Grundfos MGE-F User manual

GRUNDFOS INSTRUCTIONS
MGE model F
Service instructions

2 / 32
Preface
These service instructions describe fault finding of pumps with Grundfos motors, type MGE model F (hereafter called
MGE-F).
The service instructions are aimed at specially trained staff who are familiar with the service of electrotechnical products.
The use of these service instructions presupposes knowledge of these documents:
• Installation and operating instructions for MGE-F 11-22 kW, frame sizes 160 and 180.
• Installation and operating instructions for the pump system incorporating the motor.
If the fault cannot be remedied by means of these instructions, or you require spare parts or technical assistance,
contact your nearest Grundfos partner or company. (See the back of these service instructions).
Please state these pieces of information when you contact Grundfos to get help for fault finding:
• Nameplate data of the pump the MGE-F is fitted to
• Nameplate data of the MGE-F
• Status for indicator lights on the control panel
• Any alarm or warning and the corresponding fault code read with the Grundfos R100 remote control.
These service instructions are published and updated in the Grundfos GTI database.
Symbols used in this document
Note
These service instructions include only MGE-F and its user interfaces (control panel, R100 and
PC Tool E-products). If the application includes other Grundfos products or systems, please
refer to the service instructions of these products.
Warning
If these safety instructions are not observed, it may result in personal injury.
Warning
If these instructions are not observed, it may lead to electric shock with consequent risk of
serious personal injury or death.
Warning
One or more components may be so hot that it may cause personal injury.
Caution
If these safety instructions are not observed, it may result in malfunction or damage to the
equipment.
Note
Notes or instructions that make the job easier and ensure safe operation.

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Contents
1. Identification ............................................................................................................................... 4
1.1 Nameplates................................................................................................................................................. 4
1.2 Type key ..................................................................................................................................................... 5
1.3 Configuration .............................................................................................................................................. 5
2. General description.................................................................................................................... 6
2.1 Wiring diagrams and signal terminals......................................................................................................... 6
2.2 Control panel .............................................................................................................................................. 7
2.3 Indicator lights............................................................................................................................................. 8
2.4 Setting using the R100 remote control ....................................................................................................... 8
2.5 R100 menu structure .................................................................................................................................. 9
2.6 Alarms and warnings ................................................................................................................................ 10
2.7 Alarm overview ......................................................................................................................................... 10
3. Fault finding.............................................................................................................................. 10
3.1 Safety instructions .................................................................................................................................... 10
3.2 Fault finding procedure............................................................................................................................. 10
3.3 Operating conditions................................................................................................................................. 11
3.4 Fault observations .................................................................................................................................... 11
3.5 Fault finding using the indicator lights on the control panel ...................................................................... 12
3.6 Fault finding using alarm and warning codes ........................................................................................... 17
4. Maintenance.............................................................................................................................. 21
4.1 Lubrication of motor bearings ................................................................................................................... 21
4.2 Replacement of motor bearings................................................................................................................ 22
5. Emergency operation (bypass)............................................................................................... 24
5.1 Establishing emergency operation............................................................................................................ 24
5.2 Re-establishment of frequency converter operation ................................................................................. 25
6. Drawings and diagrams........................................................................................................... 26
7. Tightening torques and lubrication ........................................................................................ 30
7.1 Tightening torques.................................................................................................................................... 30
7.2 Lubricating intervals and grease............................................................................................................... 30
8. Service tools ............................................................................................................................. 31

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1. Identification
1.1 Nameplates
The MGE-F nameplate (fig. 1) is fitted on the side of the terminal box (fig. 2).
The motor nameplates (fig. 3) are fitted under the terminal box (fig. 4).
TM04 2002 1808 TM04 2399 2508
Fig. 1 Nameplate for MGE-F, efficiency 1 motor Fig. 2 Position of nameplate
Pos. Description Pos. Description
1 Type designation 12 Max. supply current at min. and max. supply voltage
2 Product number 13 Supply voltage
3 Power factor 14 Rated power
4 Production code, year/week 15 Output frequency
5 Serial number 16 Output voltage
6 Weight 17 CE mark
7 Enclosure class according to IEC 34-5 18 VDE mark
8 Maximum ambient temperature 19 Standard motor efficiency according to CEMEP
9 Motor protection according to IEC 34-11 20 C-Tick mark
10 Insulation class according to IEC 62114 21 Country of manufacture
11 Frequency 22 Bar code
TM04 3051 3508
Fig. 3 Nameplates for standard motors with CE and UL approvals
TM04 2843 3208
Fig. 4 Position of motor nameplates
96 348831
Type
Env.Type: 3R
P.N.
Serial No:
P.C.
PF :
U
in
I
in 1/1
f in
OUTPUT
U
out
P
2
f out
Wgt
V
kW
V
A
Hz
:
0 -
:kg
3 ~
:
Made in Hungary
INPUT
:
:
Hz
:
:
:
:
:
CL
TP 211
T
Amb
IP
:C
:
:
0 -
12 3 45 6 7 8 910
11 12 13 14 15 16 17 19 20 21
22
18
MG180MB2-48FF300-F1
22,0 85903419
D/Y 380-415/660-690
41,5-38,5/23,8-22,8
91,9-92,8 45,5-42,5/26,0-25,0
0,91-0,89 2930-2940
D/Y 380-480/660-690
42,0-33,5/24,2-22,8
46,0-37,0/26,6-25,0
3500-3550
90,0-92,5
0,92-0,89
MG180MB2-48FF300-F1
4000
85903419
1000
40
60
UNIREX N3 ESSO
6310.C4
7310BE
15
Protector type PTC 160°C TP211
114 55 F
0931

