Grundfos Geo-Flo MAGNA3 User manual

Installation Information
Wiring
Plumbing
Start-Up
Control Mode Settings
Multi-Pump Setup
Faults
IM1542EW 04/15
MAGNA3 Insulated Pumps Installation Manual
MAGNA3
Insulated Pumps

MAGNA3 INSULATED PUMPS INSTALLATION MANUAL
Table of Contents
Model Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Determining the Pump Control Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Multi-Pump Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Antifreeze Selection and Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4
MAGNA3 INSULATED PUMPS INSTALLATION MANUAL
1 - 3
040 080 B
11 12
C
-
4 -10
M3S
Pump Series
M3S = Grundfos Magna3 single insulated pump
M3C = Grundfos Magna3 single insul. pump with check valve
Available Models
040-080 = 40-80 single head, 2” ball isol. valves, 2” NPT connections
040-120 = 40-120 single head, 2” ball isol. valves, 2” NPT connections
040-180 = 40-180 single head, 2” ball isol. valves, 2” NPT connections
Note: Use model M3C for two pumps in primary/backup or cascade mode
Standard/Special
C = Cast iron volute
Voltage
B = 208-230/1/60
Model Nomenclature

5
MAGNA3 INSULATED PUMPS INSTALLATION MANUAL
The MAGNA3 pump is mounted on a wood base for shipment. Remove the four bolts that attach the pump to the wood base. Always
install the pump with motor shaft horizontal and the control box with the Grundfos logo in vertical position as shown below.
To rotate the pump head control box, loosen the screw in the clamp holding the pump head and pump housing together with a 5 mm Allen
wrench. WARNING: If the screw is loosened too much, the pump head will be completely disconnected from the pump housing. Carefully
rotate the pump head to the desired location. Position the clamp so that either the hole or the gap in the clamp is in a downward position.
Due to the pressure sensor wiring it is not recommended to move the clamp to the other side. See figure 1. Tighten the screw to minimum
6 + / - 0.7 ft-lbs (8 + / - 1 Nm)







Figure 1: Clamp
General Installation Information

6
MAGNA3 INSULATED PUMPS INSTALLATION MANUAL
Determining the Pump Control Mode
The MAGNA3 has a number of control modes for a variety of applications. However, for geothermal installations there are only two
control modes that are applicable, Constant Pressure and Constant Curve. Most of the other modes are for boiler applications, and
are not recommended.
Constant Pressure:
A central variable speed pump is common for geothermal applications of three or more heat pumps due to the opportunity for
energy savings. Figure 2 provides an example piping diagram. The central pump is controlled based upon pressure differential.
As the water valves open and close based upon the operation of the heat pump, the system pressure changes, causing the
pump to adjust speed to attain the water flow needed. For example, if only one of five heat pumps is running, the pump speed
adjusts to the flow rate needed for the one heat pump, dramatically reducing pump Watts compared to when the pump is running
at maximum flow.
Constant Curve:
Because the MAGNA3 uses a very efficient motor, the pump may be used as a constant speed pump in applications where
variable speed is not necessary or desired.
M
FCV
M
FCV
M
FCV
M
FCV
M
FCV
T T T T
Modulating
Water Valve Automatic Flow Control Valve Ball Valve
Heat
Pump
Ground Loop Piping
PD
VFD
T
Expan.
Tank
Two-Pipe System, Variable Speed Pump:
The central pump is controlled based upon pressure differential.As the modulating water valves
open and close based upon the operation of the heat pump, the system pressure changes,
causing the pump to adjust speed to attain the water flow needed for the number of heat pumps running.
2” 3-way valves
with flush ports
(2) FPL8
Figure 2: Typical central pump application, using constant pressure control and modulating water valves.

