Grundfos 15 BMQE 07B-180 User manual

GRUNDFOS INSTRUCTIONS
BMQE
Constant Pressure System
Installation and operating instructions
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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, acci-
dent, 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 distrib-
utor or dealer of Grundfos' products from which it was purchased together with proof of pur-
chase 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 DAM-
AGES, LOSSES, OR EXPENSES ARISING FROM INSTALLATION, USE, OR ANY OTHER
CAUSES. THERE ARE NO EXPRESS OR IMPLIED WARRANTIES, INCLUDING MER-
CHANTABILITY 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 dam-
ages 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.
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Original installation and operating instructions.
CONTENTS
Page
1. Product introduction
This manual describes the installation and operation of the
Grundfos BMQE Constant Pressure System.
1.1 Symbols used in this document
1.2 Introduction
The Grundfos BMQE Constant Pressure System is a complete
pressure boosting system that includes pump, controller, tank,
mounting brackets, and pressure sensor. High-quality
construction and rugged design ensure low-maintenance and
trouble free operation. The system is simple to install and simple
to operate as it automatically balances water surges and
equalizes flow and pressure according to consumption. In other
words, the system maintains a constant water pressure in spite of
varying water consumption; it provides constant water pressure
even while multiple taps are on. The pressure is registered by
means of the pressure sensor and transmitted to the controller.
The controller adjusts the BMQE pump performance accordingly.
1.3 Delivery and handling
The shipping carton your pump came in is specially designed
around your pump during production to prevent damage. As a
precaution, the pump should remain in the carton until you are
ready to install it. The components are ready for installation.
Examine the pump for any damage that may have occurred
during shipping. Examine any other parts of the shipment as well
for any visible damage.
1.4 Applications
The Grundfos BMQE Constant Pressure System is intended for
large residential & light commercial pressure boosting
applications such as:
• medical offices
• restaurants
•homes
• condos
• irrigation
• grocery
• other boosting applications.
1.4.1 Pumped liquids
The BMQE must not be used for the transfer of flammable liquids
such as diesel oil, petrol or similar liquids. The BMQE is suitable
for pumping thin, clean, non-aggressive, non-explosive liquids,
not containing solid particles or fibers. The BMQE is suitable for
pressure boosting clean, cool, potable water. The liquid must not
attack the pump materials chemically or mechanically.
The temperature of the pumped liquid must not exceed
+ 95 °F (+ 35 °C).
1. Product introduction 3
1.1 Symbols used in this document 3
1.2 Introduction 3
1.3 Delivery and handling 3
1.4 Applications 3
1.5 Features and benefits 4
1.6 How the system functions 4
1.7 System diagram 4
1.8 Quick selection guide 5
1.9 Overview of built-in protections 5
2. Operating conditions 5
3. Installation 6
3.1 Quick installation guide 6
3.2 Mechanical installation 8
3.3 Electrical installation 8
3.4 Installation of pressure sensor 9
3.5 Installation of diaphragm pressure tank 9
3.6 Installation of pressure relief valve 10
3.7 Liquid filling and BMQE pump venting 10
3.8 BMQE pumps connected in parallel 10
4. Operation 10
4.1 Starting the BMQE pump for the first time 10
4.2 Generator operation 10
4.3 BMQE controller operating functions 11
4.4 Built-in protections 12
4.5 Built-in dry-running protection 12
5. Position of LED’s 13
6. Maintenance and service 14
6.1 Storage 14
6.2 Frost protection 14
6.3 BMQE controller service 14
6.4 Optional R100 interface 14
7. Technical data 15
7.1 Technical data for BMQE pump 15
7.2 Technical data for BMQE controller 15
8. Troubleshooting 16
8.1 Fault finding chart - BMQE pump 16
8.2 Fault finding chart - BMQE controller 17
8.3 Instruments not allowed 19
8.4 Checking of motor and cable 20
8.5 Factory settings 20
8.6 Pressure sensor voltage chart 21
9. Disposal 22
Warning
Prior to installation, read these installation and
operating instructions carefully. 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.
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
Notes or instructions that make the job easier
and ensure safe operation.
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1.5 Features and benefits
The BMQE Constant Pressure System features:
• Quick and easy installation: ready-to-use system requiring
minimum space
• high user convenience: constant pressure regardless of water
consumption
• easily adjustable pressure level: push button control
• continuous control and monitoring of pump operatio
• integrated dry-running protection
• integrated overload protection
• integrated protection against over voltage and under voltage
• soft start system.