5 / 32
1.2 Type key
1.3 Configuration
The terminal box is configured from factory for the application and the pump type the motor is to be used for. The
configuration file number appears from the terminal box configuration label which is placed inside the terminal box
on the frame of the control panel. See figs 5and 6.
If the terminal box is replaced or mounted on another motor, it must be reconfigured. Contact Grundfos Service.
Example MG E 160 M D 2- 42 FF 300 -F 1
Motor Grundfos
Electronically controlled
Frame size according to IEC
(centre line height of shaft of foot motor) [mm]
160
180
Size of foot
M
L
Length of stator core
B
D
Number of poles
2
4
Diameter of shaft end [mm]
Flange version
FF (free-hole flange)
Pitch circle diameter, flange version [mm]
Model designation for motor
F
Efficiency class for standard motor
[ ] = not stated
1 =EFF1motor
2 =EFF2motor
TM04 2305 2308 TM04 2400 2508
Fig. 5 Configuration label Fig. 6 Position of configuration label

6 / 32
2. General description
Fig. 7 Block diagram showing the functional blocks of the frequency converter
2.1 Wiring diagrams and signal terminals
The wiring diagram and the signal terminals depend on the pump application. Figures 8to 11 are examples of the
different functional modules available. Refer to the figure corresponding to the functional module fitted.
TM00 8679 4206
TM04 2071 1908 TM04 2072 1908
Fig. 8 I/O module and GENIbus Fig. 9 Extended I/O module and GENIbus
Inrush circuit
RFI filter
Rectifier Intermediate circuit Inverter
Driver circuit
Control circuit
96 34 88 32
NC1
C1
NO1
SIGNAL RELAY :
M AX : 250 V /2A AC 1
MIN: 5V/10mA
CONNECTION
FOR PC- TOOL
NC2
C2
NO2
SIGNAL RELAY :
M AX : 250 V/2 A AC1
MIN: 5V/10mA
STATUS L ED
OPTIO NAL
7: SENSOR I N PU T
8: +24V
9: GND
1: DIGITAL INPUT
0- 10 V
0/4-20mA
A: RS485 A
Y: RS485 GND
B: RS485 B
0 - 10V
+
2: RUN/STOP
3: GN D
4: SETPOINT
5: +10V
6: GN D
10k
0/4 - 20mA
SUPPLY :
SEE NAMEPLATE :
FOR FURTHER DATA: L1
L2
L3
PE
OP TI ON AL
96348833
CONNECTION
FOR PC-TOOL
NC1
C1
NO1
SIGNAL RELAY :
M AX: 250 V/2 A AC 1
MIN: 5V/10mA
NC2
C2
NO2
SIGNAL RELAY :
M AX : 250 V /2A AC 1
MIN: 5V/10mA
L3
L2
L1
SUPPLY :
SEE NAMEPLATE :
FOR FURTHER DATA:
17: PT 100 A
18: PT 100 A
19: PT 100 B
20: PT 100 B
STATUS L ED
7: SENSOR I N PUT
8: +24V
9: GND
0-10V
0/ 4 - 2 0 mA
1: DIGITAL INPUT 2
10: DIGITAL INPUT 3
11: DIGITAL INPUT 4
12: ANALOG OUTPUT
13: GND
14: SENSOR INPUT 2
15: +24V (2)
16: GND
0- 10 V
0/4-20mA
A: R S4 8 5 A
Y: R S4 8 5 GND
B: RS485 B
+
0-10V
0/4 - 20 mA
2: RUN/STOP
3: GND
4: SETPOINT
5: +10V
6: GND
10k
PE