7
MAGNA3 INSULATED PUMPS INSTALLATION MANUAL
Figure 3: Control Box Front Cover
Figure 4: Start/Stop Jumper
Remove the 5 screws on the front cover of the control box with a T20 Torx driver. The Start/Stop jumper and electrical connections are
located beneath the cover. Before attaching power, remove the Start/Stop jumper located inside the pump control module (remove the
entire green plug with the grey jumper). This will prevent the pump from starting when powered.
Complete the high voltage wiring to the pump. Locate the power supply plug and conduit adapter in the box supplied with the pump.
Connect wiring from pump disconnect to the pump terminal block as shown in Figure 5. Pump terminals are labeled L, N, and ground
(symbol). Connect L to L1 and N to L2. Wiring must meet all applicable code requirements, including requirements for wire protection, such
as conduit. Wire and breaker/fuse size must be determined based upon pump nameplate ratings.
Wiring
VERIFY PUMP NAMEPLATE VOLTAGE BEFORE CONNECTING HIGH VOLTAGE WIRING.
L (L1)
N (L2)
Figure 5: High Voltage Wiring
5x T20 Screws
Start/Stop Jumper

8
MAGNA3 INSULATED PUMPS INSTALLATION MANUAL
Wiring cont.
For ease of setting up the pump it is best to leave the start/stop jumper in place until after the pump starts is completed. Once the
pump start up is completed, the start/stop jumper can be removed and the S/S and ground connections made. For multi-pump
configurations the start/stop will be used on the secondary pump.
There are two options available to turn on and off the MAGNA3 pump. Depending on the application loop pump linking or the
MAGNA3RELAY can be used to turn on and off the MAGNA3 pump.
Loop Pump Linking – NOTE: This feature is not available with the Aurora Base Controls (ABC only). Loop pump linking
can be achieved by connecting the SL terminals on connector P2 in both units with 2-wire thermostat wire. These terminals
are polarity dependent (see figure 6). The MAGNA3 pump will turn on when any of the linked units sees a call. Once the
call from all of the linked units has went away the pump will turn off. The installer will need to supply a SPST 230VAC coil
relay and two-conductor 18AWG thermostat wire (see figure 7).
NOTE: If high voltage is connected to the MAGNA3 S/S and ground terminals damage may occur the pump.
AXB to
Electromechanical Units
ToElectromechanical Unit
AXB to Premier
Unit #2 with Premier
Unit #1
with AXB Board Unit #1 with AXB Board Unit #1
with AXB Board
Unit #2
with AXB Board
AXB to AXB
CS
VSSLOSLI OUTIN C C
VSSLOSLI OUTIN C C
With pump
wired to
Unit 2
With pump
wired to Unit 1
VSSLOSLI OUTIN C C
With pump
wired to
Unit 1
With pump
wired to
Unit 2
VSSLOSLI OUTIN C C
Shut
Down CC
SL1
In SL1 Out
Figure 6: Loop Pump Linking
Two conductor thermostat wire
from N.O. relay contacts to Magna3
Start/Stop terminals (S/S and ground)
S/S
M
I
M
A
1
2
Two conductor thermostat
wire from terminal block PB1
in heat pump control box to
relay coil (230V coil)
230
VAC
PB1
IMPORTANT:
Must be 230VAC coil
SPST relay
(field supplied) Magna3
Figure 7
NOTE: If more than 2 heat pumps with AXB or Premier controls are loop pump linked, the remaining heat pumps will be daisy chained
together.

9
MAGNA3 INSULATED PUMPS INSTALLATION MANUAL
Wiring cont.
MAGNA3RELAY Board - The MAGNA3RELAY board is operated from a dry contact closure. The dry contact closure
can either be from the heat pump control accessory relay or from a SPST 230VAC coil relay. Wiring diagrams are shown
below for connecting to the accessory relay (Figure 8) or SPST 230VAC coil relay (Figure 7). Use two-conductor 18AWG
thermostat wire from the heat pump accessory relay to the relay board HP IN and OUT terminals. NOTE: When connecting
to the ABC accessory SW2-4 and SW2-5 must be in the “OFF” position (cycles with compressor).
HP-1 OUT
HP-1 IN
HP-2 OUT
HP-2 IN
HP-3 OUT
HP-3 IN
HP-4 OUT
HP-4 IN
HP-5 OUT
HP-5 IN
ACC NO
ACC COM
OUT
IN
Figure 8: Accessory relay to MAGNA3RELAY board