1.6 How the system functions
When a tap is opened, the pressure in the tank will start to drop.
The system maintains a constant pressure within the maximum
pump performance in spite of varying water consumption.
The pressure is registered by means of the pressure sensor,
which transmits a signal to the controller. The controller adjusts
the pump performance accordingly to maintain constant pressure
by changing the pump speed.
At low flow the pressure will drop slowly. When the pressure in
the tank is 7 psi below the setpoint, the pump will start. When the
pressure is 7 psi above the setpoint, the pump will stop.
Even though the BMQE controller is controlling the pressure
within + / - 3 psi, larger pressure variations may occur in the
system. If the consumption is suddenly changed, e.g. if a tap is
opened, the water must start flowing before the pressure can be
made constant again.
Such dynamic variations depend on the pipework, but typically
they will lie between 7 and 14 psi. If the desired consumption is
higher than the quantity the pump is able to deliver at the desired
pressure, the pressure follows the pump curve (illustrated at the
far right of fig. 1).
At large flow rates, the pressure will drop quickly and the pump
will start immediately and maintain constant pressure. When the
system is running, the BMQE controller makes small adjustments
to the pressure to detect whether there is consumption. If there is
none, the pump will simply refill the tank and stop after a few
seconds.
Fig. 1 System function
1.7 System diagram
Fig. 2 BMQE Constant Pressure System diagram
* Recommended size: 2 U.S. gallons (8 liter) / 130 psi
TM04 9388 4010
Pressure
Flow
A
Stop
+7 PSI
Start
-7 PSI
Controlling
±3 PSI
Dynamic
variations
±7 PSI
GPM0.8
A = Pressure setting
TM04 9415 4110
Pos. Description
1 BMQE pump
2 BMQE controller
3 Diaphragm tank*
4 Pressure sensor
5 Mounting brackets
6 Flex connector
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1.8 Quick selection guide
Example:
• The maximum demand is 15 gpm (3.4 m3/h).
• The pressure required is 70 psi system pressure at the taps in the building.
• The normal minimum inlet pressure (e.g. city pressure) is 20 psi.
• The additional boost required is 50 psi at 15 gpm (3.4 m3/h).
• Select a 15 BMQE 05A-110.
1.9 Overview of built-in protections
1.9.1 Run-dry protection
The BMQE pumps are protected against dry-running. In case
of dry-run, the BMQE will stop after an accumulated time of
5 seconds thus preventing a burnout of the motor. After a
dry-running alarm, the pump restarts automatically after
5 minutes.
1.9.2 Overload protection
Exposure of the BMQE pump to heavy load causes the current
consumption to rise. The motor will automatically compensate for
this by reducing the speed. If the speed drops to 30 % of the
rated speed, the motor will be cut out. If the rotor is being
prevented from rotating this will automatically be detected and the
power supply cutout. Consequently, no extra motor protection is
required.
1.9.3 Over-voltage and under-voltage protection
Over voltage and under voltage may occur if the voltage supply is
unstable. The integrated protection of the BMQE motor protects
the motor if the voltage falls outside the permissible voltage
range.
• With a rated voltage of 200 - 240 V, 60 Hz, the pump will be
cut out if voltage falls below 150 V or rises above 280 V.
• With a rated voltage of 110 - 115 V, 60 Hz, the pump will be cut
out if voltage falls below 75 V or rises above 150 V.
The motor is automatically cut in when the voltage is again within
the permissible voltage range. Therefore, no extra voltage
protection relay is required.
2. Operating conditions
Liquid temperature
The temperature of the pumped liquid must not exceed
+ 95 °F (+ 35 °C).
Supply voltage
1 x 200-240 V –10 % / +6 %, 60 Hz
1 x 110-115 V –10 % / +6 %, 60 Hz
Starting current
The motor starting current is equal to the highest value stated
on the BMQE nameplate.
Additional (boost)
pressure required
[psi]
Flow required [gpm]
510152025303539
90 15 BMQE 07B-180
80
70 22 BMQE 10C-190
60
50 22 BMQE 05B-120
40 15 BMQE 05A-110 30 BMQE 10C-130
30
20 22 BMQE 05A-80 30 BMQE 05B-90
10
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3. Installation
3.1 Quick installation guide
For more detailed instructions, skip this section and go to section
3.2 Mechanical installation.
1. Install the BMQE pump.
2. Secure the mounting brackets.
3. Insert BMQE pump into open mounting bracket.
4. Apply pressure to the BMQE pump until the mounting bracket
jaws close and lock.
