Grundfos Hydro 2000 S User manual

Hydro 2000 S
Installation and operating instructions
GRUNDFOS INSTRUCTIONS

Declaration of Conformity
We GRUNDFOS declare under our sole responsibility that the products
Hydro 2000 S, to which this declaration relates, are in conformity with the
Council Directives on the approximation of the laws of the EEC Member
States relating to:
— Machinery (98/37/EEC).
Standard used: EN 292.
— 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).
Standard used: EN 60 204-1.
Bjerringbro, 15th November 2001
Jan Strandgaard
Technical Manager
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CONTENTS
Page
1. General 5
1.1 Scope of these Instructions 5
1.2 Related Documents 5
2. Product Description 5
2.1 GRUNDFOS Hydro 2000 S 5
2.2 GRUNDFOS Control 2000 S 6
2.2.1 Examples of Booster Sets Hydro 2000 S 7
3. Functions 8
3.1 Control Functions and Settings 8
3.1.1 Monitoring Functions 8
3.1.2 PFU 2000 RAM Settings 8
3.1.3 Closed-Loop Control 9
3.1.4 Cascade Control 9
3.1.5 Manual On/Off and Setting to Max. or Local 10
3.1.6 Water Shortage Monitoring 10
3.1.7 Automatic Pump Change 11
3.1.8 Test Run 11
3.1.9 Clock Functions 11
3.1.10 Standby Pumps 11
3.1.11 Reduced Operation 12
3.1.12 Pump Priority 12
3.1.13 GRUNDFOS BUS 12
3.2 Control Parameters 13
3.2.1 Allocation of Pumps to Zone 13
3.2.2 Zone Type / Control Parameter 13
3.2.3 Priority of Settings 13
3.2.4 Setpoint 14
3.2.5 Setpoint Influences 14
3.2.6 On/Off Band 15
3.2.7 Measuring Unit for Control Value 16
3.2.8 System Time 16
3.2.9 Minimum Switching Sequence 16
3.2.10 Medium Switching Sequence 16
3.2.11 Control Function 17
3.2.12 PFU 2000 Analog Input 1 Configuration 17
3.2.13 PFU 2000 Analog Input 2 Configuration 17
3.2.14 PFU 2000 Analog Input 3 Configuration 17
3.2.15 PFU 2000 Input 4 Configuration 18
3.2.16 Ramp Time 18
3.2.17 Minimum Pump Speed Limit 19
3.2.18 Maximum Limit (Overpressure) 19
3.2.19 Minimum Limit 19
3.2.20 Operation at Minimum Limit 19
3.2.21 Minimum Pre-Pressure 19
3.3 Pump Parameters 19
3.3.1 Maximum Head 20
3.3.2 Operating Hours 20
3.3.3 Start Time 20
4. Installation 20
4.1 Location 20
4.2 Hydraulic Installation 20
4.3 Electrical Connection 20
5. Start-Up 21
5.1 Hydro 2000 S without a PMU 2000 21
5.1.1 Setting via a Temporarily Connected PMU 2000 21
5.2 Hydro 2000 S with a PMU 2000 21
5.3 Direction of Rotation 21
5.4 Taking out of Operation 22
6. Operation 22
6.1 Operation of PMU 2000 22
6.1.1 Display Rules 23
6.1.2 Status Display 23
6.2 Configuration of the PFU 2000 23
6.2.1 PFU 2000 DIP Switch Settings 24
6.2.2 Configuration of PCU Relays 25
7. Monitoring Functions 25
7.1 Faults, General 25
7.2 Pump- and Motor-Related Faults 26
7.2.1 Communication Faults 26
7.2.2 Motor Overtemperature 26
7.3 Zone-Related Faults 26
7.3.1 Transmitter Fault 26
7.3.2 Water Shortage 26
7.3.3 Maximum Limit of Actual Value 26
7.3.4 Minimum Limit of Actual Value 26
7.3.5 Any Fault in the Zone 26
7.3.6 Fault in Any Motor 26
7.4 System-Related Faults 26
7.4.1 Voltage Drop 26
8. Maintenance 27
8.1 Maintenance of Booster Set 27
8.1.1 Pumps 27
8.1.2 Motor Bearings 27
8.1.3 Frost Protection 27
8.2 Maintenance of the Control 2000 S 27
9. Operating and Fault Indications 28
10. Fault Finding Chart 29
11. Technical Data 30
11.1 Hydraulic Data 30
11.2 Operating Conditions 30
11.3 Sound Pressure Level 30
11.4 Electrical Data 31
12. Glossary 32
13. Display Overviews 33