10
MAGNA3 INSULATED PUMPS INSTALLATION MANUAL
Wiring cont.
Use two-conductor 18AWG thermostat wire to connect the MAGNA3RELAY dry contacts to the S/S and ground terminals
on the MAGNA3 pump (see figure 9).
Figure 9: MAGNA3RELAY board dry contacts to MAGNA3
24 VAC
24 VAC
DRY CONTACTS DRY CONTACTS
PUMP RELAY PUMP RELAY PUMP RELAY PUMP RELAY
S/S
M
I
M
A
WARNING: MAKE SURE THAT POWER IS DISCONNECTED BEFORE WIRING PUMP ENABLE RELAY.
24
VA
C
24
VA
C
PUMP
RELAY
PUMP
RELAY
Not used with
MAGNA3 Pump

11
MAGNA3 INSULATED PUMPS INSTALLATION MANUAL
Plumbing
Unit Plumbing
There are several water valve options available to regulate flow to the heat pumps.
A. WWKVS – is designed for use with variable speed units, and dual capacity units with AXB controls. When using this kit you will
need to use the AID tool to adjust minimum and maximum flow rates. The factory default is minimum = 50% and maximum =
100% flow rate for variable speed units, and minimum = 75% and maximum = 100% for dual capacity units. Refer to the units
Installation manual under unit Start Up for more information on setting up through the AID tool. Always ensure that there is
adequate flow for the heat pump. Refer to the units Specification Manual for minimum and maximum flow rates. NOTE: the
10DC must be attached to screw position 1 on the VS labeled section of the AXB. See figure 10 for wiring schematic.
Figure 10: Modulating Water Valve Connection
B. WWK3T – is designed for dual capacity units without theAXB controls. This kit uses solenoid valve, slow closing valve, and ball
valves to regulate flow for both high and low speed operation. Always ensure that there is adequate flow for the heat pump. Refer to
units Specification Manual for minimum and maximum flow rates. See figure 11 and 12 for wiring schematic.
Factory
Fault
ALG
ALM
LS
ES
ACC c
Status
Aurora
Base Control
RV – K1
CC2
CC – K2
CC Hi – K3
Fan– K4
Alarm – K5
Acc – K6
ACC no
ACC nc
O/B
C
R
LO
G
Y1
Y2
W
DH
3A-Fuse
O/B
C
R
LO
G
Y1
Y2
W
DH
LO
G
HI
CCG
CC
FG
F
R
HP
HP
LP
FP2
FP2
FP1
REV
REV
CFM
PWM
ECMPWM
Factory
Factory FanConnection
RR
CC
C
C
R
A
B
RS 485
EH2
C
EH1
C
CO
B
A
R
C
RS 485 E xp Factory
Com1
Com2
Config
G
G
G
YR
SW1 Test
FP1 – 15oF/30oF
JW2 - Alarm
P11
P5
P2 P1
P8
P7
P9
P6
P3
SW2
P13
P4 FP 2 – 15oF/30oF
RV – B/O
ACC – Dip 1
ACC – Dip 2
CC – Dual/Single
L – Pulse/Continuous
Reheat/Normal
Factory Use
Field C onnectionsField C onnections
C
LP
FP1
F
CC
G
Y1
1
2
3
4
5
6
7
8
Off On
N/A
RS 485 NE T
CC
Taco Valve
V100FPT
C
W/Y
CC2
SV
Figure 11: Aurora Dual-Capacity with Communicating or Non-
Communicating Thermostat (ABC Only)
Figure 12: Wiring diagram for dual water valve installation
VS PUMP
GND
24 VAC
0-10DC
1
2
3R
C
ABC BOARD
AXB BOARD
2 1
VALVE
(23P529-01)
C
W/Y
CCG or CC GND
CC
CC
U
SV CC2 or CCHI
Logic Board
Taco Valve
V100FPT
(Type V)
BPV/PPV
Solenoid
Compressor
Contactor
Coil Heat Pump
Control Board