.
5. Install the BMQE controller.
6. Install the diaphragm tank.
7. Install the pressure sensor.
8. Connect incoming power, BMQE pump, and pressure sensor
to BMQE controller.
Warning
Before starting work on the BMQE controller or
BMQE pump, make sure that the electricity
supply has been switched OFF and that it cannot
be accidentally switched on.
The BMQE must be grounded. The BMQE
controller must be connected in accordance with
the local rules and regulations.
Note
When the BMQE pump is installed horizontally,
the air relief vent must be in the 12 o’clock
position.
When the BMPQE pump is installed vertically, the
air vent must be at the top of the unit.
TM04 9423 4210TM04 9424 4210TM04 9425 4210TM04 9426 4210
TM04 9452 4210TM04 9453 4210TM04 9454 4210TM04 9455 4210
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.
9. Close the BMQE controller cover.
10.Switch on main power.
11.Set controller discharge psi and verify diaphragm pre-charge
pressure.
12.Switch on the BMQE controller.
13.Verify that the BMQE pump is operating. If not, refer to section
8. Troubleshooting.
14.Verify that the BMQE controller is operating.
15.Optional: lock the buttons.
TM04 9456 4210TM04 9457 4210TM04 9458 4210TM04 9459 4210
Diaphragm tank
pre-charge
psi psi
Consult
Troubleshooting
section
TM04 9460 4210TM04 9461 4210
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3.2 Mechanical installation
3.2.1 Pre-installation checks
Before installation, the following checks should be made:
1. Confirm pump type
Check that the pump type stated on the nameplate fitted to the
module sleeve corresponds to your order.
2. Check electricity supply
The motor voltage and frequency details stated on the nameplate
should be compared with the actual electricity supply available.
3.2.2 Location of installation
The sound pressure level of the BMQE is <74 db[A] at a distance
of 3 feet (1 meter). It is recommended by Grundfos that the pump
be installed with sound and vibration dampening equipment such
as flexible piping adapters and anti-vibration mounting.
The pump should not be mounted in or adjacent to living quarters.
The pump can also be wrapped with sound proofing insulation to
reduce noise.
3.2.3 Positioning the pump
The GRUNDFOS BMQE pump is supplied with a built-in
non-return valve. An arrow on the BMQE sleeve shows the
direction of liquid flow through the pump (fig. 3).
The BMQE is suitable for both vertical and horizontal installation;
however, the discharge port should never fall below the horizontal
plane. See fig. 4.
The BMQE must be installed with the air relief vent in the 12
o’clock position when installed horizontally and when installed in
the vertical position, the air vent must be at the top of the unit.
Fig. 3 Arrow showing direction of liquid flow through pump
Fig. 4 Installation positions
3.2.4 Power line communication
The communication between the BMQE controller and the BMQE
pump is via the power supply cable. This communication principle
is known as power line communication.
Using this principle means that no additional cables to the pump
are required. The communication of data is effected by means of
a high-frequency signal transmitted to the power supply cable.
In situations where multiple BMQE pump power cables are run
parallel in wiring trays or conduit and less than 12 inches apart,
the possibility for undesired communication between units exists.
When this occurs, intermittent or continuous NO CONTACT is
typically seen. Other unexpected errors may also be seen.
There are two ways to eliminate the possibility of cross
communication:
1. Physical separation of the cables – maintain a minimum of 12
inches between pump power cables, and never place more
than one cable in a conduit.
2. Use shielded cable – the use of shielded cable prevents cross
communication between parallel cables and allows sharing of
conduit and cable trays. Tie the cable shield to ground only at
the BMQE controller panel.
3.2.5 Sound pressure level
See section 3.2.2 Location of installation.
3.3 Electrical installation
Rain-tight or wet location hubs that comply with the requirements
in the standard for Fittings for Conduit and Outlet Boxes, UL514B,
are to be used. Suitable devices for BMQE controller are rated
with enclosure type 3, 3R, 3S, 4, 4X, 6 or 6P.
Note
Like most mechanical equipment, this system
can create noises and vibrations. Grundfos
recommends that the BMQE pump should not be
mounted in or adjacent to living quarters.
