Grundfos CR Series User manual

CR, CRI, CRN
Installation and operating instructions
GRUNDFOS INSTRUCTIONS

English (GB)
2
English (GB) Installation and operating instructions
Original installation and operating instructions
These installation and operating instructions
describe Grundfos CR, CRI and CRN pumps, 0.37 -
75 kW.
Sections 1-4 give the information necessary to be
able to unpack, install and start up the product in a
safe way.
Sections 5-10 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 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:
1.2 Notes
The symbols and notes below may appear in
Grundfos installation and operating instructions,
safety instructions and service instructions.
1. General information 2
1.1 Hazard statements 2
1.2 Notes 2
2. Receiving the product 3
2.1 Transporting the product 3
2.2 Unpacking the product 3
2.3 Inspecting the product 3
2.4 Lifting the product 3
3. Installing the product 4
3.1 Mechanical installation 4
3.2 Electrical connection 10
4. Starting up the product 12
4.1 Shaft seal run-in 12
4.2 Frequency of starts and stops 13
4.3 Operating the product 13
5. Product introduction 14
5.1 Identification 14
5.2 Intended use of the product 15
6. Servicing the product 15
6.1 Contaminated products 16
6.2 Service documentation 16
6.3 Maintaining the product 16
7. Taking the product out of operation 18
7.1 Frost protection 18
7.2 Taking the product permanently out of
operation 18
8. Fault finding the product 19
9. Technical data 21
9.1 Operating conditions 21
9.2 Electrical data 23
9.3 Dimensions and weights 23
10. Disposing of the product 23
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.
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 (GB)
3
2. Receiving the product
2.1 Transporting the product
2.2 Unpacking the product
2.3 Inspecting the product
Before you install the product, do the following:
1. Check that the product is as ordered.
2. Check that no visible parts have been damaged.
If parts are damaged or missing, contact your local
Grundfos sales company.
2.4 Lifting the product
When lifting the entire product with motor, follow
these instructions:
• Pump with motor sizes 0.37 - 5.5 kW:
Lift the pump in the motor flange by means of
straps or the like.
• Pump with motor sizes 7.5 - 22 kW:
Lift the pump by means of the motor eyebolts.
• Pump with motor sizes 30-45 kW:
Lift the pump by means of the lifting brackets on
the motor flange.
• Pump with motor sizes 55-75 kW:
Lift the pump by means of the eyebolts on the
motor side.
Fig. 1 Lifting points
In case of CR, CRI and CRN pumps with other
motors than MG or Siemens, we recommend that
you lift the pump by means of the straps in the motor
flange.
WARNING
Falling objects
Death or serious personal injury
- Keep the product in a stable and fixed
position during transportation.
- Wear personal protective equipment.
WARNING
Falling objects
Death or serious personal injury
- Keep the product in a stable position
during unpacking.
- Wear personal protective equipment.
WARNING
Falling objects
Death or serious personal injury
- Follow the lifting instructions.
- Use lifting equipment which is approved
for the weight of the product.
- Persons must keep a safe distance to
the product during lifting operations.
- Wear personal protective equipment.
Note that typically the centre of gravity of
the pump is close to the motor.
0.37 - 5.5 kW 7.5 - 22 kW
TM04 0339 0608 TM04 0341 0608
30-45 kW 55-75 kW
TM05 9564 4113 TM04 0341 0608

English (GB)
4
3. Installing the product
3.1 Mechanical installation
3.1.1 Lifting the product
For lifting instructions, see section 2.4 Lifting the
product.
WARNING
Contamination when pumping drinking
water
Death or serious personal injury
- Before the pump is used for supplying
drinking water, flush the pump
thoroughly with clean water.
- Do not use the pump for drinking water
if the internal parts have been in contact
with particles or substances not suitable
for water intended for human
consumption.
WARNING
Falling objects
Death or serious personal injury
- Follow the lifting instructions.
- Use lifting equipment which is approved
for the weight of the product.
- Persons must keep a safe distance to
the product during lifting operations.
- Wear personal protective equipment.

