Grundfos MAGNA1 D User manual

MAGNA1
Installation and operating instructions
GRUNDFOS INSTRUCTIONS

English (GB)
2
English (GB) Installation and operating instructions
Original installation and operating instructions
CONTENTS
These installation and operating instructions describe MAGNA1.
Sections 1-5 give the information necessary to be able to unpack,
install and start up the product in a safe way.
Sections 6-11 give important information about the product, as
well as information on service, fault finding and disposal of the
product.
Page
1. General information
1.1 Symbols used in this document
The text accompanying the three hazard symbols DANGER,
WARNING and CAUTION is structured in the following way:
1.2 Safety symbols on the pump
1. General information 2
1.1 Symbols used in this document 2
1.2 Safety symbols on the pump 2
2. Receiving the product 3
2.1 Inspecting the product 3
2.2 Scope of delivery 3
2.3 Lifting the pump 4
3. Installing the product 4
3.1 Location 4
3.2 Tools 4
3.3 Mechanical installation 5
3.4 Electrical installation 8
4. Starting up the product 11
5. Storing and handling the product 11
5.1 Storing the product 11
6. Product introduction 12
6.1 Applications 12
6.2 Pumped liquids 12
6.3 Identification 13
6.4 Insulating shells 13
6.5 Non-return valve 13
7. Control functions 14
7.1 Overview of control functions 15
7.2 Selecting control function 16
7.3 Operating the product 17
7.4 Grundfos Eye 17
7.5 Light fields indicating the pump setting 17
8. Fault finding the product 18
8.1 Grundfos Eye operating status 18
8.2 Fault finding 18
9. Accessories 19
9.1 Insulating kits for air-conditioning and cooling systems 19
9.2 Blanking flanges 19
9.3 Counterflanges 19
9.4 ALPHA plugs 19
10. Technical data 20
11. Disposing of the product 20
Prior to installation, read this document and the quick
guide. 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.
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.
Notes or instructions that make the work easier and
ensure safe operation.
Check the position of the clamp before you tighten
the clamp. Incorrect position of the clamp will cause
leakage from the pump and damage the hydraulic
parts in the pump head.
Fit and tighten the screw holding the clamp to 8 Nm ±
1 Nm.
Do not apply more torque than specified even though
water is dripping from the clamp. The condensed
water is most likely coming from the drain hole under
the clamp.
8Nm!

English (GB)
3
2. Receiving the product
2.1 Inspecting the product
Check that the product is in accordance with the order.
Check that the voltage and frequency of the product match
voltage and frequency of the installation site. See section
6.3.1 Nameplate.
2.2 Scope of delivery
2.2.1 Plug-connected single-head pump
Fig. 1 Plug-connected single-head pump
The box contains the following items:
• MAGNA1-pump
• insulating shells
•gaskets
• quick guide
• safety instructions
• one ALPHA plug.
2.2.2 Plug-connected twin-head pump
Fig. 2 Plug-connected twin-head pump
The box contains the following items:
• MAGNA1-pump
•gaskets
• quick guide
• safety instructions
• two ALPHA plugs.
2.2.3 Terminal-connected single-head pump
Fig. 3 Terminal-connected single-head pump
The box contains the following items:
• MAGNA1-pump
• insulating shells
•gaskets
•quickguide
• safety instructions
• box with terminal and cable glands.
2.2.4 Terminal-connected twin-head pump
Fig. 4 Terminal-connected twin-head pump
The box contains the following items:
• MAGNA1-pump
•gaskets
•quickguide
• safety instructions
• two boxes with terminal and cable glands.
Pumps tested with water containing anticorrosive
additives are taped on the inlet and outlet ports to
prevent residual test water from leaking into the
packaging. Remove the tape before installing the
pump.
TM05 5508 3016TM06 7222 3016
TM06 7223 3016TM06 6791 3016

English (GB)
4
2.3 Lifting the pump
Always lift directly on the pump head or the cooling fins when
handling the pump. See fig. 5.
For large pumps, it may be necessary to use lifting equipment.
Position the lifting straps as illustrated in fig. 5.
Fig. 5 Correct lifting of pump
Fig. 6 Incorrect lifting of pump
3. Installing the product
3.1 Location
The pump is designed for indoor installation.
3.2 Tools
Fig. 7 Recommended tools
Observe local regulations concerning limits for
manual lifting or handling.
TM05 5819 3016
Do not lift the pump head by the control box, i.e. the
red area of the pump. See fig. 6.
TM006 7219 3016
TM05 6472 4712
Pos. Tool Size
1 Screwdriver, straight slot 0.6 x 3.5 mm
2 Screwdriver, straight slot 1.2 x 8.0 mm
3 Screwdriver, torx bit TX10
4 Screwdriver, torx bit TX20
5 Hexagon key 5.0 mm
6 Side cutter
7 Open-end spanner Depending on DN size
8 Pipe wrench Only used for pumps with
unions
0.6 x 3.5
5.0
1.2 x 8.0
TX20
TX10
1
2
3
4
5
6
7
8