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2. Product Description
2.1 GRUNDFOS Hydro 2000 S
GRUNDFOS booster sets Hydro 2000 S consist of a number of
pumps with all necessary fittings and a GRUNDFOS Control 2000
S mounted on a common base frame, all ready for installation.
A diaphragm tank must be included in the installation.
Fig. 1
TM00 5391 4796
PRESSURE
TRANSMITTER
VALVE
PFU 2000
PRESSURE GAUGE
NON-RETURN
VALVE
ISOLATING
PUMP
Control 2000
GRUNDFOS Booster Set Hydro 2000 S
1. General
1.1 Scope of these Instructions
These Installation and Operating Instructions apply to GRUND-
FOS booster sets Hydro 2000 S.
GRUNDFOS booster sets Hydro 2000 S are designed for the
transfer and pressure boosting of clean water in waterworks,
blocks of flats, hotels, industry, hospitals, schools, etc.
The Hydro 2000 S range includes two types of systems, i.e. MS
and MSH.
1.2 Related Documents
For some booster sets, the detailed information can be found in
the related documents.
• List of Control Parameters (factory configuration).
• Wiring diagram.
• Installation and Operating Instructions.
• Data booklet.
System
Type System Function
Hydro 2000 S
MS All pumps are full-size pumps which are mains-
operated (on/off).
MSH
One half-size pump. The other pumps are full-
size pumps.
All pumps are mains-operated (on/off).

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Fig. 2
Fig. 3
PFU 2000 Front Cover
Reset
TM00 2721 2397
PMU 2000 Front Cover
TM00 7023 2497
2.2 GRUNDFOS Control 2000 S
The GRUNDFOS Control 2000 S controls a number of pumps on
mains operation.
The Control 2000 S always includes the PFU 2000 with applica-
tion-optimized software, but it is also available with a PMU 2000.
The operating conditions and factory settings can be optimized
via a temporarily connected PMU 2000.
If the Control 2000 S includes the PFU 2000 only, it will be placed
in the front cover. If the Control 2000 S includes both the PFU
2000 and the PMU 2000, the PMU 2000 will be placed in the front
cover and the PFU 2000 inside the cabinet.
The Control 2000 S is factory-assembled and tested with the con-
trol parameters mentioned in the “List of Control Parameters”,
which is delivered with the booster set.
The Control 2000 S offers the following functions:
• Closed-loop control.
• Automatic cascade control of pumps.
• Selection of switching sequences, automatic pump change
and pump priority.
• Manual operation.
• Possibility of various analog setpoint influences:
– friction loss compensation (flow-dependent setpoint
control with or without flow measurement),
– temperature-dependent setpoint control,
– setpoint adjustment.
• Possibility of various digital remote-control functions:
– system on/off,
– reduced operation,
– setpoint control with two-point switch,
– setpoint control with three-point switch,
– alternative setpoint,
– fire-fighting operation,
– switching off individual pumps.
• Pump and system monitoring functions:
– minimum and maximum limits of actual value,
– pre-pressure,
– motor protection,
– BUS communication.
• Display and indication functions:
– 2 x 24 character LCD display,
– green indicator light for operating indications and
red indicator light for fault indications,
– potential-free changeover contacts for operation and fault.
• Clock functions.
• GRUNDFOS BUS communication.

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2.2.1 Examples of Booster Sets Hydro 2000 S
Example:
GRUNDFOS Hydro 2000 MS.
Four pumps and a diaphragm tank.
Example:
GRUNDFOS Hydro 2000 MSH.
One half-size pump, three full-size pumps
and a diaphragm tank.
One pump in operation. One half-size pump in operation.
Three pumps in operation.
One half-size pump and one full-size
pump in operation.
GRUNDFOS Hydro 2000 MS maintains an
almost constant pressure through cutting in/
out the required number of pumps.
The operating range of the pumps will lie
between the lines Hset and Hstop (cut-out
pressure). The cut-out pressure cannot be
set but is calculated automatically.
Changeover among the pumps is automatic
and depends on load, time and fault.
GRUNDFOS Hydro 2000 MSH maintains an
almost constant pressure through cutting in/
out the half-size pump and the full-size
pumps.
The half-size pump will always start first.
The half-size pump will be cut out again
when a full-size pump is cut in.
The operating range of the pumps will lie
between the lines Hset and Hstop (cut-out
pressure). The cut-out pressure cannot be
set but is calculated automatically.
Changeover among the full-size pumps is
automatic and depends on load, time and
fault.
TM00 2674 0294
PFU 2000
TM00 2678 0294
PFU 2000
Q
stop
set
H
H
H
TM00 2749 0294
Q
stop
set
H
H
H
TM00 2773 0294
Q
stop
set
H
H
H
TM00 2751 0294
Q
stop
set
H
H
H
TM00 2775 0294