7 / 32
2.2 Control panel
2.2.1 Operation
The motor control panel has the following buttons and indicator lights:
• Buttons and for setting of setpoint.
• Light fields, yellow, for indication of setpoint.
• Indicator lights, green (operation) and red (fault).
Switch control mode by pressing in this sequence:
• constant pressure,
• proportional pressure, .
Set the pump head by pressing or .
The light fields of the control panel will indicate the set head (setpoint).
TM04 2073 1908 TM04 2074 1908
Fig. 10 TPED module Fig. 11 Multi-E module
TM02 8513 0304 TM03 0126 4104
Fig. 12 CRE and TPE, TPED Fig. 13 TPE, TPED Series 2000
96348945
NC1
C1
NO1
SIGNAL RELAY :
M AX: 250 V/2 A AC 1
MIN: 5V/10mA
CONNECTION
FOR PC -TOOL
NC2
C2
NO2
SIGNAL RELAY :
MAX: 250 V/2 A AC 1
MIN: 5V/10mA
TPE D
0 - 1 0 V
+
2: RUN/STOP
3: GND
4: SETPOINT
5: +10V
6: GN D
10k
0/ 4 - 2 0m A
SUPPLY :
SEE NAMEPLATE
FOR FURTHER DATA L1
L2
L3
PE
A: RS485A
Y: RS485 GND
B: RS485B
7: SENSOR I N PU T
8: +24V
9: GND
1: DIGITAL INPUT 1
0- 10 V
0/4-20mA
CONNECTION FOR
TWIN PUMP
TWIN PUMP
SWITCH
STATUS L ED
96348946
NC1
C1
NO1
SIGNAL RELAY :
MAX: 250 V/2A AC1
MIN: 5V/10mA
CONNECTION
FOR PC- TOOL
NC2
C2
NO2
SIGNAL RELAY :
MAX: 250 V/2A AC1
MIN: 5V/10mA
Multi-E
0 - 10V
+
2: RUN/STOP
3: GND
4: SETPOI N T
5: +10V
6: GN D
10k
0/4 - 20mA
SUPPLY :
SEE NAMEPLATE
FOR FURTHER DATA L1
L2
L3
PE
A: RS485A (ext. bus)
Y: RS485 GND ( ext. bus)
B: RS485B (ext. bus)
A1: RS485A (int. bus)
Y: RS485 GND (int. bus)
B1: RS485B (int. bus)
7: SENSOR I N PU T
8: +24V
9: GND
1: DIGITAL INPUT 1
0-10V
0/4-20mA
STATUS L ED

8 / 32
2.3 Indicator lights
2.3.1 Indicator lights on the control panel
The indicator lights on the control panel show the MGE-F motor's operating and alarm condition.
2.3.2 Indicator lights inside the terminal box
The indicator lights beside the terminal block on the control board normally have the same functions as the indicator
lights on the control panel. See fig. 14.
See section 3.5 Fault finding using the indicator lights on the control panel to get an overview of the meaning of the
indicator lights.
2.4 Setting using the R100 remote control
The Grundfos R100 remote control is designed for wireless (IR) communication with the Grundfos E-products, including
the MGE-F.
Fig. 15 The R100 communicates with the motor via infrared light
During communication, the R100 must be pointed at the control panel. When the R100 communicates with the motor,
the red indicator light will flash rapidly. Keep pointing the R100 towards the control panel until the red indicator light stops
flashing.
The R100 gives access to settings and status displays for the motor.
The displays are divided into four parallel menus. See fig. 16:
0. GENERAL (see operating instructions for the R100)
1. OPERATION
2. STATUS
3. INSTALLATION.
Note
In case of certain faults in the electronics, the indicator lights on the control panel may indicate
differently from the indicator lights on the control board. In these cases, the indicator lights on
the control board indicate the current operating and alarm condition.
TM04 2569 2708
Fig. 14 Indicator lights inside the terminal box
TM02 0936 0501
Indicator lights for operation and alarm on the control board

9 / 32
2.5 R100 menu structure
Figure 16 shows an overview of all the R100 displays available for the MGE-F.
Note
The R100 menus will adapt to the application set and possible functional modules.
The menu structure below applies to a CRE pump. To see the correct menu structure, see
installation and operating instructions for the pump on which the MGE-F motor is mounted.
0. GENERAL 1. OPERATION 2. STATUS 3. INSTALLATION
Fig. 16 R100 menu structure (for CRE pump)

