Grundfos MAGNA3 25-80 (N) User manual

MAGNA3
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 MAGNA3
model D.
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.
CONTENTS
Page
1. General information 3
1.1 Hazard statements 3
1.2 Notes 3
1.3 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 5
3.1 Location 5
3.2 Tools 5
3.3 Mechanical installation 5
3.4 Positioning the pump 6
3.5 Control box positions 6
3.6 Pump head position 7
3.7 Changing the control box position 7
3.8 Electrical installation 9
3.9 Wiring diagrams 10
3.10 Connecting the power supply, plug-connected versions 12
3.11 Connecting the power supply, terminal-connected
versions 13
3.12 Connecting the external control 14
4. Starting up the product 15
4.1 Single-head pump 15
4.2 Twin-head pump 16
5. Handling and storing the product 16
5.1 Frost protection 16
6. Product introduction 17
6.1 Applications 17
6.2 Pumped liquids 17
6.3 Pump heads in twin-head pumps 17
6.4 Identification 18
6.5 Model type 18
6.6 Radio communication 18
6.7 Closed valve operation 18
6.8 Insulating shells 19
6.9 Non-return valve 19
7. Control functions 20
7.1 Quick overview of control modes 20
7.2 Operating modes 22
7.3 Control modes 22
7.4 Additional control mode features 26
7.5 Multipump modes 27
7.6 Flow estimation accuracy 28
7.7 External connections 29
7.8 Priority of settings 29
7.9 Input and output communication 30
8. Setting the product 34
8.1 Operating panel 34
8.2 Menu structure 34
8.3 Startup guide 34
8.4 Menu overview 36
8.5 "Home" menu 38
8.6 "Status" menu 38
8.7 "Settings" menu 39
8.8 "Assist" menu 48
8.9 "Description of control mode" 49
8.10 "Assisted fault advice" 49
9. Servicing the product 50
9.1 Differential-pressure and temperature sensor 50
9.2 External sensor condition 50
9.3 Disassembling the plug 50
10. Fault finding the product 51
10.1 Grundfos Eye operating indications 51
10.2 Fault finding table 52
10.3 Fault finding 53
11. Accessories 54
11.1 Grundfos GO 54
11.2 Communication interface module, CIM 54
11.3 Counterflanges 59
11.4 External sensors 60
11.5 Cable for sensors 60
11.6 Blanking flange 61
11.7 Insulating kits for air-conditioning and cooling systems 61
12. Technical data 61
12.1 Sensor specifications 62
13. Disposing of the product 63
Read this document and the quick guide before
installing the product. 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.

English (GB)
3
1. General information
1.1 Hazard statements
The symbols and hazard statements below may appear in
Grundfos installation and operating instructions, safety
instructions and service instructions.
The hazard statements are structured in the following way:
1.2 Notes
The symbols and notes below may appear in Grundfos
installation and operating instructions, safety instructions and
service instructions.
1.3 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
6.4.1 Nameplate.
2.2 Scope of delivery
2.2.1 Plug-connected single-head pump
The box contains the following items:
• MAGNA3 pump
• insulating shells
•gaskets
•quickguide
• safety instructions
• one ALPHA plug.
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.
Observe these instructions for explosion-proof
products.
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.
Tips and advice that make the work easier.
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.
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!

English (GB)
4
2.2.2 Plug-connected twin-head pump
The box contains the following items:
• MAGNA3 pump
•gaskets
• quick guide
• safety instructions
• two ALPHA plugs.
2.2.3 Terminal-connected single-head pump
The box contains the following items:
• MAGNA3 pump
• insulating shells
•gaskets
• quick guide
• safety instructions
• box with terminal and M20 cable gland.
2.2.4 Terminal-connected twin-head pump
The box contains the following items:
• MAGNA3 pump
•gaskets
• quick guide
• safety instructions
• two boxes with terminals and M 20 cable glands.
2.3 Lifting the pump
Always lift directly on the pump head or the cooling fins when
handling the pump. See fig. 1.
For large pumps, it may be necessary to use lifting equipment.
Position the lifting straps as illustrated in fig. 1.
Fig. 1 Correct lifting of pump
Fig. 2 Incorrect lifting of pump
TM06 7225 3216TM05 8159 2013TM06 6791 2316
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. 2.
TM05 5821 3216