12
MAGNA3 INSULATED PUMPS INSTALLATION MANUAL
Plumbing cont.
C. WWK2T – is designed for single speed units. This kit uses slow closing valve, and ball valve to regulate flow. Always ensure that
there is adequate flow for the heat pump. Refer to units Specification Manual for minimum and maximum flow rates. See figure 13
for wiring schematic
Figure 13: Wiring diagram for single speed units.
Heat Pump
Control Board

13
MAGNA3 INSULATED PUMPS INSTALLATION MANUAL
Start-Up
1. Make sure the grey start/stop jumper is installed as shown in figure 4. If not replace the start/stop jumper and apply power to the
pump.
NOTE: When the start/stop jumper is installed and power is connected the pump will start to run. If the start/stop jumper is installed
make sure the loop is filled, flushed and all valves are open as the pump will run.
2. After a few seconds (if the pump has not been powered previously), the pump display will change to the startup guide. The
startup guide will step through general settings such as language, date, and time (see Figure 14).
3. Once general settings are complete, press the home button, and set up the pump for the application.
4. Refer to Option 1 or 2 based upon application type (Constant Curve or Constant Pressure Mode).
CAUTION: VERIFY THAT AIR HAS BEEN PURGED FROM THE PIPING SYSTEM, AND THAT THE SYSTEM HAS
BEEN PRESSURIZED (IF APPLICABLE) BEFORE PROCEEDING.
Figure 14: Startup Screen
Figure 15: Control Panel

14
MAGNA3 INSULATED PUMPS INSTALLATION MANUAL
Option 1: Constant Curve Mode
Follow steps below to set up the pump for Constant Curve Mode.
1. Select Settings
2. Scroll down to Control mode and press OK.
3. Scroll down to Constant curve and press OK.
4. Press to go back to the Settings menu.
5. Scroll down to Setpoint and press OK.
6. Press OK to select the pump % set point.
NOTE: For less than 100%, select the 1 and change it to a 0. Then change the second digit, accordingly.
7. If the installation is a single pump system disconnect power to the pump and remove the grey start/stop jumper. Connect the S/S and
ground wires refer to wiring section after complete turn power back on to the pump. If the installation is a dual pump system leave the
jumper in place until both pumps are setup.
Start-Up Cont.
+RPH
6WDWXV
6HWWLQJV
$VVLVW
+RPH
+RPH
Size Minimum %
40-80 36%
40-120 29%
40-180 23%
MAGNA3 minimum % setting for
Constant Curve Mode

15
MAGNA3 INSULATED PUMPS INSTALLATION MANUAL
Start-Up Cont.
Option 2: Constant Pressure Mode
Follow Steps below to set up the pump in Constant Pressure mode.
1. Open all of the water valves at the heat pumps for full flow.
2. Select Settings.
3. Scroll down to Control mode and press OK.
4. Scroll down to Const. press. and press OK.
5. Press to go back to the Settings menu.
6. Scroll down to Setpoint and press OK.
7. Press OK to select the psi.
8. Before changing the setting, review Steps 9 through 11 below.
9. Balance the flow if necessary. Larger applications may utilize flow control valves; smaller applications may simply have
balancing or ball valves at each heat pump.
10. Once the system is balanced, the psi setting may be adjusted. If the flow rate at the heat pumps is higher than design flow
rate, start to lower the psi setting, and recheck the flow rate at several heat pumps. Continue to adjust psi until the flow rate is
within design specifications.
11. Close some of the water valves, and recheck flow. The pump should slow down. If flow is within design specifications, press
the Home key, and place the water valves in normal operating mode. If flow rates are off, return to Step 10. Depending upon
how the system is balanced (i.e. with balancing valves or with flow control valves), this could be an iterative process.
12. If the installation is a single pump system disconnect power to the pump and remove the grey start/stop jumper. Connect the
S/S and ground wires refer to wiring section after complete turn power back on to the pump. If the installation is a dual pump
system leave the jumper in place until both pumps are setup.
+RPH
6WDWXV
6HWWLQJV
$VVLVW
+RPH
+RPH

