Grundfos Hydro 1000 User manual

Hydro 1000
Installation and operating instructions
GRUNDFOS INSTRUCTIONS

Declaration of Conformity
We Grundfos declare under our sole responsibility that the products Hydro 1000, to which this dec-
laration relates, are in conformity with the Council Directives on the approximation of the laws of the
EC Member States relating to:
— Machinery (98/37/EC).
Standard used: EN ISO 12100.
— Electromagnetic compatibility (89/336/EEC).
Standards used: EN 61 000-6-2 and EN 61 000-6-3.
— Electrical equipment designed for use within certain voltage limits
(73/23/EEC) [95].
Standard used: EN 60 204-1.
Bjerringbro, 1st April 2005
Jan Strandgaard
Technical Director
2

3
CONTENTS
Page
1. General 3
1.1 Applications 3
1.2 Operating conditions 3
2. Product description 3
2.1 Grundfos Hydro 1000 3
2.2 Grundfos Control 1000 3
2.3 Monitoring and indication functions 4
2.4 Example of booster set Hydro 1000 4
3. Operation 4
3.1 CS 1000 front cover 4
4. Installation 5
4.1 Location 5
4.2 Foundation 5
4.3 Pipework 5
4.4 Dry-running protection 5
4.5 Priming 5
4.6 Electrical connection 5
5. Settings 5
5.1 Timers 5
5.2 Operation selection 6
5.3 Alarm resetting 7
5.4 Pressure setting 7
5.5 Pressure switch 7
5.6 Tank precharge pressure 7
6. Start-up 8
7. Maintenance 8
7.1 Maintenance of booster set 8
7.2 Maintenance of Control 1000 8
7.3 Checking the precharge pressure 8
8. Fault finding chart 9
8.1 Emergency operation 9
9. Parts list 10
10. Technical data 10
10.1 Sound pressure level 10
10.2 Hydraulic data 10
10.3 Electrical data 10
Before beginning installation procedures, these in-
stallation and operating instructions should be stud-
ied carefully. The installation and operation should
also be carried out in accordance with local regula-
tions and accepted codes of good practice.
1. General
1.1 Applications
Grundfos booster sets Hydro 1000 are designed for the transfer
and pressure boosting of clean water in waterworks, blocks of
flats, hotels, industry, hospitals, schools, etc.
1.2 Operating conditions
Liquid temperature: Maximum +50°C.
Ambient temperature: 0°C to +40°C.
Operating pressure: Maximum 10 bar.
Minimum and maximum
inlet pressures: See installation and operating
instructions for CR pumps.
Liquid temperature and operating pressure may be limited by the
diaphragm tank.
2. Product description
2.1 Grundfos Hydro 1000
The booster set consists of 2 to 4 pumps mounted on a common
base frame, isolating valves, non-return valves, suction and dis-
charge manifolds with pressure switches and a control box com-
plete with the controller CS 1000.
Note: A diaphragm tank must be included in the installation. Dia-
phragm tanks can be connected directly to the discharge mani-
fold.
Fig. 1
2.2 Grundfos Control 1000
The Grundfos Control 1000 controls a number of mains-operated
pumps.
The Control 1000 always includes the controller CS 1000 and of-
fers the following functions:
• Automatic cascade control of pumps.
• Manual operation.
• Pump and system monitoring functions:
- maximum pressure,
- pre-pressure / level,
- motor protection.
• Display and indication functions:
- green indicator lights for operating indications and
red indicator lights for fault indications,
- potential-free changeover contact for fault indications.
Fig. 2
TM00 9718 0297
TM00 9738 0397
VALVE
CS 1000
PRESSURE GAUGE
NON-RETURN
VALVE
ISOLATING
PUMP
PRESSURE
SWITCH
Hydro 1000
Grundfos booster set Hydro 1000
CS 1000 front cover