TM04 9411 4110TM04 1375
Manufacturer Product number Gage
Anixter 2A-1403S 14
Anixter 2A-1203S 12
Anixter 2A-1003S 10
Anixter 800-321-1486
Warning
The electrical connection should be carried out
by an authorized electrician in accordance with
local regulations.
Warning
Before starting work on the BMQE controller or
BMQE pump, make sure that the electricity
supply has been switched OFF and that it cannot
be accidentally switched on.
The BMQE must be grounded. The BMQE
controller must be connected in accordance with
the local rules and regulations.
Warning
IMPORTANT: The ON/OFF button on the BMQE
controller must not be used as a safety switch
when installing and servicing the pump.
Warning
The BMQE must never be connected to a
capacitor or to another type of control box than
BMQE controller.
The BMQE must never be connected to an
external frequency converter.
Warning
Reduced risk of electric shock during operation
of the BMQE system requires the provision of
acceptable grounding. If the means of connection
to the supply connected box is other than
grounded metal conduit, ground the pump back
to the service by connecting a copper conductor,
at least the size of the circuit supplying the
pump.
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The supply voltage and frequency are marked on the nameplate.
Make sure that the BMQE controller and BMQE pump are
suitable for the electricity supply on which they will be used.
The current consumption can only be measured by means of a
true RMS instrument. If other instruments are used, the value
measured will differ from the actual value.
All BMQE pumps can be connected to BMQE controllers. Each
BMQE pump must be connected to its own BMQE controller.
3.3.1 Connection of motor
The BMQE incorporates a starter device and can therefore be
connected directly to the main power supply.
Motor protection
The BMQE incorporates thermal overload protection and requires
no additional motor protection.
3.3.2 Cable sizing
In situations where multiple BMQE power cables are run parallel
in wiring trays or conduit and less than 12 inches apart, the
possibility for undesired communication between units exists.
When this occurs, intermittent or continuous NO CONTACT is
typically seen. Other unexpected errors may also be seen. Refer
to section 3.2.4 Power line communication and 8.4 Checking of
motor and cable for further information.
Chart shows single-phase 60 Hz maximum cable length motor
service to entrance. The maximum cable length with one BMQE
controller is 650 ft; the maximum wire size is 10 AWG.
3.3.3 BMQE controller connection
The BMQE controller has two terminal blocks:
• Terminals 1 to 4
• Terminals 5 to 7.
Furthermore, the BMQE controller is equipped with two screw
terminals for the ground leads.
3.3.4 Main power supply, POWER, terminals 1, 2 and PE
(ground)
Connect terminals 1 and 2 to the line and neutral leads of the
main supply. Each terminal can be connected to any of the two
leads.
3.3.5 Motor leads, PUMP, terminals 3, 4 and PE (ground)
Connect terminals 3 and 4 to the line and neutral leads of the
pump. Each terminal can be connected to any of the two leads.
Connect one PE terminal to the green ground lead from the pump
and one to the ground lead from the main power supply. Each PE
terminal must be connected to its own ground lead.
Maximum wire size of the cables to be connected to BMQE
controller is 10 AWG.
3.4 Installation of pressure sensor
3.4.1 Positioning the pressure sensor
Pressure losses often cause inconvenience to the user. The
BMQE controller keeps the pressure constant in the place where
the pressure sensor is positioned. See fig. 2 on p. 4.
In the diagram tap 1 is placed close to the pressure sensor.
Therefore, the pressure will be kept nearly constant at tap 1, as
the friction loss is small.
At the shower and tap 2, the friction loss is greater. This, of
course, depends on the piping. Therefore, it is recommended that
the pressure sensor be positioned as close to the places of
consumption as possible.
The maximum shielded cable length for the sensor must not
exceed 1600 feet.
3.4.2 Connecting the pressure sensor
SENSOR, terminals 5, 6 and 7:
Terminals 5, 6 and 7 (SENSOR) are used for the pressure sensor.
3.4.3 Sensor signals
The pressure sensor to be conected provides a 4-20 mA signal
(factory setting).
Fig. 5 Connection for pressure sensor
3.5 Installation of diaphragm pressure tank
The BMQE controller is designed to work with a 2 gallon
diaphragm tank. (For diaphragm tank(s) for two pumps connected
in parallel, see section 3.8 BMQE pumps connected in parallel.)