English (GB)
5
3.3 Mechanical installation
The pump range includes both flanged and threaded versions.
These installation and operating instructions apply to both
versions, but give a general description of flanged versions. If the
versions differ, the threaded version will be described separately.
Install the pump so that it is not stressed by the pipes. For
maximum permissible forces and moments from pipe connections
acting on the pump flanges or threaded connections, see page
26.
You can suspend the pump directly in the pipes, provided that the
pipes support the pump.
Twin-head pumps are prepared for installation on a mounting
bracket or base plate. Pump housing with M12 thread.
To ensure adequate cooling of motor and electronics, observe the
following requirements:
• Position the pump in such a way that sufficient cooling is
ensured.
• The ambient temperature must not exceed 40 °C.
3.3.1 Pump positions
Always install the pump with horizontal motor shaft.
• Pump installed correctly in a vertical pipe. See fig. 8, pos. A.
• Pump installed correctly in a horizontal pipe.
See fig. 8, pos. B.
• Do not install the pump with vertical motor shaft.
See fig. 8, pos. C and D.
Fig. 8 Pump installed with horizontal motor shaft
3.3.2 Control box positions
To ensure adequate cooling, make sure that the control box is in
horizontal position with the Grundfos logo in vertical position. See
fig. 9.
Fig. 9 Pump with control box in horizontal position
Fig. 10 Automatic vent
Step Action Illustration
1
Arrows on the pump housing
indicate the liquid flow direction
through the pump. The liquid flow
direction can be horizontal or
vertical, depending on the
control-box position.
TM05 5513 3812TM05 5514 3812
2
Close the isolating valves and
make sure that the system is not
pressurised during installation of
the pump.
TM05 2863 0612
3Mount the pump with gaskets in
the pipes.
TM05 5515 3812
4
Flanged version:
Fit the bolts, washers and nuts.
Use the correct size of bolts
according to system pressure.
For further information about
torques, see page 26.
Threaded version:
Tighten the union nuts.
TM05 5516 3816TM05 5517 3812
TM05 5518 3016TM05 5522 3016
Fit twin-head pumps installed in horizontal pipes
with an automatic air vent, Rp 1/4, in the upper part
of the pump housing. See fig. 10.
TM05 6062 3016
A B
C D

English (GB)
6
3.3.3 Pump head position
If you remove the pump head before installing the pump in the
pipes, pay special attention when fitting the pump head to the
pump housing:
1. Visually check that the floating ring in the sealing system is
centred. See figures 11 and 12.
2. Gently lower the pump head with rotor shaft and impeller into
the pump housing.
3. Make sure that the contact face of the pump housing and that
of the pump head are in contact before you tighten the clamp.
See fig. 13.
Fig. 11 Correctly centred sealing system
Fig. 12 Incorrectly centred sealing system
Fig. 13 Fitting the pump head to the pump housing
3.3.4 Changing the control box position
TM05 6650 3016TM05 6651 3016
Check the position of the clamp before you tighten
it. Incorrect position of the clamp will cause leakage
from the pump and damage the hydraulic parts in
the pump head. See fig. 13.
TM05 5837 3016
The warning symbol on the clamp holding the pump
head and pump housing together indicates that there
is a risk of personal injury. See specific warnings
below.
CAUTION
Pressurised system
Minor or moderate personal injury
- Pay special attention to any escaping vapour
when loosening the clamp.
CAUTION
Crushing of feet
Minor or moderate personal injury
- Do not drop the pump head when loosening the
clamp.
Fit and tighten the screw holding the clamp to 8 Nm ±
1 Nm. Do not apply more torque than specified even
though water is dripping from the clamp. The
condensed water is most likely coming from the drain
hole under the clamp.
Check the position of the clamp before you tighten
the clamp. Incorrect position of the clamp will cause
leakage from the pump and damage the hydraulic
parts in the pump head.
8Nm!

English (GB)
7
As an alternative to insulating shells, you can insulate the pump
housing and pipes as illustrated in fig. 13.
Fig. 14 Insulation of pump housing and pipe
Step Action Illustration
1
Loosen the screw in the clamp
that holds the pump head and
pump housing together.
If you loosen the screw too
much, the pump head will be
completely disconnected from
the pump housing.
TM05 2867 3016
2
Carefully turn the pump head to
the desired position.
If the pump head is stuck,
loosen it with a light blow of a
rubber mallet.
TM05 5526 3016
3
Place the control box in
horizontal position so that the
Grundfos logo is in vertical
position. The motor shaft must
be in horizontal position.
TM05 5527 3016
4
Due to the drain hole in the
stator housing, position the gap
of the clamp as shown in step
4a or 4b.
TM05 2870 3016
4a
Single-head pump.
Position the clamp so that the
gap points towards the arrow.
It can be in position 3, 6, 9 or 12
o'clock.
TM05 2918 3016
4b
Twin-head pump.
Position the clamps so that the
gaps point towards the arrows.
They can be in position 3, 6, 9
or 12 o'clock.
TM05 2917 3016
5.0
5
Fit and tighten the screw
holding the clamp to 8 ± 1 Nm.
Do not retighten the screw if
condensed water is dripping
from the clamp.
TM05 2872 3016
6
Fit the insulating shells.
The insulating shells for pumps
in air-conditioning and cooling
systems must be ordered
separately.
TM05 5529 3016
Do not insulate the control box or cover the control
panel.
TM05 5549 3016
Step Action Illustration
8 Nm5.0