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3. Functions
3.1 Control Functions and Settings
The display numbers mentioned in the following refer to the dis-
play overviews in section 13. Display Overviews.
In the PFU 2000, two sets of control parameter settings are
stored:
• PFU 2000 EPROM settings, which are default values.
• PFU 2000 RAM settings, which are configuration values.
(These values can be changed).
The PFU 2000 RAM settings are configured and displayed in the
PMU 2000.
Operation with PFU 2000 EPROM settings or PFU 2000 RAM
settings can be changed by means of the DIP switches in the
PFU 2000.
The PFU 2000 EPROM default settings and the PFU 2000 RAM
settings are listed in the “List of Control Parameters”. This list
should be updated after each change of setting.
PFU 2000 EPROM settings should not be used for continuous op-
eration. It is preferable to operate the booster set with PFU 2000
RAM settings.
3.1.1 Monitoring Functions
The following functions are available:
• Red indicator light (LED) for indication of fault condition.
• Green indicator light (LED) for indication of operating condi-
tion.
• PFU 2000 fault signal relay for indication of fault condition.
• PFU 2000 operating signal relay for indication of operating
condition.
• PMU 2000 fault signal relay for indication of fault condition
(if a PMU 2000 is installed).
• PMU 2000 operating signal relay for indication of operating
condition (if a PMU 2000 is installed).
• GRUNDFOS BUS communication.
See also section 9. Operating and Fault Indications.
Fig. 4
Fig. 5
PFU 2000 Front Cover
Reset
TM00 2721 2397
PMU 2000 Front Cover
TM00 7023 2497
3.1.2 PFU 2000 RAM Settings
The PMU 2000 maintains the PFU 2000 RAM settings as long as
the units are connected via the GRUNDFOS BUS.
If a PMU 2000 is to be connected or replaced, please note the fol-
lowing:
To enter data from a PMU 2000 into the PFU 2000 RAM:
Fig. 6
1. Connect the GRUNDFOS BUS between the PMU 2000 and
the PFU 2000.
2. Switch on the electricity supply to the PMU 2000.
3. Switch on the electricity supply to the PFU 2000.
4. The settings from the PMU 2000 will be entered into the PFU
2000 RAM. This operation will take about 1 minute. During this
period, the PMU 2000 will display “Master”.
To enter data from a PFU 2000 RAM into the PMU 2000:
Fig. 7
1. Connect the GRUNDFOS BUS between the PMU 2000 and
the PFU 2000.
2. Switch on the electricity supply to the PFU 2000.
3. Switch on the electricity supply to the PMU 2000.
4. The settings from the PFU 2000 RAM will be entered into the
PMU 2000. This operation will take about 1 minute. During this
period, the PMU 2000 will display “Slave”.
For further information, see section
3.1 Control Functions and Settings.
PMU 2000
PFU 2000
GRUNDFOS BUS
TM00 8462 2896
PMU 2000
PFU 2000
GRUNDFOS BUS
TM00 8461 2896