10 / 32
2.6 Alarms and warnings
An alarm or a warning is indicated by a red indicator light on the control panel and inside the terminal box. The alarm
and warning indication can be read with the R100.
2.7 Alarm overview
In section 3.6.1 Alarm and warning list, you will find an overview of the MGE-F alarms and warnings.
3. Fault finding
3.1 Safety instructions
3.2 Fault finding procedure
Fault finding is based on these sections in this order:
•3.3 Operating conditions
•3.4 Fault observations
•3.5 Fault finding using the indicator lights on the control panel
•3.6 Fault finding using alarm and warning codes
•7. Tightening torques and lubrication.
The necessary tools for the fault finding can be seen in section 8. Service tools.
Actual alarm and warning
Alarms and warnings are shown at the bottom of the OPERATION menu.
The first line shows the fault code. See section 3.6.1 Alarm and warning list.
The second line shows the fault text.
Reset the alarm or warning by pressing [OK].
If there are no alarms or warnings, the display will show "No alarm indication" or
"No warning indication".
Alarm and warning logs
In case of alarm or warning, the latest five alarms and warnings appear from the alarm and
warning logs.
"Alarm log 1" and "Warning log 1" show the latest alarm and warning, respectively.
"Alarm log 2" and "Warning log 2" show the latest alarm and warning but one, respectively,
etc.
The display shows the logged alarm or warning with fault code and fault text.
The top right corner shows how long ago the alarm or warning occurred.
If the log in question is empty, the display will show "No alarm indication" or
"No warning indication".
Warning
All service work must be carried out by specially trained staff.
Warning
Due to the capacitors of the MGE-F, touching live electrical parts may be fatal, even after the
mains supply has been switched off.
Disconnect the mains supply, and as a minimum wait the amount of time stated on the warning
label under the terminal box cover before touching any live parts.
Note that the relay may be connected to an external power supply and still be live after the
mains supply to the motor has been disconnected.
Warning
The MGE-F may be hot!
Fault code
Fault text

11 / 32
3.3 Operating conditions
Correct functioning of the MGE-F depends on these points:
Mains supply
• Check nameplate data, and measure the actual supply voltage with a digital voltmeter (true RMS).
• Check the earth leakage circuit breaker and the backup fuses. The MGE-F has no internal fuses.
Pump and motor load
• Check nameplate data, and measure the actual current consumption with a digital amperemeter (true RMS).
Do the pump and the MGE-F match?
External signals, for instance from another controller
• Check that the external signals are suitable for the MGE-F. See section 2.1 Wiring diagrams and signal terminals
and installation and operating instructions for MGE 160 and MGE 180.
• Check that terminals 2 and 3 are connected and that the MGE-F has been started via the control panel.
Sensors connected
• Check that the sensor measuring range matches the pump application.
• Check that the settings of the MGE-F match the sensors (current, voltage, minimum and maximum values)
(requires an R100).
Condensation
• Check whether condensation occurs in the terminal box. This may happen if the ambient temperature becomes
very low. The problem may be overcome by enabling the standstill heating function and by removing the drain plug
in the motor. See installation and operating instructions for MGE 160 and MGE 180.
Electromagnetic disturbances
• Check that the wiring complies with the EMC Directive. See installation and operating instructions for MGE 160 and
MGE 180.
Start-up, installation and operating settings via the control panel or the R100
• Check that the green indicator light on the control panel (or inside the terminal box) is on.
• Check that the settings in the INSTALLATION menu match the pump application (requires an R100).
The menu displays are described in detail in the installation and operating instructions for MGE 160 and MGE 180.
If the above points are according to the installation and operating instructions for MGE 160 and MGE 180 and the pump
application, but a fault still exists and the red indicator light is on, continue the fault finding in sections 3.5 Fault finding
using the indicator lights on the control panel and 3.6 Fault finding using alarm and warning codes.
3.4 Fault observations
3.4.1 Condensation in the terminal box
Description Condensation in the terminal box.
Explanation During standstill, the motor temperature will fall below the dew point of the surrounding air.
Then the humidity in the air may condensate and settle on the surface of the terminal box.
Check/remedy Activate Standstill heating with the R100 in the
INSTALLATION menu.

