Grundfos Hydro Multi-B User manual

Hydro Multi-B
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 the
Grundfos Hydro Multi-B booster system.
Sections 1-4 give the information necessary to be able to unpack,
install and start up the product in a safe way.
Sections 5-16 give important information about the product, as
well as information on service, fault finding and disposal of the
product.
CONTENTS
Page
1. Symbols used in this document
1.1 Warnings against hazards involving risk of death
or personal injury
The text accompanying the three hazard symbols DANGER,
WARNING and CAUTION is structured in the following way:
1.2 Other important notes
1. Symbols used in this document 2
1.1 Warnings against hazards involving risk of death or
personal injury 2
1.2 Other important notes 2
2. Receiving the product 3
2.1 Transporting the product 3
3. Installing the product 3
3.1 Location 3
3.2 Mechanical installation 3
3.3 Electrical installation 4
4. Starting up the product 5
4.1 Handling the product 5
5. Product introduction 6
5.1 Product description 6
5.2 Applications 6
5.3 Identification 8
6. Control unit 10
7. Operating modes 12
7.1 Local mode, external stop not activated 12
7.2 Local mode, external stop activated 12
7.3 Remote-controlled, external stop not activated 13
7.4 Remote-controlled, external stop activated 13
7.5 Adjusting the proportional-pressure setpoint 14
8. Functions 15
8.1 General functions 15
8.2 Functions for constant-pressure systems 15
8.3 Functions for tank-filling systems 17
9. Data communication 17
10. Servicing the product 17
10.1 Maintaining the product 17
11. Protecting the product against frost 17
12. Taking the product out of operation 17
13. Fault finding 18
14. Technical data 19
14.1 Pressure 19
14.2 Temperature 19
14.3 Relative humidity 19
14.4 Sound pressure level 19
14.5 Electrical data 19
15. Related documents 20
15.1 Service documentation 20
16. Disposing of the product 20
Read this document before installation. Installation
and operation must comply with local regulations and
accepted codes of good practice.
This appliance can be used by children aged from 8
years and above and persons with reduced physical,
sensory or mental capabilities or lack of experience
and knowledge if they have been given supervision
or instruction concerning use of the appliance in a
safe way and understand the hazards involved.
Children shall not play with the appliance. Cleaning
and user maintenance shall not be made by children
without supervision.
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.
If these instructions are not observed, it may result in
malfunction or damage to the equipment.
Tips and advice that make the work easier.
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.

English (GB)
3
2. Receiving the product
2.1 Transporting the product
The booster system is delivered in a recyclable packaging,
specially designed for transport by forklift truck or a similar
vehicle.
The forks of the forklift truck must be at least 2 m long.
3. Installing the product
Before installing the product, check the following:
• The booster system corresponds to the order.
• All visible parts are intact.
3.1 Location
Install the booster system in a well-ventilated room to ensure
sufficient cooling of the control cabinet and pumps.
Place the booster system with a 1 m clearance on all sides for
inspection and removal.
3.2 Mechanical installation
3.2.1 Pipes
Connect the pipes to the manifolds of the booster system. Either
end can be used. Apply sealing compound to the unused end of
the manifold, and fit the screw cap. For manifolds with flanges, fit
a blanking flange with gasket.
We recommend that you install pipe supports for the inlet and
outlet pipes. See figs 1and 2.
To achieve optimum operation and minimise noise and vibration,
it may be necessary to consider vibration dampening of the
booster system.
Noise and vibration are generated by the rotations in the motor
and pump and by the flow in pipes and fittings. The effect on the
environment is subjective and depends on correct installation and
the state of the other parts of the system.
If booster systems are installed in blocks of flats or the first
consumer on the line is close to the booster system, we
recommend that you fit expansion joints on the inlet and outlet
pipes to prevent that vibrations are transmitted through the pipes.
Fig. 1 Example showing the position of expansion joints, pipe
supports and machine shoes
Fig. 2 Example showing the position of expansion joints, pipe
supports and mounting bolts
Tighten all nuts before startup.
Fasten the pipes to parts of the building to ensure that they
cannot move or be twisted.
The booster system is designed for indoor
installation. Do not expose the product to direct
sunlight.
The pipes connected to the booster system must be
of adequate size.
TM03 2154 3805
Pos. Description
1 Expansion joint
2 Pipe support
3 Machine shoe
TM04 9900 0211
Pos. Description
1 Expansion joint
2 Pipe support
3 Mounting bolt
Expansion joints, pipe supports as well as machine
shoes or mounting bolts shown in figs 1and 2
respectively are not included in a standard booster
system.
2
11
33
2