16
MAGNA3 INSULATED PUMPS INSTALLATION MANUAL
Multi-Pump Setup
1. For two pumps in parallel with check valves, choose a mulit-pump control mode from the choices below. The multi-pump function
enables the control of single-head pumps connected in parallel and without the use of external controllers. The pumps in a multi-
pump system communicate with each other via the wireless Grundfos GENIair connection. A multi-pump system is set up via a
selected pump, i.e. the primary pump (first selected pump).
A. Alternating operation: Only one pump is operating at a time. The change from one pump to the other depends on time or
energy. If a pump fails, the other pump will take over automatically.
Pump system:
• Two single-head pumps connected in parallel.
• The pumps must be of same type and size.
B. Back-up operation: One pump is operating continuously. The back-up pump is operated at intervals to prevent seizing up. If
the duty pump stops due to a fault, the back-up pump will start automatically.
Pump system:
• Two single-head pumps connected in parallel.
• The pumps must be of same type and size.
C. Cascade operation: Cascade operation ensures that the pump performance is automatically adapted to the consumption
by switching pumps on or off. The system thus runs as energy-efficiently as possible with a Constant Pressure and a limited
number of pumps. All pumps in operation will run at equal speed. Pump changeover is automatic and depends on speed,
operating hours and fault.
Pump system:
• Two single-head pumps connected in parallel. The pumps must be of same type and size.
• The control mode must be set to “Constant Pressure” or “Constant Curve”.
2. In the Assist menu, scroll down to Multi-pump setup, and follow the screens below to select pump operation. NOTE: This step
must be completed for each pump (through Step 2 of 9) before continuing to the pump search screen (step 3 of 9).

17
MAGNA3 INSULATED PUMPS INSTALLATION MANUAL
Multi-Pump Setup
IMPORTANT: The correct day/time for the primary pump must
first be completed before going to this screen. The settings
automatically propagate to the second (backup) pump.
3. Go back to the Assist menu (after both pumps are set up as Alternating, Backup or Cascade), and follow the steps above
(through Step 2 of 9). Then, continue with the screens below.
IMPORTANT: The assist menu will not go past this step if the
second pump has not been set up for multi-pump operation.

18
MAGNA3 INSULATED PUMPS INSTALLATION MANUAL
Multi-Pump Setup
4. Verify the pump function by selecting Pump Identification from the Status menu. See examples below.
5. Disconnect power to the primary pump and remove the grey start/stop jumper. Connect the S/S and ground wires refer to wiring
section after complete turn power back on to the primary pump. DO NOT remove the grey start/stop jump from the secondary
pump. NOTE: The secondary pump will not operate if the grey start/stop jumper is not installed. Replace the pump front cover.
Start the system, and check for proper operation. Record temperatures and flow rates as appropriate.
IMPORTANT: Step 8 (not shown) will start the pumps. If the
start/stop jumper is removed, Step 8 will be skipped.
Example screen for pump 1 Example screen for pump 2
Figure 16: Default home screen for
MAGNA3 insulated pumps
IMPORTANT NOTE: Figure 16 shows the home screen default data. The home
screen can show up to four panels of data. It is not recommend that flow rate (in
gpm) is used as one of the four panels. The MAGNA3 does not use a flow sensor; it
“estimates” flow, which can be misleading, especially when setting up the pump for
constant pressure mode. Verification of system flow rate should be done by checking
pressure drop at each of the heat pumps.