12 / 32
3.5 Fault finding using the indicator lights on the control panel
The operational state of the motor incl. possible faults can be read via the indicator lights on the control panel.
If an R100 remote control is available, we recommend you to start fault finding via the R100 fault code.
See section 3.6 Fault finding using alarm and warning codes.
Note
In case of certain faults in the electronics, the indicator lights on the control panel may indicate
differently from the indicator lights on the control board. In these cases, the indicator lights on
the control board indicate the current operating and alarm condition.
Indicator lights Condition/cause Remedy
Green Red
On On Normal operation + indication of previous fault
1. The pump is running at
normal performance.
– The pump's duty/
standby function has
been activated, but
there is no
communication with the
standby pump.
a) Has the power supply to the standby pump been switched off?
YES:
NO:
Re-establish the power supply.
Proceed to point b).
b) Has the communication cable been disconnected?
YES:
NO:
Check the communication cable.
Contact Grundfos Service.
2. The pump is running at
maximum speed.
– The sensor signal is
outside the set signal
range.
a) Does the sensor setting correspond to the sensor type installed?
(0-10 V, 0-20 mA, 4-20 mA)
NO:
YES:
Correct the setting using the R100.
Proceed to point b).
b) Is the voltage to the sensor connection 24 VDC?
TM02 1606 1601TM04 2072 1908
NO:
YES:
Replace the I/O module.
Proceed to point c).
c) Is the sensor signal
– below 10 V (type 0-10 V sensor)?
– below 20 mA (type 0-20 mA sensor)?
– between 4 and 20 mA (type 4-20 mA sensor)?
TM02 1604 1601TM04 2072 1908
NO:
YES:
Replace the sensor.
Proceed to point d).
d) Has the sensor been connected correctly, and does the sensor
signal correspond to the system pressure?
NO:
YES:
Connect the sensor signal correctly.
Replace the I/O module or the terminal box.
If the sensor is defective, replace it.
[To be continued on the next page]
8: +24V
9: GND
12: ANALOG OUTPUT
13: GND
14: SENSOR INPUT 2
15: +24V (2)
16: GND
0- 10 V
0/4-20mA
7: SENSOR INPUT
8: +24V
9: GND
4-20mA
+
OUT
0-10V
0/4-20mA
- +OUT
GU
12: ANALOG OUTPUT
13: GND
14: SENSOR INPUT 2
15: +24V (2)
16: GND
0- 10 V
0/4-20mA

13 / 32
On On
3. The pump is running at
minimum speed.
– The setpoint signal is
outside the set signal
range.
a) Set the pump to "open loop" operation, and connect 10 V supply to
the setpoint input.
Does the pump switch to maximum speed?
NO:
YES:
Proceed to point b).
The pump is OK.
b) Does the setpoint setting correspond to the setpoint type
installed?
(0-10 V, 0-20 mA, 4-20 mA)
NO:
YES:
Correct the setting using the R100.
Proceed to point c).
c) Is the voltage to the setpoint connection 10 VDC?
TM02 1607 1601
NO:
YES:
Replace the terminal box.
Proceed to point d).
d) Is the setpoint signal
– below 10 V (type 0-10 V sensor)?
– below 20 mA (type 0-20 mA sensor)?
– between 4 and 20 mA (type 4-20 mA sensor)?
NO:
YES:
Check for fault in the external setpoint signal.
Re-establish the correct setpoint signal, if necessary.
If the pump still does not run correctly, replace the
terminal box.
[To be continued on the next page]
Indicator lights Condition/cause Remedy
Green Red
0-10V
+
-
0/4-20mA 10K
4: SETPOINT
5: +10V
6: GND

14 / 32
On Off Normal operation
1. The pump is running.
– Normal operational
state.
On Off
2. The pump is not running.
Operational stop which
may be caused by
– the flow switch
connected
– the pump stop function.
a) The flow switch is closed.
The connection of a flow switch depends on the MGE functional
modules. See the wiring diagrams in figs 8to 11.
Is there 5 VDC across terminals 1-9?
(If an extended I/O module is installed, the flow switch may be
connected to DI3 (terminals 9-10) or DI4 (terminals 9-11)).
NO:
YES:
Flow switch closed = Pump is not supposed to run.
Flow switch open = Pump must be running.
If the flow switch is defective, replace it.
Does the pump start when the connection between the flow switch
terminals is cut?
NO:
YES:
Replace the I/O module.
The digital input is OK.
The flow switch is defective. Replace it.
b) The stop function has stopped the pump.
Does the pump start when you increase the flow and/or reduce the
pressure in the system?
NO:
YES:
If the sensor is OK, replace the terminal box.
The input is OK.
[To be continued on the next page]
Indicator lights Condition/cause Remedy
Green Red

