Grundfos MAGNA3 25-60 (N) User manual

MAGNA3
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 MAGNA3.
Sections 1-5 give the information necessary to be able to unpack,
install and start up the product in a safe way.
Sections 6-13 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. General information 2
1.1 Symbols used in this document 2
1.2 Safety symbols on the pump 3
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 Positioning the pump 5
3.5 Control box positions 6
3.6 Pump head position 6
3.7 Changing the control box position 7
3.8 Electrical installation 8
3.9 Connecting the power supply 9
4. Starting up the product 12
4.1 Single-head pump 12
4.2 Twin-head pump 13
5. Storing and handling the product 13
5.1 Frost protection 13
6. Product introduction 13
6.1 Applications 13
6.2 Pumped liquids 13
6.3 Identification 14
6.4 Model type 15
6.5 Radio communication 15
6.6 Insulating shells 15
6.7 Non-return valve 15
7. Control functions 16
7.1 Overview of settings 16
7.2 External connections 17
7.3 Input and output communication 18
7.4 Priority of settings 18
8. Setting the product 21
8.1 Operating the product 23
8.2 "+RPH" menu 23
8.3 Menu overview 24
8.4 6WDWXV menu 26
8.5 "2SHUDWLQJVWDWXV"26
8.6 "6HWWLQJV" menu 26
8.7 Setting values for control modes 33
8.8 "$VVLVW" menu 38
8.9 External setpoint influence 41
8.10 Flow estimation accuracy 41
8.11 Pump heads in twin-head pumps 41
8.12 "'HVFULSWLRQRIFRQWUROPRGH"42
8.13 "$VVLVWHGIDXOWDGYLFH"42
8.14 Wireless GENIair 42
9. Servicing the product 43
9.1 Differential-pressure and temperature sensor 43
9.2 External sensor condition 43
10. Fault finding the product 44
10.1 Grundfos Eye operating indications 44
10.2 Fault finding 45
11. Accessories 47
11.1 Grundfos GO 47
11.2 Communication interface module, CIM 47
11.3 Counterflanges 52
11.4 External sensors 52
11.5 Cable for sensors 52
11.6 Blanking flange 53
11.7 Insulating kits for air-conditioning and cooling systems 53
12. Technical data 53
12.1 Sensor specifications 54
13. Disposing of the product 54
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.

English (GB)
3
1.2 Safety symbols on the pump
2. Receiving the product
2.1 Inspecting the product
Check that the product received is in accordance with the order.
Check that the voltage and frequency of the product match the
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:
• MAGNA3 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:
• MAGNA3 pump
•gaskets
•quickguide
• 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:
• MAGNA3 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:
• MAGNA3 pump
•gaskets
•quickguide
• safety instructions
• two boxes with terminals and cable glands.
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 that holds 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.
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.
TM06 7224 3216
8Nm!
TM06 7225 3216TM05 8159 2013TM06 6791 2316

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 5820 3216
Do not lift the pump head by the control box, i.e. the
red area of the pump. See fig. 6.
TM05 5821 3216
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
2
3
4
5
6
7
8
1

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 for pipe connections
acting on the pump flanges or threaded connections, see page
59.
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. The pump housing has a 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.
3.4 Positioning the pump
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
Step Action Illustration
1
Arrows on the pump housing
indicate the flow direction
through the pump. The flow
direction can be horizontal or
vertical, depending on the
control box position.
TM05 2862 3216 - TM05 8456 3216
2
Close the isolating valves
and make sure that the
system is not pressurised
during the installation of the
pump.
TM05 2863 3216
3Mount the pump with gaskets
in the pipes.
TM05 2864 3216
4
Flanged version:
Fit bolts and nuts. Use the
right size of bolts according
to system pressure.
For further information about
torques, see page 59.
Threaded version:
Tighten the union nuts.
TM05 2865 3216 - TM05 8455 3216
TM05 2866 3216
BA
DC

English (GB)
6
3.5 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
3.6 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
TM05 2915 3216
Fit twin-head pumps installed in horizontal pipes
with an automatic vent, Rp 1/4, in the upper part of
the pump housing. See fig. 10.
TM05 6061 3216
TM05 6650 3216TM05 665132162
Observe 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 3216

English (GB)
7
3.7 Changing the control box position
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
Crushing of feet
Minor or moderate personal injury
- Do not drop the pump head when loosening the
clamp.
CAUTION
Pressurised system
Minor or moderate personal injury
- Pay special attention to any escaping vapour
when loosening the clamp.
Fit and tighten the screw that holds 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.
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 3216
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 2868 3216
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 2869 3216
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 0612
8Nm!
5.0
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 3216
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 3216
5
Fit and tighten the screw that
holds the clamp to 8 Nm ± 1
Nm.
Do not retighten the screw if
condensed water is dripping
from the clamp.
TM05 2872 0612
6
Fit the insulating shells.
The insulating shells for
pumps in air-conditioning and
cooling systems must be
ordered separately.
TM05 2874 3216
Step Action Illustration
8 Nm5.0

English (GB)
8
As an alternative to insulating shells, you can insulate the pump
housing and pipes as illustrated in fig. 14.
Fig. 14 Insulating the pump housing and pipe
3.8 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 (IEC 34-11: TP 211).
• When switched on via the power supply, the pump starts after
approximately 5 seconds.
3.8.1 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.
Do not insulate the control box or cover the control
panel.
TM05 2889 3216
WARNING
Electric shock
Death or serious personal injury
- Before starting any work on the product, make
sure that the power supply has been switched off.
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:

English (GB)
9
3.9 Connecting the power supply
Terminal-connected versions
Step Action Illustration
1
Remove the front
cover from the
control box.
Do not remove the
screws from the
cover.
TM05 2875 3416
2
Locate the power
supply plug and
cable gland in the
small cardboard box
supplied with the
pump.
TM05 2876 3416
3
Connect the cable
gland to the control
box.
TM05 2877 3416
4
Pull the power
supply cable through
the cable gland.
TM05 2878 3416
5
Strip the cable
conductors as
illustrated.
TM05 2879 3416
6
Connect the cable
conductors to the
power supply plug.
TM05 2880 3416
7 mm
20 mm
Min. Ø 7 mm
Max. Ø 14 mm
7
Insert the power
supply plug into the
male plug in the
pump control box.
TM05 2881 3416
8
Tighten the cable
gland.
Fit the front cover.
TM05 2882 3416
Step Action Illustration

English (GB)
10
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 3216
2
Connect the cable
conductors to the
power supply plug.
TM05 5539 3812
3
Bend the cable
with the cable
conductors
pointing upwards.
TM05 5540 3812
4
Pull out the
conductor guide
plate and throw it
away.
TM05 5541 3812
5
Click the plug
cover onto the
power supply plug.
TM05 5542 3812
6
Screw the cable
gland onto the
power supply plug.
TM05 5543 3812
17 mm
12 mm
7 mm
Ø 5.5 - 10 mm
Max. 1.5 mm2
Click
Click
7
Insert the power
supply plug into
the male plug in
the pump control
box.
TM05 8454 2313
Step Action Illustration
1
Loosen the cable
gland and remove
it from the plug.
TM05 5545 3812
2
Pull off the plug
cover while
pressing on both
sides.
TM05 5546 3812
3
Loosen the cable
conductors one by
one by pressing a
screwdriver gently
into the terminal
clip.
TM05 5547 3812
4
The plug has now
been removed
from the power
supply plug.
TM05 5548 3812
Step Action Illustration
Click
x 3
Max 0.8 x 4