Note
Note
The cable screen must be exposed and in
physical contact with the mounting plate and
clamp.
TM03 9449 4007
Note
Note
The cable screen must be exposed and in
physical contact with the mounting plate and
clamp.
Caution
Check that mains voltage and frequency
correspond to the values on the nameplate of the
CUE and the motor.
Caution
The motor cable must be screened for the CUE to
meet EMC requirements.
TM03 9016 2807
Note
Note
The cable screen must be exposed and in
physical contact with the mounting plate and
clamp.
Caution
Check that mains voltage and frequency
correspond to the values on the nameplate of the
CUE and the motor.

English (US)
10
Motor connection
1. Connect the ground conductor to terminal 99 (PE).
See figs 19 and 20.
2. Connect the motor conductors to terminals 96 (U), 97 (V),
98 (W).
3. Fix the screened cable with a cable clamp.
Fig. 19 Mains and motor connection, C3
Fig. 20 Mains and motor connection, C4
7.3 Connecting the signal terminals
Connect the signal cables according to the guidelines for good
practice to ensure EMC-correct installation. See section
7.6 EMC-correct installation.
• Use screened signal cables with a conductor gauge size of
min. 22 AWG (0.5 mm2) and max. 16 AWG (1.5 mm2).
• Use a 3-conductor screened bus cable in new systems.
7.3.1 Wiring diagram, signal terminals
Fig. 21 Wiring diagram, signal terminals
Terminals 27, 29 and 37 are not used.
Caution
The motor cable must be screened for the CUE to
meet EMC requirements.
TM03 9448 4007
Note
Note
The cable screen must be exposed and in
physical contact with the mounting plate and
clamp.
TM03 9447 4007
Note
Note
The cable screen must be exposed and in
physical contact with the mounting plate and
clamp.
Caution
As a precaution, signal cables must be separated
from other groups by reinforced insulation in
their entire lengths.
Note
Note
If no external on/off switch is connected, short-
circuit terminals 18 and 20 using a short wire.
TM06 3250 1214
Terminal Type Function
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 Ground for digital inputs
32 DI 3 Digital input, programmable
33 DI 4 Digital input, programmable
39 GND Ground 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 Ground for analog inputs
61 RS-485 GND Y GENIbus, GND
68 RS-485 A GENIbus, signal A (+)
69 RS-485 B GENIbus, signal B (-)
Note
Note
The RS-485 screen must be connected to ground.