15 / 32
On Off
3. The pump is running at
unexpectedly high or low
speed.
– Can be caused by fault
in installation, setting or
signal from setpoint/
sensor or that the
sensor input has been
set to "active".
a) Has the correct setpoint type been set in the motor?
(0-10 V, 0-20 mA, 4-20 mA)
NO:
YES:
Correct the setting using the R100.
Proceed to point b).
b) Has the external setpoint signal from potentiometer or external
controller been connected correctly?
TM02 1606 1601
NO:
YES:
Connect the setpoint signal correctly.
Proceed to point c).
c) Has the correct sensor type been set in the motor?
(0-10 V, 0-20 mA, 4-20 mA)
NO:
YES:
Correct the setting using the R100.
Proceed to point d).
d) Has the sensor been connected correctly, and does the sensor
signal correspond to the system pressure?
TM02 1604 0601TM04 2072 1908
NO:
YES:
Connect the sensor signal correctly.
If the pump does not run correctly, replace the I/O module
or the terminal box.
If the sensor is defective, replace it.
Off Off The pump is not running
1. The power supply to the
motor has been cut.
Re-establish correct power supply.
2. The control panel or one
of the functional modules
is defective.
Switch off the power supply. Then remove the control panel and the
functional modules, one at a time, and switch on the power supply every
time a component has been removed. When the fault has disappeared
after switching on the power supply, the defective component has been
localised and can be replaced.
3. The terminal box is
defective.
Replace the terminal box, or contact Grundfos Service.
[To be continued on the next page]
Indicator lights Condition/cause Remedy
Green Red
0-10V
+
-
0/4-20mA 10K
4: SETPOINT
5: +10V
6: GND
7: SENSOR INPUT
8: +24V
9: GND
4-20mA
+
OUT
0-10V
0/4-20mA
- +OUT
GU
12: ANALOG OUTPUT
13: GND
14: SENSOR INPUT 2
15: +24V (2)
16: GND
0- 10 V
0/4-20mA

16 / 32
Off On The pump has stopped due to a fault
The pump has been stopped
due to one of the following
causes:
See the fault indication on the R100 or
PC Tool E-products.
1. The pump is blocked or
overloaded.
Remove the blockage, or reduce the load.
2. The ambient temperature
is too high, or the cooling
is insufficient.
Re-establish sufficient cooling.
3. Power supply fault:
– undervoltage
– overvoltage
– phase failure
– mains supply failure.
Check that the supply voltage is within the stated voltage range.
If not, re-establish correct power supply.
4. External fault. a) Has the R100 been set to external fault?
NO: Correct the setting using the R100.
YES: Proceed to point b).
b) Can 5 VDC be measured across terminals 1-9?
TTM02 1605 0601
NO: Contact between terminals 1 and 9 is closed.
Seek the cause of fault in external signal transmitter.
YES: Contact between terminals 1 and 9 is open.
The E-pump is OK. Proceed to the next fault possibility.
5. Other faults:
– wrong terminal box
– wrong configuration
– fatal fault.
• Replace the terminal box.
• Reconfigure the terminal box.
• Replace the terminal box.
Flashing,
1Hz Off Normal operational stop
The pump has been stopped
• with the button
• with the R100
• using the Grundfos GENIbus
• by the motor start/stop function. (Input on terminal 2-3 is open).
Flashing,
1Hz On Normal operational stop + indication of previous fault
The pump has been stopped
• with the button
• with the R100
• using the Grundfos GENIbus
• by the motor start/stop function, but was previously stopped
due to a fault which has now disappeared.
Flashing,
5Hz On The pump has been stopped due to a fault in the product
Pump is not running and
• communication with the
R100 is not possible.
• no reaction when you
press or .
• fatal internal
communication fault in the
pump.
Try resetting the fault by
• disconnecting the power supply.
• waiting until all diodes are off.
• re-establishing the power supply.
If this does not remedy the fault, the terminal box is defective. Replace
the terminal box.
Indicator lights Condition/cause Remedy
Green Red
9: GND
1: DIGITAL INPUT
0/1