4
2.3 Monitoring and indication functions
The following functions are available:
• Red indicator lights (LED) for indication of fault conditions:
- maximum pressure (if a pressure switch is installed),
- dry-running protection (if a pressure switch is installed),
- motor protection.
• Green indicator lights (LED) for indication of operating condi-
tions:
- power on,
- automatic operation,
- pump in operation.
• Potential-free changeover contact for fault indications.
2.4 Example of booster set Hydro 1000
3. Operation
3.1 CS 1000 front cover
The CS 1000 front cover shows all possible operating conditions.
Fig. 3
Grundfos Hydro 1000 CS
Four identical full-size mains-operated pumps and a dia-
phragm tank.
TM00 8084 2396
One pump in operation.
TM00 8085 2396
Three pumps in operation.
TM00 5086 2396
Grundfos Hydro 1000 CS maintains an almost constant pres-
sure by cutting in/out the required number of pumps.
The CS 1000 alters the starting sequence of the pumps after
each pump stop, thus giving all pumps equal operating time.
Pump changeover is automatic and depends on load and fault.
CS 1000
Q
stop
H
Hstart
H
Cut-out
Cut-in
H
start
Q
stopH
H
Cut-out
Cut-in
TM00 9738 0397
Button/
indicator light Function
Power indication. The green indicator light
is on when the electricity supply to the
CS 1000 is connected.
Dry-running alarm. The red indicator light is
on when the dry-running alarm is activated.
The light goes out when the alarm is reset.
If automatic resetting is chosen, the indica-
tor light goes out automatically when nor-
mal operating conditions are achieved.
Maximum pressure alarm. The red indicator
light is on when maximum pressure is acti-
vated. The light goes out when the alarm is
reset. If automatic resetting is chosen, the
indicator light goes out automatically when
normal operating conditions are achieved.
Reset button. Resets the dry-running alarm
and the maximum pressure alarm if auto-
matic resetting has not been chosen.
Automatic operation. The green indicator
light is on when the pump is released and
ready for operation.
Pump alarm. The red indicator light is on
when the thermal relay of the pump is acti-
vated. The pump is out of operation. The
alarm can be reset on the thermal relay.
Pump in operation. The green indicator
light is on when the pump is operating.
Auto button. When the auto button is
pressed, the pump will be released for op-
eration and the indicator light for automatic
operation will be lit.
Stop button. When the stop button is
pressed, the pump will be taken out of op-
eration and the indicator light for automatic
operation goes out.
Test button. The pump is operating as long
as the test button is pressed. The maxi-
mum pressure and the dry-running protec-
tion are not activated as long as the button
is pressed.
CS 1000 front cover

5
4. Installation
4.1 Location
The booster set should be placed in a well-ventilated room to en-
sure adequate cooling of the pump motors. It should be placed
with a 1 metre clearance in front and on the two sides.
Use a fork-lift truck to move the booster set.
4.2 Foundation