English (GB)
8
3.4 Electrical installation
Carry out the electrical connection and protection according to
local regulations.
Check that the supply voltage and frequency correspond to the
values stated on the nameplate.
• Make sure that the pump is connected to an external main
switch.
• The pump requires no external motor protection.
• The motor incorporates thermal protection against slow
overloading and blocking.
• When switched on via the power supply, the pump starts after
approximately 5 seconds.
3.4.1 Supply voltage
1 x 230 V ± 10 %, 50/60 Hz, PE.
The voltage tolerances are intended for mains-voltage variations.
Do not use the voltage tolerances for running pumps at other
voltages than those stated on the nameplate.
3.4.2 Connection to the power supply
Terminal-connected versions
WARNING
Electric shock
Death or serious personal injury
- Lock the main switch in position 0. Type and
requirements as specified in EN 60204-1, 5.3.2.
WARNING
Electric shock
Death or serious personal injury
- Connect the pump to an external main switch with
a minimum contact gap of 3 mm in all poles.
- Use earthing or neutralisation for protection
against indirect contact.
- If the pump is connected to an electric installation
where an electrical circuit breaker (voltage
sensing ELCB, residual-current device RCD or
residual-current circuit device RCCB) is used as
an additional protection, this circuit breaker must
be marked with the first or both of the symbols
shown below:
Step Action Illustration
1
Remove the front
cover from the
control box.
Do not remove the
screws from the
cover.
TM05 5530 3016
2
Locate the power
supply plug and
cable gland in the
small cardboard
box supplied with
the pump.
TM05 5531 3016
1 x 230 V
3
Connect the cable
gland to the
control box.
TM05 5532 3016
4
Pull the power
supply cable
through the cable
gland.
TM05 5533 3016
5
Strip the cable
conductors as
illustrated.
TM05 5534 3016
6
Connect the cable
conductors to the
power supply plug.
TM05 5535 3016
7
Insert the power
supply plug into
the male plug in
the control box.
TM05 5536 3016
8
Tighten the cable
gland.
Refit the front
cover.
TM05 5537 3016
Step Action Illustration
7 mm
20 mm
7 mm
25 mm
Min. Ø 7 mm
Max. Ø 14 mm

English (GB)
9
Plug-connected versions
Assembling the plug
Disassembling the plug
Step Action Illustration
1
Fit the cable gland
and plug cover to
the cable. Strip
the cable
conductors as
illustrated.
TM05 5538 3016
2
Connect the cable
conductors to the
power supply
plug.
TM05 5539 3016
3
Bend the cable
with the cable
conductors
pointing upwards.
TM05 5540 3016
4
Pull out the
conductor guide
plate and throw it
away.
TM05 5541 3016
5
Click the plug
cover onto the
power supply
plug.
TM05 5542 3016
6
Screw the cable
gland onto the
power supply
plug.
TM05 5543 3016
17 mm
12 mm
7 mm
Ø 5.5 - 10 mm
Max. 1.5 mm
2
Click
Click
7
Insert the power
supply plug into
the male plug in
the control box.
TM05 5544 3016
Step Action Illustration
1
Loosen the cable
gland and remove
it from the plug.
TM05 5545 3016
2
Pull off the plug
cover while
pressing on both
sides.
TM05 5546 3016
3
Loosen the cable
conductors one by
one by pressing a
screwdriver gently
into the terminal
clip.
TM05 5547 3016
4
The plug has now
been removed
from the power
supply plug.
TM05 5548 3016
Step Action Illustration
Click
x 3
Max 0.8 x 4

English (GB)
10
3.4.3 Connection diagrams
Fig. 15 Example of a mains-connected motor with main switch, backup fuse and additional protection
Fig. 16 Example of a plug-connected motor with main switch, backup fuse and additional protection
TM03 2397 3016
External switch
Fuse
RCD/RCCB
TM05 5277 3016
External switch
Fuse
RCD/RCCB
Make sure that the fuse is dimensioned according to
the nameplate and local regulations.
Connect all cables in accordance with local
regulations.
Make sure that all cables are heat-resistant up to 75
°C.
Install all cables in accordance with EN 60204-1 and
EN 50174-2:2000.