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3.6 Fault finding using alarm and warning codes
Apart from being indicated by the indicator lights on the control panel, alarms, warnings and their fault codes can be
read using the R100.
3.6.1 Alarm and warning list
The list below gives you an overview of the possible alarms and warnings and a description of their causes and
suggestions for remedy.
These abbreviations are used in the column "Fault type":
W: Warning.
A: Alarm.
1): The alarm can be configured to Warn/Max/Min/Stop/User using the PC Tool E-products.
Fault code Fault reading in the R100 Fault reading in PC Tool E-products Fault type
Explanation/cause Remedy
3External fault External fault signal A
The digital input set for "External fault" was or is
closed (terminal 1, 10 or 11).
When the digital input is no longer closed, the fault indication can be reset
either with the R100 or by pressing or .
4Too many restarts Too many restarts (from standby mode per 24 hours) A
• The number of attempted restarts at 10-second
intervals after a fault has exceeded four within
one minute.
• The number of attempted restarts at five-minute
intervals after a fault has exceeded 16 within
24 hours.
Seek the cause under the fault log code numbers in the R100.
The pump will automatically attempt to restart after 24 hours.
The fault indication can be reset either with the R100 or by
pressing or .
30 Replace motor bearings Motor bearings need change (service information) W
The motor has reached the number of operating hours
for the bearing service life that is stated in the
configuration.
Replace the bearings. See section 4.2 Replacement of motor bearings.
31 Replace varistor Motor varistor(s) need change (service information) W
The varistor has been exposed to the allowable
number of transients and needs replacing.
Contact Grundfos Service.
32 Overvoltage Overvoltage A
The supply voltage has been or is too high. Reduce the voltage to the specified level (see the nameplate).
40 Undervoltage Undervoltage A
The supply voltage has been or is too low. Increase the voltage to the specified level (see the nameplate).
41 Undervoltage Undervoltage transient A
There has been a voltage drop in the supply voltage
caused by one of the following:
• Supply cable too small.
• Another big user is supplied from the same
panel.
45 Mains voltage asymmetry Voltage asymmetry A
The supply voltage has been or is asymmetric. Check the supply voltage while the motor is loaded.
49 Overload Overcurrent (i_line, i_dc, i_mo) A
The terminal box or the motor is heavily overloaded.
Cause:
• Blocked pump. • Remove the blockage.
• Blocked rotor. • Remove the blockage.
• Continued overload. • Reduce the load.
• Incorrect configuration of the terminal box. • Contact Grundfos Service.
• Wrong terminal box. • Contact Grundfos Service.
• Fault in stator windings. • Contact Grundfos Service.
• Power supply failure (phase failure). • Re-establish correct power supply.
51 Overload Blocked motor/pump A
The pump is blocked during start-up which causes
a heavy overload. The input current is very high;
the motor P > 120 % for 60 seconds.
Remove the blockage.

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55 Overload Motor current protection activated (MCP) A
The built-in motor-current protection function has
registered a continued overload of more than 125 % of
rated current for 60 seconds.
Cause:
• Continued overload. • Reduce the load by limiting the pump flow.
• Incorrect configuration of the terminal box. • Contact Grundfos Service.
• Fault in stator windings. • Contact Grundfos Service.
56 Underload Underload A
The motor is underloaded.
Cause:
• Incorrect configuration of the terminal box. • Check the settings of the terminal box.
• The pump has run dry. • Make sure that all valves in the piping system are open and that there
is water in the piping system.
57 Dry running Dry running A
The pump has run dry. Make sure that all valves in the piping system are open and that there is
water in the piping system.
65 Too high motor temperature Motor temperature A
The temperature sensor in the motor has measured a
too high winding temperature.
Cause:
• Dust and dirt in the cooling fins. • Clean the cooling fins.
• Too high ambient temperature. • Improve the cooling.
• Fault in stator windings. • Contact Grundfos Service.
73 Undervoltage Hardware shutdown (HSD) A
The current limit of the electronic module has been
exceeded.
Cause:
• Incorrect configuration of the terminal box. • Contact Grundfos Service.
• Fault in stator windings. • Contact Grundfos Service.
• Terminal box defective. • Contact Grundfos Service.
77 Duty/standby, Communication fault Twin pump communication fault W
Communication between the two pumps which have
been set to duty/standby function has been
interrupted.
Cause:
• Power supply to standby pump has been cut. • Re-establish the power supply.
• Communication cable has been cut. • Check the communication cable.
• Communication module defective. • Replace communication module.
85 Other fault Freq. conv. parameter verification error (EEPROM) A
The EEPROM has lost its contents. Contact Grundfos Service.
88 Sensor 1 signal outside signal range General sensor signal fault / feedback sensor signal
fault 1)
Sensor signal type 4-20 mA: signal below 2 mA or
above 22 mA.
Sensor signal type 0-20 mA: signal above 22 mA.
Sensor signal type 0-10 V: signal above 11 V.
• Signal range set incorrectly. • Correct the signal range setting.
• Sensor incorrectly connected. • Connect the sensor correctly.
• Incorrect power supply to sensor. • Check the power supply from the terminal box. If it is not 24 V ± 1 V,
replace the terminal box.
• Sensor defective. • Replace the sensor.
• Sensor cable defective. • Check the sensor cable.
91 Temperature sensor 1 signal outside
signal range Temperature sensor 1 signal fault 1)
The sensor signal has been short-circuited or cut. Replace the temperature sensor.
Fault code Fault reading in the R100 Fault reading in PC Tool E-products Fault type
Explanation/cause Remedy