English (GB)
4
3.2.2 Foundation
Position the booster system on an even and solid surface, for
instance a concrete floor or foundation. The booster system must
be bolted to the floor or foundation.
3.2.3 Vibration dampers
To prevent the transmission of vibrations to buildings, we
recommend that you isolate the booster system foundation from
building parts by means of vibration dampers.
The right damper varies from installation to installation, and a
wrong damper may increase the vibration level. Vibration
dampers must therefore be sized by the supplier. If the booster
system is installed on a base frame with vibration dampers,
always fit expansion joints on the manifolds. This is important to
prevent the booster system from "hanging" in the pipes.
3.2.4 Expansion joints
Fit expansion joints for these reasons:
• to absorb expansions or contractions in the pipes caused by
changing liquid temperature
• to reduce mechanical strains in connection with pressure
surges in the pipes
• to isolate mechanical structure-borne noise in the pipes (only
rubber bellows expansion joints).
Fit expansion joints at a distance of minimum 1 to 1 1/2 times the
nominal flange diameter from the manifold on the inlet as well as
on the outlet side. This prevents the development of turbulence in
the expansion joints, resulting in better inlet conditions and a
minimum pressure loss on the outlet side.
Fig. 3 Examples of rubber bellows expansion joints without
and with limiting rods
Expansion joints with limiting rods can be used to minimise the
forces caused by the expansion joints. We always recommend
that you use expansion joints with limiting rods for flanges larger
than DN 100.
Anchor the pipes so that they do not stress the expansion joints
and the pump. Follow the supplier’s instructions and pass them
on to advisers or pipe installers.
3.2.5 Prefilling of diaphragm tank, if applicable
If a diaphragm tank is connected to the system, prefill the tank
with nitrogen to a pressure of -0.7 times the setpoint.
3.3 Electrical installation
• The electrical installation of the booster system must comply
with enclosure class IP54.
• Check that the power supply and frequency correspond to the
values stated on the nameplate.
• Make sure that the conductor cross-section meets the
specifications in the wiring diagram.
The weight of a concrete foundation must be 1.5
times the weight of the booster system.
Do not install expansion joints to compensate for
inaccuracies in the pipes such as centre
displacement of flanges.
TM02 4981 1902 - TM02 4979 1902
Use nitrogen to avoid corrosion.
CAUTION
Electric shock
Minor or moderate personal injury
- The electrical installation must be carried out by an
authorised person in accordance with local
regulations and the relevant wiring diagram.
- Switch off the power supply and lock the main
switch with a padlock to ensure that the power
supply cannot be accidentally switched on.
See the wiring diagram supplied with the booster
system.
If the system cannot be installed with the supply
disconnecting device located minimum 0.6 m above
service level according to EN 60204-1 paragraph
5.3.4, install the system with an external "supply
disconnecting device" made according to EN
60204-1, paragraph 5.3.2. The system must be
provided with a means permitting it to be locked in
the OFF (isolated) position.

English (GB)
5
4. Starting up the product
After having carried out the mechanical, electrical and hydraulic
installation described in sections 3.2 Mechanical installation,
3.3 Electrical installation and 4. Starting up the product, proceed
as follows:
1. Check that the precharge pressure in the diaphragm tank, if
any, is 0.7 times the required outlet pressure (setpoint).
2. Switch off the main switch on the front of the control cabinet.
3. Switch off the circuit breakers of all pumps. The circuit
breakers are located inside the cabinet.
4. Set the "Auto-Manual" switch for all pumps to "Manual". The
switch is located on the front of the control cabinet.
5. Close all pump outlet valves, and prime all pumps. See the
installation and operating instructions for the pumps.
6. Switch on the main switch.
7. Start pump 1 by switching on the relevant circuit breaker.
8. Check the direction of rotation of the pump. If the pump
rotates in the wrong direction, interchange two phases of the
incoming mains supply.
9. Slowly open the outlet valve to vent the pump.
10. Set the "Auto-Manual" switch for the relevant pump to "Auto".
11. Repeat steps 6, 8 and 9 for the other pumps in the system.
12. Adjust the required setpoint via CU 323 by pressing arrow up
or arrow down. In the case of tank filling with level switches,
adjust the switches in the tank to the desired start and stop
levels.
13. Press [On/Off] to set the system to "On".
The booster system is now in automatic mode and ready for
operation.
4.1 Handling the product
Lift the booster systems with CM and CME pumps as shown in
fig. 4.
During handling, the lifting point must always be above the centre
of gravity of the booster system.
Fig. 4 Correct lifting of Hydro Multi-B with CM and CME
pumps
When lifting the booster system, only use suitable lifting
equipment that is in good condition and approved for the weight.
The weight is stated on the nameplate of the booster system.
A positive inlet pressure is required before startup
and during operation.
Do not start the pumps until they have been fully
primed.
CAUTION
Electric shock
Minor or moderate personal injury
- A positive inlet pressure is required before startup
and during operation.
- Do not start the pumps until they have been fully
primed.
TM05 0221 0911
CAUTION
Overhead load
Minor or moderate personal injury
- When lifting the booster system, do not use the
eyebolts of the motors.
- Do not lift the booster system by the manifolds.
- Do not stand on the manifolds.
CAUTION
Crushing of feet
Minor or moderate personal injury
- When lifting the booster system, do not use the
eyebolts of the motors.
- Do not lift the booster system by the manifolds.
- Do not stand on the manifolds.