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3.1.4 Cascade Control
Cascade control ensures automatic matching of the performance
to the system demand by cutting in/out the required number of
pumps.The controller will operate the system with as few pumps
as possible.
The frequency of starts and stops is limited by the setting of mini-
mum and medium switching sequences.
The pumps are cut in if the actual value remains below the set-
point.
With the “control function” (display 214) set to “normal”, the
switching-off levels for the cascade-controlled pumps are calcu-
lated as follows:
Operation with PFU 2000 RAM / PMU 2000 Settings:
The actual switching-off level is the lower value of Hstop calcu-
lated with PFU 2000 RAM / PMU settings and PFU 2000 EPROM
settings.
The Hstop is calculated as:
Operation with PFU 2000 EPROM Settings:
The Hstop is calculated as:
Hstop: The pressure at which a pump is cut out.
n: Number of pumps in operation.
H0: Pump head at zero flow.
The default setting of H0with PFU 2000 EPROM
settings is the highest value of:
setpoint max. + 10% of setpoint or
setpoint max. + 5% of transmitter measuring range.
Hp: Pre-pressure.
Hset: Actual setpoint.
On/off-band: The pressure above the setpoint.
If H0+ Hpis higher than “max. limit” (display 228), the value for
“max. limit” is used instead of H0+ Hp.
For further information, see sections
3.2.9 Minimum Switching Sequence,
3.2.10 Medium Switching Sequence and
3.2.17 Minimum Pump Speed Limit.
Hstop
On/off band–
n
---------------------------------------H
set
+=
Hstop
H0HpHset –+
n1+
----------------------------------------- H set +=
3.1.3 Closed-Loop Control
The closed-loop controller (a control system with a feed-back sig-
nal from a transmitter) is programmed for operation of centrifugal
pumps and takes their influence on the hydraulic system into ac-
count.
Fig. 8
The only control parameter to be set to adapt the controller to the
system conditions is “system time” (display 204), instead of PID
parameters as is the case with conventional closed-loop control-
lers.
• Operation with PFU 2000 RAM / PMU 2000 Settings:
With the settings in the start/stop menu (displays 300 and 301)
and with the function selector in the PFU 2000 within the range
from 0% to 100%, the closed-loop controller is operating.
• Operation with PFU 2000 EPROM Settings:
With the function selector in the PFU 2000 within the range
from 0% to 100%, the closed-loop controller is operating.
Fig. 9
For further information, see section
3.2.5 Setpoint Influences.
PMU 2000
PFU 2000
PP
GRUNDFOS BUS
TM00 8277 2596
100%0%
MAXSTOP
Setpoint
Function Selector in the PFU 2000
TM00 5217 2796

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3.1.5 Manual On/Off and Setting to Max. or Local
Operation with PFU 2000 RAM / PMU 2000 Settings:
Fig. 10
In the start/stop menu, the “On/Off” button on the PMU 2000
gives quick access to:
• manual on/off of zone and setting to max. or local,
• manual on/off of individual pumps.
In this menu, the zone and the pumps allocated to this zone ap-
pear one by one when the arrow buttons are pressed.
The operating condition of the zone or pump in question is dis-
played in the top line. In the bottom line, a new status can be se-
lected.
Start/stop of zones (display 300):
• “on”
All pumps in the zone are ready for operation.
• “off”
All pumps in the zone are switched off.
•“max.”
All pumps in the zone are operating at maximum performance.
•“local”
The controller has been set to local mode and will operate ac-
cording to the local control parameter settings.
See section 6.2.1 PFU 2000 DIP Switch Settings.
If the function selector in the PFU 2000 has been turned to posi-
tion MAX, the setpoint influences, “clock program” and “remote
on/off” are not effective.
Start/stop of pumps (display 301):
• “on”
The pump is ready for operation.
•“off”
The pump is switched off.
Operation with PFU 2000 EPROM Settings:
The controller will operate according to the local control parame-
ter settings.
For further information, see section
6.2.1 PFU 2000 DIP Switch Settings.
On
Off
3.1.6 Water Shortage Monitoring
The water shortage monitoring function switches off all
pumps.
Note: If the booster set has been delivered without a water short-
age monitor, it should not be started until a water shortage moni-
tor has been installed. Otherwise, there is a risk of damage to the
pumps.
If the function “fire fight” (display 222) is activated, the water
shortage monitoring function is suppressed.
Operation with PFU 2000 RAM / PMU 2000 Settings:
Pre-pressure measuring can be set to “on” or “off” (display 216).
Via an Analog Signal:
Set “prepress.measuring” to “on” (display 216) if a pressure
transmitter is installed on the suction side of the booster set.
The PFU 2000 analog input 2 measures the pre-pressure. The
water shortage monitoring will be carried out according to the set
“min. prepressure” (display 231).
Via a Digital Signal:
Set “prepress.measuring” to “off” (display 216).
The signal on the PFU 2000 analog input 2 is evaluated as a dig-
ital signal for water shortage monitoring from a pressure switch,
level switch or an electrode relay.
Operation with PFU 2000 EPROM Settings:
The pre-pressure can be measured via the PFU 2000 analog in-
put 2.
Via an Analog Signal:
If the signal is lower than 5% of the measuring range for more
than 5 secs., a fault is indicated.
Via a Digital Signal:
If the switch contact indicates water shortage for more than 5
secs., a fault is indicated.
For further information, see section
3.2.13 PFU 2000 Analog Input 2 Configuration.