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93 Sensor 2 signal outside signal range Sensor 2 signal fault 1)
Same as fault 88. Same as fault 88.
96 Setpoint signal outside signal range Reference input signal fault 1)
Sensor signal type 4-20 mA: signal below 2 mA or
above 22 mA.
Sensor signal type 0-20 mA: signal above 22 mA.
Sensor signal type 0-10 V: signal above 11 V.
• Signal range set incorrectly. • Correct the signal range setting.
• Setpoint signal incorrectly connected. • Connect the setpoint signal correctly.
• Incorrect supply voltage to the setpoint. • Check the supply voltage from the terminal box. If it is not 10 V,
replace the terminal box.
105 Overload Electronic rectifier protection activated (ERP) A
The electronic module/motor is heavily overloaded,
and the temperature of the electronics is above
100 °C.
The measured temperature can be read via PC Tool
E-products.
Cause:
• Temperature sensor defective. • Contact Grundfos Service.
• Continued overload. • Reduce the load.
• The ambient temperature is too high, or
the cooling is insufficient.
• Improve the cooling.
• Incorrect configuration of the terminal box. • Contact Grundfos Service.
106 Overload Electronic inverter protection activated (EIP) A
The electronic module/motor is heavily overloaded,
and the temperature of the electronics is above
100 °C.
The measured temperature can be read via PC Tool
E-products.
Cause:
• Temperature sensor defective. • Contact Grundfos Service.
• Continued overload. • Reduce the load.
• The ambient temperature is too high, or
the cooling is insufficient.
• Improve the cooling.
• Incorrect configuration of the terminal box. • Contact Grundfos Service.
148 DE bearing temperature high Motor drive-end (DE) bearing temp. warning limit
Motor drive-end (DE) bearing temp. alarm limit W A
The drive-end motor bearing has become too hot.
Cause:
• The bearing is worn. • Replace the bearing. See section 4.2 Replacement of motor bearings.
• The motor is dirty. • Check and clean, if necessary,
– the fan
– the motor cooling fins.
149 NDE bearing temperature high Motor non-drive-end (NDE) bearing temp. warn. limit
Motor non-drive-end (NDE) bearing temp. alarm limit W A
The non-drive-end motor bearing has become too hot.
Cause:
• The bearing is worn. • Replace the bearing. See section 4.2 Replacement of motor bearings.
• The motor is dirty. • Check and clean, if necessary,
– the fan
– the motor cooling fins.
155 Undervoltage Inrush fault A
The terminal box voltage is outside the alarm limit.
Cause:
• Fault in the voltage supply. • Re-establish the voltage supply.
• Transients in the voltage supply during
operation.
• Contact Grundfos Service.
Fault code Fault reading in the R100 Fault reading in PC Tool E-products Fault type
Explanation/cause Remedy

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156 Other fault Internal communication failure in frequency converter A
Internal communication fault in the pump due to defect
in the terminal box.
Contact Grundfos Service.
175 Temperature sensor 2 signal outside
signal range Temperature sensor 2 signal fault 1)
Same as fault 91. Same as fault 91.
190
191 Limit 1 exceeded Limit 2 exceeded Limit 1 exceeded Limit 2 exceeded 1)
This is a monitoring function offering information,
alarm or warning if a low or high limit is exceeded.
The function can only be set with the PC Tool
E-products.
The function can be set to monitor
• sensor 1 or 2
• Pt100 sensor 1 or 2
• external setpoint
• the feedback signal.
The limit set has been exceeded either upwards or
downwards.
Procedure:
1. Using PC Tool E-products, check which function is being monitored.
2. Check in the pump system whether the alarm or warning is real. If it is
real, remedy the fault.
3. If the alarm or warning seems to be wrong for the pump system,
troubleshoot according to the selected sensor using these service
instructions.
240 Relubricate motor bearings Motor bearings need lubrication (service information) W
The motor has reached the number of operating hours
stated in the configuration for the bearing lubrication.
Lubricate the bearings. See section 4.1 Lubrication of motor bearings.
Fault code Fault reading in the R100 Fault reading in PC Tool E-products Fault type
Explanation/cause Remedy