The booster set does not require a special foundation, but it should
be positioned on a plane and solid surface, e.g. a concrete floor.
4.3 Pipework
Arrows on the pump bases show the flow direction of the water
through the pumps.
The pipes connected to the booster set must be of adequate size.
To avoid resonance, expansion joints should be fitted in the suc-
tion and discharge pipes, see fig. 4.
The pipes are connected to the manifolds of the booster set. Ei-
ther end can be used. Apply sealing compound to the unused end
of the manifold and fit a screw cap. For manifolds with flanges, a
blind flange with gasket is fitted.
The booster set should be tightened up before start-up.
The pipes must be fastened to parts of the building to ensure that
they cannot move or be twisted.
Fig. 4
1. Expansion joint.
2. Pipe hanger.
Expansion joints, pipe hangers and vibration dampers shown in
fig. 4 are not included in the standard booster set.
4.4 Dry-running protection
It is possible to install a pressure switch on the suction side of the
booster set to monitor the inlet pressure and to prevent the
booster set from running dry (a level switch can be used if the
suction side is connected to an open tank).
The booster set should not be started until a dry-running protec-
tion has been installed. When the inlet pressure/level drops below
the set value, the pumps are cut out. When the correct pressure/
level value is restored, the pumps can be reset to operation auto-
matically or manually.
4.5 Priming
Do not start the pumps until they have been filled with water. See
installation and operating instructions for CR pumps.
4.6 Electrical connection
The electrical connection should be carried out by an authorized
electrician in accordance with local regulations.
The wiring diagram and motor labels show required values for the
electricity supply.
No additional motor protection is required as the control box in-
corporates motor protection.
5. Settings
5.1 Timers
The three timers incorporated in the controller CS 1000 can be
used to optimize the operation of the booster set. The timers are
to be adjusted individually.
Start-up delay TR 1 (0-5 secs.)
Defined as: The minimum time between starts of individual
pumps.
Prevents: simultaneous start of all pumps in case of:
- momentary power failure,
- peak of water demand,
- automatic resetting of dry-running.
negative pressure in suction manifold.
overload of power mains.
water hammer.
Stop delay TR 2 (0-5 secs.)
Defined as: The minimum time between stops of individual
pumps.
Prevents: simultaneous stop of all pumps in case of:
- rapid fall of water demand.
water hammer.
Reduces: number of starts and stops per hour.
After-run delay TR 3 (0-5 secs.)
Defined as: The time that pumps are kept in operation after
the cut-out pressure is reached.
Keeps: pumps in operation when the cut-out pressure is
reached.
Reduces: number of starts and stops per hour.
Fig. 5
TM00 7748 1996
2
2
11
2
Before making any connections in pumps, terminal
boxes or control box, the electricity supply must be
switched off.
TM00 9742 0397
J2 J4
TR 1
TR 2
TR 3