English (GB)
6
5. Product introduction
5.1 Product description
Hydro Multi-B is a range of factory-assembled booster systems,
ready for installation and operation.
As standard, the booster systems consist of two to four pumps
connected in parallel and mounted on a common base frame with
a control cabinet and all necessary fittings.
Fig. 5 Front view of Hydro Multi-B booster system with three
CM(E) pumps
Fig. 6 Rear view of Hydro Multi-B booster system with three
CM(E) pumps
Fig. 7 Front view of Hydro Multi-B booster system with two
CR pumps
Fig. 8 Rear view of Hydro Multi-B booster system with two
CR pumps
5.2 Applications
The booster systems are suitable for the following application
types:
• constant-pressure boosting
• tank filling.
Furthermore, two control variants of the booster systems are
available. The control variants are described below.
TM04 9898 0211TM04 9899 0211
Pos. Description Quantity
1 Control cabinet 1
2 Inlet manifold 1
3 Outlet manifold 1
4 Diaphragm tank 1
5 Isolating valve 2 per pump
6 Non-return valve 1 per pump
7Pump 2-4
8 Base frame 1
9 Pressure transmitter and pressure gauge 1
10 Pressure switch or inlet pressure sensor 1
11 Union nut 1 per pump
12 Screw cap or blanking flange 2
12
11
9

TM06 2867 4814TM06 2868 4814
Pos. Description Quantity
1 Control cabinet 1
2 Inlet manifold 1
3 Outlet manifold 1
5 Isolating valve 2 per pump
6 Non-return valve 1 per pump
7Pump 2-4
8 Base frame 1
9 Pressure transmitter and pressure gauge 1
12 Screw cap or blanking flange 2
7
1
2
5
12
9
6
3
8

English (GB)
7
5.2.1 Booster system for constant-pressure applications
The booster system for constant-pressure applications is
designed to maintain a constant pressure on the outlet side of the
pumps. The booster systems for constant-pressure applications
adjust the performance according to the demand and keep a
constant pressure in the following ways:
• by cutting the required number of pumps in and out
• through continuous adjustment of the speed of the running
pumps.
Operating principle
The user enters the required pressure of the system (setpoint) via
the user interface of the CU 323 control unit. CU 323 adjusts the
system performance according to the feedback received from the
pressure transmitter installed in the outlet manifold.
Control variants
The booster systems for constant-pressure applications are
available as control variants E and ES.
Both systems work as described below.
5.2.2 Booster system for tank-filling applications
The booster system for tank-filling applications is designed to fill
a tank such as a roof tank or a break tank in a controlled manner.
The booster system controls the filling either via level switches or
a level sensor.
• Operating principle
The system has two methods of operation, one based on level
switches and the other on a level sensor.
• Operation with level switches
The user adjusts the switches in the tank to the desired stop
and start levels.
• Operation with level sensor
The user adjusts the setpoint so it corresponds to the real tank
height, measured from the bottom of the tank to the top, via
the user interface of the CU 323 control unit.
• Factory setting
Start level: 15 % of setpoint
Stop level: 85 % of setpoint
High-level alarm: 95 % of setpoint.
Control variant E Control variant ES
Two to four electronically speed-controlled pumps One to three mains-operated pumps and one speed-controlled
pump
TM03 0993 0905 TM03 0996 0905
One speed-controlled pump in operation. One speed-controlled pump in operation.
TM00 7995 2296 TM00 7995 2296
Three speed-controlled pumps in operation. One speed-controlled pump and two mains-operated pumps in
operation.
TM00 7996 2296 TM00 7998 2296
• Control variant E for constant-pressure applications
maintains a constant pressure through continuous adjustment
of the speed of the pumps.
• The system performance is adjusted to the demand by cutting
the required number of pumps in and out and through parallel
control of the pumps in operation.
• Control variant ES for constant-pressure applications
maintains a constant pressure through continuous adjustment
of the speed of the speed-controlled pump. The other pumps
are cut in/out according to demand and to achieve a
performance corresponding to the consumption.
• The speed-controlled pump always starts first and will be the
last to stop. If the pressure cannot be maintained by the
pump, one or both mains-operated pumps will be cut in.
• Changeover among the mains-operated pumps is automatic
and depends on load, time and fault.
PT
PT
Q
H
Hset
Q
H
Hset
Q
H
Hset
Q
H
Hset