19
MAGNA3 INSULATED PUMPS INSTALLATION MANUAL
Type Size Volume
(U.S. Gal/100’ Pipe) Volume (Liters/10 Meters)
Copper 1" CTS 4.1 15.5
Copper 1.25" CTS 6.4 24.2
Copper 1.5" CTS 9.2 34.8
Polyethylene .75" - IPS SDR 11 3.0 11.4
Polyethylene 1" - IPS SDR 11 4.7 17.8
Polyethylene 1.25" - IPS SDR 11 7.5 28.4
Polyethylene 1.50" - IPS SDR 11 9.8 37.1
Polyethylene 2" - IPS SDR 11 15.4 58.3
Approximate Fluid Volume per 100’ of Pipe
Type Minimum Temperature for Freeze Protection
10
° F (-12.2 ° C) 15 ° F (-9.4 ° C) 20 ° F (-6.7 ° C) 25 ° F (-3.9 ° C)
Methanol* 25% 21% 16% 10%
Environol™ 1000* (premix) 100% 87% 72% 48%
Environol™ 2000* (pure) 27% 24% 20% 13%
Antifreeze Requirements
NOTES: Not all currently available in all areas. All % are by volume.
Antifreeze Selection and Use
Some of the equipment includes freeze detection thermistors to protect the water-to-refrigerant heat exchanger from damage caused by
freezing liquid. Be sure the “Loop/Well” DIP switch is in the “Loop” position if antifreeze is used and in the “Well” position if plain water is
used in the loop.
Selection of the antifreeze solution for closed loop earth coupled systems requires the consideration of many important factors which have
long-term implications on the performance and life of the equipment. Each area of concern leads to a different “best choice” of antifreeze.
The fact is that there is no “ideal” antifreeze and any choice will require compromises in one area or another. Some of the factors to
consider are:
Safety - The toxicity and flammability of the brine (antifreeze
solution of any type).
Thermal performance - The heat transfer and viscosity effects
of the brine.
Cost - The prices vary widely.
Corrosiveness - System materials must be compatible with the brine.
Stability - Will the brine require periodic change out or maintenance?
Convenience - Is the brine available and easy to transport and install?
Codes - Will the brine meet local and national regulatory standards?
The following are some general observations about the types of brine presently being used:
Methanol - Considered toxic in pure form, good heat transfer, low to mid price, flammable in concentrations greater than 25%,
non-corrosive, low viscosity.
Ethanol (Environol 1000 and 2000) - Good heat transfer (slightly less than methanol), high price, flammable in concentrations
greater than 25%, non-corrosive and low viscosity.
Propylene glycol - Nontoxic-noncorrosive, expensive, hard to handle when cold, poorest heat transfer, has formed “slime-type”
coatings inside pipe. Poor heat transfer has required its removal in some systems.
NOTE: Consult with your representative or distributor if you have any questions regarding antifreeze selection, or any comments to report
about problems or success with any particular methods.
CAUTION: Only use premixed antifreeze in a
non-flammable state. Failure to observe safety
precautions may result in fire, injury, or death.

20
MAGNA3 INSULATED PUMPS INSTALLATION MANUAL
Figure 17: Freeze Protection Curves
.96
.97
.98
.99
1.00
-20-100 10203040
Specific Gravity
Freeze Protection Temperature ( ˚F)
Methanol Mixture
Environol™ Mixture
* With reference to 60°F water courtesy of Carbide and
Carbon Chemicals Corporation
35
-10
-5
0
10
15
20
25
30
1009080706050403020010
˚F
% by Volume
5
Figure 19: Environol™ 2000 Freeze Protection (Concentrate)
Figure 18: Environol™ 1000 Freeze Protection (Premixed)
35
-10
-5
5
10
15
20
25
30
350 5 10 15 20 25 30 40
˚F
% by Volume
0
1.000
0.900
10
20
30
40
50
60
70
80
90
10
P/N: CAMT
Methanol Hydrometer
Antifreeze Selection and Use cont.