English (GB)
5
3. Installing the product
3.1 Location
The pump is designed for indoor installation.
Always install the pump in an dry environment where it will not be
exposed to drops or splashes, for example water, from
surrounding equipment or structures.
As the pump contains stainless-steel parts, it is important that it is
not installed directly in environments, such as:
• Indoor swimming pools where the pump would be exposed to
the ambient environment of the pool.
• Locations with direct and continuous exposure to a marine
atmosphere.
• In rooms where hydrochloric acid (HCl) can form acidic
aerosols escaping from, for example, open tanks or frequently
opened or vented containers.
The above applications do not disqualify for installation of
MAGNA3. However, it is important that the pump is not installed
directly in these environments.
Stainless steel variants of MAGNA3 can be used to pump pool
water. See section 6.2 Pumped liquids.
To ensure sufficient 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.
3.2 Tools
Fig. 3 Recommended tools
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
64.
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.
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
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

English (GB)
6
3.4 Positioning the pump
Always install the pump with horizontal motor shaft.
• Pump installed correctly in a vertical pipe. See fig. 4(A).
• Pump installed correctly in a horizontal pipe. See fig. 4(B).
• Do not install the pump with vertical motor shaft. See fig. 4(C
and D).
Fig. 4 Pump installed with horizontal motor shaft
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. 5.
Fig. 5 Pump with control box in horizontal position
Fig. 6 Automatic vent
4
Flanged version:
Fit bolts and nuts. Use the
right size of bolts according
to system pressure.
For further information about
torques, see page 64.
Threaded version:
Tighten the union nuts.
TM05 2865 3216 - TM05 8455 3216
TM05 2866 3216
Step Action Illustration
BA
DC
Make sure that the isolating valves are closed
before rotating the control box.
TM05 2915 3216
Twin-head pumps installed in horizontal pipes can
be fitted with an automatic vent, Rp 1/4, in the
upper part of the pump housing if no venting valve
is installed in the system. See fig. 6.
TM05 6061 3216

English (GB)
7
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 figs 7and 8.
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. 9.
Fig. 7 Correctly centred sealing system
Fig. 8 Incorrectly centred sealing system
Fig. 9 Fitting the pump head to the pump housing
3.7 Changing the control box position
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. 9.
TM05 5837 3216
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.
Make sure that the isolating valves are closed
before rotating the control box.
8Nm!

English (GB)
8
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
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
5.0
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)
9
As an alternative to insulating shells, you can insulate the pump
housing and pipes as illustrated in fig. 10.
Fig. 10 Insulating the pump housing and pipe in a heating
system
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.
In heating systems, do not insulate the control box or
cover the operating 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 a plug-connected 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.
If the pump is terminal-connected, the circuit
breaker must be marked with both of the symbols
below.
Make sure that the fuse is dimensioned according to
the nameplate and local legislation.
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.

English (GB)
10
3.9 Wiring diagrams
3.9.1 Connection to power supply, plug-connected versions
Fig. 11 Example of plug-connected motor with main switch, backup fuse and additional protection
3.9.2 Connection to external controllers, plug-connected versions
Fig. 12 Example of connections in the control box of plug-connected versions
The connection terminals of plug-connected versions (fig. 12)
differ from those of terminal-connected versions (fig. 13), but they
have the same function and connection options.
TM05 5277 3712
External switch
Fuse
RCD/RCCB
TM07 0380 1518
NC NO C
NC NO C
S/S
M
A
M
I
24V IN
Relay 1 Relay 2Digital inputAnalog input
Sensor
Vcc Signal
Operation Alarm
Start/
stop On/off
timer
Use C and NC for fault signals as this enables serial
connections of more relays and detection of signal
cable defects.