English (GB)
5
3.1.2 Installation guidelines
The pump must be secured to a horizontal, plane
and solid foundation with bolts through the holes in
the base plate. When installing the pump, be aware
of the information below in order to avoid damaging
the pump.
Illustration Information
1
TM02 0013 3800
Arrows on the pump base show the direction of flow of liquid
through the pump.
2
TM00 2256 3393
This information is stated in fig. 3in the appendix:
• port-to-port lengths
• dimensions of the base plate
• pipe connections
• diameter and position of anchor bolts.
3
TM01 1241 4097
You can install the pump vertically or horizontally. CR, CRN 120
and 150, 75 kW, only vertically. However, the motor must neither
fall below the horizontal plane nor be installed upside down.
Make sure that an adequate supply of cool air reaches the motor
cooling fan.
Motors above 4 kW must be supported.
3a
TM05 7705 1013
Additional support. As the centre of gravity of the pump is relatively
high, we recommend that pumps installed on ships, in areas with
risk of earth quake or in systems which can be moved, are
equipped with an additional support bracket. You can fit the bracket
from the motor stool to the bulkhead of the ship, a rigid wall in a
building or to a rigid part.
4
TM02 0116 3800
To minimise possible noise from the pump, we recommend that you
fit expansion joints on either side of the pump.
Build a foundation and carry out mechanical installation as
described in section 3.1.3 Foundation. Fit the isolating valves on
either side of the pump to avoid draining the system if the pump
needs to be removed for cleaning, repair or replacement.
Always protect the pump against backflow by means of a non-
return valve.
5
TM02 0114 3800
Install the pipes so that air pockets do not occur, especially on the
inlet side of the pump.
6
TM02 0115 3800
Fit a vacuum valve close to the pump if the installation has one of
these characteristics:
• The outlet pipe slopes downwards away from the pump.
• There is a risk of siphon effect.
• Protection against backflow of unclean liquids is needed.
2
1
2
1
L
L
B
4 x ø
B

English (GB)
6
3.1.3 Foundation
We recommend that you install the pump on a
concrete foundation which is heavy enough to
provide permanent and rigid support for the entire
pump. The foundation must be capable of absorbing
any vibration, normal strain or shock. The concrete
foundation must have an absolutely level and even
surface.
Place the pump on the foundation, and fasten it. The
base plate must be supported on the whole area.
The following instruction applies when mounting the
pump in both vertical and horizontal position. Place
the pump on the foundation, and fasten it. See fig. 2.
Fig. 2 Correct installation
The recommended length and width of the
foundation are shown in fig. 3. Note that for pumps
with motor size below or equal to 30 kW, the length
and width of the foundation must be 200 mm larger
than the base plate.
For pumps with motor size equal to 37 kW or above,
the length and width must always be 1.5 x 1.5 (Lf x
Bf) m.
Fig. 3 Foundation, vertical mounting
WARNING
Falling objects
Death or serious personal injury
- Keep the product in a stable and fixed
position before installing it.
- Make sure that the foundation is
suitable for the weight of the product.
TM04 0342 0608
TM04 0343 0608

English (GB)
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The foundation length and width must always be 200
mm larger than the length and width of the pump.
See fig. 4.
Fig. 4 Foundation, horizontal mounting
The mass of the foundation must be at least 1.5
times the total mass of the pump. The minimum
height of the foundation (hf) can then be calculated:
The density (δ) of concrete is usually taken as 2200
kg/m3.
In installations where noise-less operation is
particularly important, we recommend that you use a
foundation with a mass up to 5 times that of the
pump.
The foundation must be provided with anchor bolts
for fixing the base plate. See fig. 5.
Fig. 5 Bolt in foundation
When the anchor bolts are in position, place the
pump on the foundation. Then align the base plate
using shims, if necessary, so that it is completely
horizontal. See fig. 6.
Fig. 6 Alignment with shims
3.1.4 Vibration dampening
Elimination of noise and vibrations is best achieved
by means of a concrete foundation, vibration
dampers and expansion joints.
If you use vibration dampers, install them under the
foundation. For pumps with motor size below or
equal to 30 kW, you can use vibration dampers as
shown in fig. 7.
For pumps with motor sizes equal to 37 kW or above,
use a Sylomer®plate as shown in fig. 8.
Fig. 7 Pump on vibration dampers
TM05 9579 4113
hf = Mpump ×1.5
Lf ×Bf ×δconcrete
TM03 4589 2206
TM04 0362 0608TM04 1691 1008
Shims
Vibration dampers

English (GB)
8
Fig. 8 Pump on Sylomer®plate
3.1.5 Outdoor installation
When the pump is installed outdoors, we recommend
that you provide the motor with a rain cover. We also
recommend that you open one of the drain holes in
the motor flange.
3.1.6 Tightening torques
The table shows the recommended torques for base
plate anchor bolts and flange bolts.
The bolt quality must be minimum class 8.8.
3.1.7 Flange forces and torques
If not all loads reach the maximum permissible value
stated in the tables below, one of these values may
exceed the normal limit. Contact Grundfos for further
information.
Fig. 9 Flange forces and torques
The following tables represent the values that apply
according to the material quality.
TM04 1692 1008
WARNING
Flange gasket blowout
Death or serious personal injury
- Tighten flange bolts according to the
torque values stated in the installation
and operating instructions.
CR,
CRI,
CRN
Base
[Nm]
Flange bolts [Nm]
Bolt
size
DIN, JIS,
ANSI Oval
1s-5 40 M10 - 50-60
10-20 50 M12 60 60-70
32-150 70
M16 100 70-80
M20 150 -
M24 200 -
Sylomer®plate
TM04 0346 2013
Y-direction: Inlet or outlet
Z-direction: Direction of chamber stack
X-direction: 90 ° from inlet or outlet