6
5.2 Operation selection
All operating possibilities for the pumps in your booster set are
listed below:
To select operation, proceed as follows:
• Switch off the electricity supply to the Control 1000.
• Open the control box and set the DIP switches according to
the desired selection.
• Close the control box, switch on the electricity supply and
press buttons as indicated in column “Front panel selection”.
Fig. 6
Note: A pilot pump is the pump that:
• starts first / stops last.
• is generally smaller than the other pumps (smaller flow -
higher head).
• is not to be alternated.
• must be installed in position P1.
Before changing DIP switch setting, switch off the
electricity supply.
TM03 0649 0405
ON
1234
ON
SW 1
1234
Number of
pumps installed Front panel selection DIP switch
setting Pumps in operation Pumps to be alternated Pilot pump
4 pumps
P1 P2 P3 P4 P1 P2 P3 P4 P1 P2 P3 P4
P1 P2 P3 P4 — — — —
— — — — P1 P2 P3 P4 — P2 P3 P4 P1
3 pumps
P1 P2 P3 P1 P2 P3 P1 P2 P3
P1 P2 P3 — — —
P4 P1 P2 P3 — P2 P3 P1
2 pumps
P1 P2 P1 P2 P1 P2
P1 P2 — —
P3 P4

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5.3 Alarm resetting
There are two possible resetting modes which can be selected by
means of each of the switches SL and SP.
• SL: Dry running.
• SP: High pressure.
Fig. 7
• M (Manual). When acceptable conditions have been restored,
the pumps are started by pressing the reset button on the front
cover.
• A (Automatic). When the pressure/level has reached an ac-
ceptable value, the pumps start automatically.
5.4 Pressure setting
The pumps are cut in and out according to the pressures set on
the pressure switches.
A common differential (ƒ) pressure (cut-out pressure – cut-in
pressure = ƒpressure) must be set on the pressure switches.
The cut-out pressures differ 0.3 to 0.5 bar respectively (cascade
step).
Example:
• 3 pumps.
•ƒpressure = 1.5 bar.
• Cascade step = 0.3 bar.
• Pr 1, 2, 3 = Pressure switch 1, 2, 3.
• P 1, 2, 3 = Pump 1, 2, 3.
Fig. 8
The settings of the pressure switches Pr 2 and Pr 3 are in a de-
creasing sequence as shown in the table and fig. 8.
When water is consumed, this is first tapped from the diaphragm
tank. Then the pressure drops to the first cut-in pressure, and the
first pump is cut in. If the consumption is still rising, more pumps
will be cut in until the performance of the pumps in operation cor-
responds to the requirements.
When the water consumption falls, the discharge pressure rises
to the cut-out pressure and the CS 1000 cuts out one pump. If the
consumption is still falling, more pumps will be cut out.
Note: Each pressure switch is related to one pump only and not
necessarily to the same pump when pump alternation is selected
on the DIP switch, see section 5.2 Operation selection.
Pressure switch Pr 1 must be set to the highest cut-in and cut-out
values.
5.5 Pressure switch
On each pressure switch, the following settings must be made:
• Cut-out pressure.
•ƒpressure (differential pressure).
Note: The cut-in pressure is set as the cut-out pressure minus
ƒpressure.
Fig. 9
1. Cut-out pressure:
+ to increase.
– to decrease.
2. ƒpressure (differential pressure):
+ to increase.
– to decrease.
5.6 Tank precharge pressure
The precharge pressure is equal to the minimum cut-in pressure.
TM00 9744 0397
Pressureswitch
and
pump numbers
Cut-in
pressure
[bar]
Cut-out
pressure
[bar]
ƒpressure
[bar]
Pr 1 / P 1 2.6 4.1 1.5
Pr 2 / P 2 2.3 3.8 1.5
Pr 3 / P 3 2.0 3.5 1.5
TM00 9732 0297
SL
SP
Pr 1
Pr 2
Pr 3
Pr 1
Pr 2
Pr 3
Cut-outCut-in
ƒpressure
Cascade
step
One pump
in operation Two pumps
in operation Three pumps
in operation
TM00 9740 0397
1
2

8
6. Start-up
To start up a booster set Hydro 1000, follow this procedure:
1. Connect water and electricity supplies.
2. Check that the precharge pressure in the diaphragm tank is
equal to the minimum cut-in pressure.
3. Close the discharge valves of the pumps and prime the
booster set and the suction pipe.
4. Adjust the pressure switches according to the desired dis-
charge pressure.
5. Check that the DIP switch setting corresponds to the number
of pumps installed.
6. Switch on the electricity supply.
7. Start pump 1 by pressing the button on the front cover.
8. Pump 1 will now start.
9. Check the direction of rotation of the pump. In case of incor-
rect rotation, interchange two phases of the electricity supply.
10. Vent the pump while slowly opening its discharge valve.
11. Repeat points 7 to 10 for all pumps.
12. Release the pumps for operation by pressing the buttons on
the front cover.
Hydro 1000 is now ready for operation.
7. Maintenance
7.1 Maintenance of booster set
See installation and operating instructions for CR pumps.
7.2 Maintenance of Control 1000
The Control 1000 is maintenance-free.
7.3 Checking the precharge pressure
To ensure reliable and correct operation, including the frequency
of starts and stops, the precharge pressure of the diaphragm tank
should be checked regularly (at least twice a year).