English (GB)
8
Control variants
The booster systems for tank-filling applications are available as control variants E and ES. Both systems work as described below.
5.3 Identification
5.3.1 Nameplate
The nameplate of the booster system is fitted on the base frame.
Fig. 10 Nameplate
Control variants E and ES
E: Two to four electronically speed-controlled pumps
ES: One to three mains-operated pumps and one speed-controlled pump
TM05 0222 0911
Fig. 9 Example of control variant ES
• In tank-filling applications, the booster system fills the tank with focus on protecting the piping and preventing water hammer. When
low level in the tank is reached, a speed-controlled pump starts by running approximately 70 % of maximum speed to slowly and
safely fill the pipes. After a while, it increases the speed to 100 %, and the next pump is started. When the tank is full, the pumps
stop.
• Systems with more than two pumps will as default set one pump as standby pump.
• Changeover among the mains-operated pumps is automatic and depends on load, time and fault.
E-pump starts Fixed-speed pump
starts
Fixed-speed pump
stops E-pump stops
Time
Pump speed
t
n
100 %
70 %
TM06 8850 1217
Type:
Model:
Serial No.:
IP Class:
Weight: kg
MADE IN GERMANY
DK - 8850 - Bjerringbro - Denmark
Main supply:
98681617
pMax: bar
Liq. temp.: °C
Q Nom / Max: /
/
m /h
3
H Nom / Max: m
QR
code
2
3
4
5
9
10
12
13
15
14
11
8
7
6
1
Pos. Description
1 Product type
2 Product configuration
3 Code for model
4 Serial number
5 Mains supply
6 Maximum operating pressure
7 Liquid temperature, minimum
8 Liquid temperature, maximum
9 Nominal flow rate [m3/h]
10 Maximum flow rate [m3/h]
11 Nominal head [m]
12 Maximum head [m]
13 Technical documents
14 Insulation class
15 Weight
16-20 Approval marks
21 QR code
22 Country of origin
23 Company address