English (GB)
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Force limits
Torque limits
3.1.8 Positioning the terminal box
You can turn the terminal box to four positions, in
90 ° steps. Follow this procedure:
1. If necessary, remove the coupling guards. Do not
remove the coupling.
2. Remove the bolts securing the motor to the
pump.
3. Turn the motor to the required position.
4. Replace and tighten the bolts.
5. Replace the coupling guards.
Carry out the electrical connection as shown in the
diagram inside the terminal box cover.
Flange,
DN [mm] Type
CR -
Cast iron pump housing
CRI, CRN -
Stainless steel pump housing
Force, Y-
direction
[N]
Force, Z-
direction
[N]
Force, X-
direction
[N]
Force, Y-
direction
[N]
Force, Z-
direction
[N]
Force, X-
direction
[N]
25/32 1s-5 338 394 319 675 788 638
40 10 413 469 375 825 938 750
50 15 and 20 563 581 506 1125 1163 1013
65 32 694 788 638 1388 1575 1275
80 45 938 769 844 1875 1538 1688
100 64 and 90 1256 1013 1125 2513 2025 2250
125/150 120 and 150 1256 1013 1125 2513 2025 2250
Flange,
DN [mm] Type
CR -
Cast iron pump housing
CRI, CRN -
Stainless steel pump housing
Torque, Y-
direction
[Nm]
Torque, Z-
direction
[Nm]
Torque, X-
direction
[Nm]
Torque, Y-
direction
[Nm]
Torque, Z-
direction
[Nm]
Torque, X-
direction
[Nm]
25/32 1s-5 300 175 125 600 350 250
40 10 400 275 200 800 550 400
50 15 and 20 450 325 250 900 650 500
65 32 500 350 300 1000 700 600
80 45 325 400 550 650 800 1100
100 64 and 90 375 475 625 750 950 1250
125/150 120 and 150 375 475 625 750 950 1250

English (GB)
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3.2 Electrical connection
The electrical connection must be carried out by an
authorised electrician in accordance with local
regulations.
The operating voltage and frequency are marked on
the motor nameplate. Make sure that the motor is
suitable for the power supply on which it is used and
that the motor terminal connection is correct. You will
find a wiring diagram in the terminal box.
3.2.1 Cable entry/screwed connection
All motors are supplied without screwed cable
entries. The table below shows the numbers and
sizes of cable entry holes of the terminal box
according to the standard EN 50262.
3.2.2 Three-phase connection
1) 60 Hz motors, 0.37 - 1.1 kW: 220-277/380-440 V.
Fig. 10 Delta connection
Fig. 11 Star connection
If the motor is provided with PTC sensors or PTO
contacts, the connection must be in accordance with
the wiring diagram in the terminal box.
Connect three-phase motors to a motor-protective
circuit breaker.
Follow the instructions for the motor when
carrying out the electrical connections.
WARNING
Electric shock
Death or serious personal injury
- Before starting any work on the product,
make sure that the power supply has
been switched off and that it cannot be
accidentally switched on.
- Connect the pump to an external main
switch close to the pump and to a
motor-protective circuit breaker or a
CUE frequency converter. Make sure
you can lock the main switch in OFF
position (isolated). Type and
requirements as specified in EN 60204-
1, 5.3.2.
Consider whether it is necessary to install
an emergency stop switch.
Motor
[kW]
Number and
size of cable
entries
Description
0.25-
0.55 2 x M20 x 1.5
The holes have precast
threads and are closed
with knock-out cable
entries.
0.75-
3.0 2 x M20
The holes are closed
with knock-out cable
entries.
4.0-
7.5 4 x M25
The holes are closed
with knock-out cable
entries.
11-22 2 x M20
4 x M40
The holes are closed
with knock-out cable
entries.
30-45 2 x M50 x 1.5 Blanking plug.
55-75 2 x M63 x 1.5 Blanking plug.
Mains supply [V]
Delta
connection
Star
connection
50 Hz 220-240 / 380-415
380-415 / 660-690
60 Hz 220-277 / 380-4801)
380-480 / 660-690
TM02 6656 1305TM02 6655 1305
W2 U2 V2
U1 V1 W1
U1
U2
V1
V2
W1
W2
L
3
L
2
L
1
W2 U2 V2
U1
U1
V1
V1 W1
U2
V2
W1
W2
L3
L2
L1