9
8. Fault finding chart
8.1 Emergency operation
In case of damage to electronic components belonging to the
printed circuit board, the system can be operated by moving the
multiplug from J2 to J4, see fig. 10.
Pumps will still operate automatically by pressure switches but
without LED indications and the alternation function.
Maximum pressure and dry-running protection are not active
when the booster set is in emergency operation.
Fig. 10
Before making any connections in pumps, terminal boxes or control box, the electricity supply must be switched off.
Fault Cause Remedy
1. Motor does not run
when started. a) Electricity supply disconnected. Connect the electricity supply.
b) Automatic circuit breakers cut out. Correct the fault and cut in the automatic circuit break-
ers.
c) Fuse in the CS 1000 defective. Replace the fuse.
d) Motor defective. Repair/replace the motor.
2. Motor starts, but stops
immediately after-
wards.
a) Incorrect setting of pressure switch. Increase the cut-out pressure and/or differential
pressure.
b) Wrong diaphragm tank precharge pressure. Check the diaphragm tank precharge pressure.
3. Frequent starts and
stops. a) Incorrect setting of time delay TR 2. Set the time delay TR 2 accordingly.
b) Incorrect setting of pressure switch. Increase the cut-out pressure and/or differential
pressure.
c) Diaphragm tank defective. Repair the diaphragm tank.
4. Pumps are running but
deliver no water. a) Suction pipe/pumps blocked by impurities. Clean the suction pipe/pumps.
b) Non-return valve blocked in closed position. Clean the non-return valve.
c) Suction pipe leaky. Repair the suction pipe.
d) Air in suction pipe/pumps. Vent the pumps. Check the suction pipe for leakages.
e) Motors running with the wrong direction of rota-
tion. Change the direction of rotation.
5. Leakage from the shaft
seal. a) Shaft seal defective. Replace the shaft seal.
b) Height adjustment of the pump shaft inaccurate. Readjust the shaft height. See installation and oper-
ating instructions for CR pumps.
6. Noise. a) The pumps are cavitating. Clean the suction pipe/pumps and possibly the suc-
tion strainer.
b) The pumps do not rotate freely (frictional
resistance) due to inaccurate height adjust-
ment of the pump shaft.
Readjust the shaft height. See installation and oper-
ating instructions for CR pumps.
TM00 9742 0397
J2 J4
J2 J4

10
9. Parts list
Fig. 11
10. Technical data
10.1 Sound pressure level
For sound pressure level, see installation and operating instruc-
tions for CR pumps.
The sound pressure level for a number of pumps can be calcu-
lated as follows:
Lmax. = Lpump + (n - 1) x 3.
Lmax. = Maximum sound pressure level.
Lpump = Sound pressure level for one pump.
n = Number of pumps.
10.2 Hydraulic data
Minimum pre-pressure:
The minimum pre-pressure “H” in metres head required to avoid
cavitation in the pumps is calculated as follows:
H = pbx 10.2 - NPSH - Hf- Hv- Hs
pb= Barometric pressure in bar.
Barometric pressure can be set to 1 bar.
NPSH = Net Positive Suction Head i metres head
(to be read from the NPSH curve at the highest flow).
See installation and operating instructions for
CR pumps.
Hf= Friction loss in suction pipe in metres head.
Hv= Vapour pressure in metres head, tm= liquid
temperature.
See installation and operating instructions for
CR pumps.
Hs= Safety margin of minimum 0.5 metres head.
10.3 Electrical data
Supply Voltage: 3 x 400 V +6%/–10%, 50 Hz, PE.
Pos. Description Number
1 Suction manifold 1
2 Discharge manifold 1
3 Base frame 1
4 Stand 1
5 Control box 1
6 CR pump 2-4
7 Non-return valve 1 per pump
8 Isolating valve 2 per pump
9 Pressure switch 1 per pump
10 Pressure gauge 1
TM00 9741 0397
Hydro 1000
5
10
4
6
2
9
1
8
7
3
Terminal
designation
or number Function CS 1000 Technical data
J1
1Input for thermal relay
pump 1
2Input for thermal relay
pump 2
3Input for thermal relay
pump 3
4Input for thermal relay
pump 4
5
6Common terminal for
multiplug J1
J2
1 - 2 Input for dry-running pro-
tection
3 - 4 Input for maximum pres-
sure protection
5 - 6 Input for pressure switch 1
7 - 8 Input for pressure switch 2
9 - 10 Input for pressure switch 3
11 - 12 Input for pressure switch 4
J3
1 - 2 Output for contactor K1 AC 24 V
3 - 4 Output for contactor K2 AC 24 V
5 - 6 Output for contactor K3 AC 24 V
7 - 8 Output for contactor K4 AC 24 V
J5
1 - 2 Electricity supply for
CS 1000 AC 24 V
3 - 4 Electricity supply for
CS 1000 AC 18 V
5 - 6 Electricity supply for
CS 1000 AC 8 V
J6 1 - 3 Fault relay
Potential-free
changeover
contacts.
Maximum con-
tact load:
250 V / 3.0 A,
AC 1
Subject to alterations.