English (GB)
9
5.3.2 Type key
* ES systems: The first pump is equal to an E-pump. The other pumps are fixed-speed pumps, except for cases where the E-pump is
controlled by a CUE or VFD. In these cases, all pumps are fixed-speed pumps.
** Hydro Multi-B, ES systems, are only shown with the E-pump description, meaning that the fixed-speed pumps have the same size,
number of stages, material combination and kW.
The exception is where the E-pump is controlled by a CUE or VFD. In this case, all pumps are shown as fixed-speed pumps.
*** The control cabinet can be placed up to 2 m from the pumps.
Code Example Hydro Multi-B ES 4 CME 10-8 U1 G- E- P- G- A-
Type range
E
ES
System variants
All pumps with E-motor or all fixed-speed pumps with CUE/VFD
Fixed-speed pumps, one E-motor or fixed-speed pump with CUE/VFD
Number of main pumps*
Pump type**
U1
U2
U3
U4
U5
U6
U7
U8
U9
UA
UB
UC
UE
UF
UG
Voltage code
3 x 380-415 V, N, PE, 50/60 Hz
3 x 380-415 V, PE, 50/60 Hz
3 x 380-415 V, N, PE, 50 Hz
3 x 380-415 V, PE, 50 Hz
3 x 380-415 V, N, PE, 60 Hz
3 x 380-415 V, PE, 60 Hz
1 x 200-240 V, PE, 50/60 Hz
1 x 200-240 V, N, PE, 50/60 Hz
3 x 220-240 V, PE, 60 Hz
3 x 440-480 V, PE, 60 Hz
1 x 220-240 V, N, PE, 50/60 Hz
1 x 220-240 V, N, PE, 50 Hz
3 x 220-240 V, PE, 50/60 Hz
3 x 440-480 V, PE, 50/60 Hz
3 x 440-480 V, PE, 50 Hz
A
I
G
Pump material
Cast iron (EN-GJL-200)
Stainless steel (EN 1.4301/AISI 304)
Stainless steel (EN 1.4401/AISI 316)
A
B
E
F
G
H
I
Design
Systems with the control cabinet mounted on the same base frame as the pumps.
Systems with the control cabinet centred on the base frame.
ASEAN design and systems with the control cabinet mounted on the same base frame as the pumps.
ASEAN design and systems with the control cabinet centred on the base frame.
ASEAN design and systems with the control cabinet mounted on its own base for floor mounting.***
ASEAN design and systems with the control cabinet mounted on its own base for floor mounting.***
ASEAN design and systems with the control cabinet prepared for wall mounting.***
P
U
Applications
Constant-pressure boosting
Tank filling
I
G
X
Manifold/base fame material
Stainless steel (EN 1.4301, AISI 304) / Black painted mild steel (Q235)
Galvanised steel, black painted mild steel (Q235)
Other materials
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
A
R
S
V
X
Z
Options
Standard hydraulics (no options)
Tank filling with high-level alarm (float switch)
Tank filling with high-level alarm (level sensor)
Non-return valve on inlet manifold
Pressure devices, complete, 0-10 bar, sensor
No inlet manifold
Communication interface module, CIM
Dry-running protection
Repair switch
Redundant sensor
Low inlet manifold
Operating/alarm indicator light
Valve with WaterMark approval
High-pressure release valve
Beacon
Audible alarm
External transformer
Emergency operation switch
CSU variant
Phase-failure monitoring
More than one option, other
Diaphragm tank, Hydro Multi-B with CR pumps

English (GB)
10
6. Control unit
The booster system incorporates a CU 323 control unit which enables manual setting and monitoring of the system.
Figure 11 shows the user interface for a system with four pumps.
Fig. 11 User interface of control cabinet and CU 323
TM05 0479 1111
PT
WS
On
Off
RESET
OFF AUTO
OFF AUTO
OFF AUTO
OFF AUTO
CU 323
4
3
2
1
system run
alarm
1
2
3
4
5
8
9
10 11
12
13
14
15
16
PT
WS
On
Off
RESET
OFF AUTO
OFF AUTO
OFF AUTO
OFF AUTO
CU 323
4
3
2
1
system run
alarm
6
7
Pos. Buttons Description
1 [On/Off]: Changes the system operating mode between "Normal" and "Stop".
2 [Up]: Increases the setpoint value.
3 [Down]: Decreases the setpoint value.
4 [RESET]: Resets all alarms.
5[>]: Changes the operating mode of the individual pumps between "AUTO" and "OFF". Each pump in
the system has an Auto/Off button.
6
Enables manual operation.
Note: If a pump is set to manual operation, it will run at 100 % speed, and the power supply to CU
323 will be switched off. There is a delay of 30 seconds before the pumps are set to manual.
7 Switches the power supply to the control cabinet on or off.
On
Off
RESET
Pos. Display Description
8
"Setpoint" Shows the setpoint. After unlocking CU 323, the setpoint will flash.
Proportional-pressure control. "PPP" flashes for one second followed by the current setpoint for four
seconds. This function is only available for E-pump systems.
The tank symbol appears in tank-filling mode with float switches.
or "Setpoint" Alternates between the tank symbol and the setpoint in tank-filling mode with analog input.
External stop: Indicates that the system has been stopped externally via a digital input.
Indicates that the system has been set to "OFF".
Indicates that the system has been set from "OFF" to "On". "On" is only shown for 3 seconds after
which the setpoint is shown.
Indicates that the buttons on CU 323 have been locked automatically. To unlock the buttons, press
[RESET] and arrow up or [RESET] and arrow down simultaneously.
Indicates that the system is remotely controlled.
Local: Appears if attempts to change local settings are made while the system is remotely controlled.
1___!
1___!
E.St
OFF
On
0-N
bUS
LOC