Install a diaphragm tank to insure that the BMQE will shut off at
zero flow. The diaphragm tank must be installed at some point
between the BMQE pump and the pressure sensor.
Maximum cable length (one controller)
Motor rating Copper wire size (AWG)
Volts Hp 14 12 10
Maximum cable length [ft (m)]
115 0.50 100 (30.5) 160 (48.8) 250 (76.2)
230
0.50 400 (121.9) 650 (198.1) 650 (198.1)
0.75 300 (91.4) 480 (146.3) 650 (198.1)
1.0 250 (76.2) 400 (121.9) 630 (192)
Note
Circuit breaker: Maximum 16 A.
Caution
IMPORTANT: The main power supply cables must
not be connected to terminals 3 and 4 (PUMP).
Pos. Description
1Standard pressure sensor.+ 24 VDC, brown lead,
terminal 5.
2Standard pressure sensor. Input signal, black lead,
terminal 6.
3 Standard pressure sensor. Braid, terminal 7.
TM04 9412 4110
Brown Black
SENSOR
+24V IN GND
POWER PUMP
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3.5.1 Pre-charge pressure setting
The pre-charge pressure of the diaphragm tank must be set to
70 % of the pressure setting in order to use the tank to the limit of
its capacity.
Use the values in the following table. Pre-charge pressure is
measured with 0 psi in the pipeline:
If the user wants to adjust the pressure without changing the
pre-charge pressure of the diaphragm tank, the pre-charge
pressure must be equal to the lowest pressure setting used.
Failure to follow this instruction will increase pressure
fluctuations.
3.6 Installation of pressure relief valve
In order to provide protection against the possibility of over-
pressurization, a pressure relieve valve may be installed
downstream of the BMQE. If a relief valve is installed, it is
recommended that its discharge be plumbed into an appropriate
drainage point.
3.7 Liquid filling and BMQE pump venting
The BMQE is filled with water through the suction port by the
water in the piping system. Follow this procedure:
1. Install the BMQE pump with the air relief vent in the 12 o’clock
position when installed horizontally; when installed in the
vertical position the air vent must be at the top of the unit.
2. Loosen the air vent screw in the BMQE pump.
3. Fill the BMQE with water until it starts running out of the vent
hole.
4. Tighten the air vent screw.
3.8 BMQE pumps connected in parallel
When connecting BMQE pumps in parallel (fig. 6) a separate
BMQE controller must be used on each BMQE pump.
Set the pressure on one BMQE 10 psi lower than the other.
For BMQE pumps connected in parallel, mounted one above the
other, it is recommended to connect the pipes as shown in fig. 6.
This layout ensures that the BMQE pumps are filled with water
before starting.
Fig. 6 Booster unit with two BMQE pumps connected in
parallel, mounted one above the other
3.8.1 Additional considerations when connecting in parallel
• All BMQE modules are supplied with a non-return valve.
• BMQE modules connected in parallel may also be installed
vertically.
• As venting problems may arise in such installations, it is
advisable to install suitable air vent devices.
• The BMQE should be positioned with the discharge and air
vent at the top when installed vertically.
• When the maximum flow for BMQE pumps in parallel will
exceed 35 gpm, a 4-gallon or two 2-gallon diaphragm tank(s)
should be used.
4. Operation
4.1 Starting the BMQE pump for the first time
When the BMQE has been connected correctly, it should be
started with the discharge valve closed approximately one-third.
Due to the soft start feature, the pump takes approximately 2
seconds to develop full pressure.
Check that the actual inlet pressure is equal to or greater than the
previously estimated inlet pressure.
When not being used, all modules should be filled with water as
all internal bearings are water lubricated.
If the BMQE is taken out of operation for a long period, the BMQE
should be flushed through with clean water. The modules are
then left with clean water until they are to be used again.
4.2 Generator operation
Power may be supplied to BMQE pumps by an adequately sized
generator. The generator must be sized 50 % above the pumps
P1 (input power) values. Refer to following chart.
Setting (psi) Pre-charge pressure (psi)
40 28
50 35
60 42
70 49
80 56
90 63
100 70
Note
If the pre-charge pressure is higher than the
pressure setting, the system will have difficulty
controlling the pressure.
TM04 9413 4110
Motor Hp Minimum generator
size
Recommended
generator
output (watts)
0.33 to 0.50 A 1100 1500
0.50 to 0.75 B 1700 2300
1.0 to 1.5 B 2000 3500
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