Grundfos Redi-Flo3 User manual

1
GRUNDFOS PRODUCT GUIDE
Redi-Flo3™ and CU 300
Environmental Pumps
60Hz

Table of Contents
Features and Benefits .....................................pages4-5
Applications .............................................pages6-7
Communications ........................................pages8-12
Performance and Technical Data ..........................pages13-17
Accessories ..............................................page18
3

4
Features and Benefits
Redi-Flo3 Submersible Pumps
Redi-Flo3 pumps are suitable for both continuous and
intermittent operation for a variety of environmental
applications including:
• Remediation
• Pollution Recovery
• Leachate Recovery
• Dewatering
• Tank Applications
Redi-Flo3 pumps offer the following features:
• Dry-Run Protection
• High Efficiency Pump End and Motor
• High Starting Torque
• Protection Against Up-Thrust
• Soft-Start
• Over- and Under-Voltage Protection
• Overload Protection
• Over-temperature Protection
• Variable Speed
• Electronic Control and Communication
Redi-Flo3 pumps incorporate a totally new motor
design. With the use of permanent-magnet technology
within the motor, Redi-Flo3 pumps deliver unmatched
performance. The combination of permanent-magnet
motors and Grundfos’ own micro frequency converter,
we are now able to communicate with the pump in ways
never before possible. Just a few of the features that
come out of this combination are constant level control,
soft-start and integrated dry-run protection. These are
just a few of the many features that Redi-Flo3 pumps
can offer.
Redi-Flo3 pumps use the Grundfos “Smart Motor”.
This permanent-magnet motor is single phase input
and with a 2-wire design makes installation easy. The
combination of integrated microelectronics in the pump
with the optional CU300 status box and R100 at the
surface allows communication with the pump through
standard electrical motor power leads. No additional
wires are required. This feature allows the direct use of
multiple sensors, digital input and relays without adding
extra control electronics and costs.
The surface CU300 status box allows communication
with the “Smart Motor” through the R100 infrared
remote control unit or via the CU300 PC Software
Tool. This gives you the ability to monitor and setup
or change your pumping system to meet the specific
needs of your application.
High Pump Efficiency
The pump end components are made from Polyvinylidene
Fluoride (PVDF). The pumps are designed to deliver at
peak efficiency levels. Because of high pump efficiencies,
overall power consumption will be reduced.
Dry-Run Protection
The Redi-Flo3 incorporates integrated Dry-Run protection.
When the fluid level falls below the inlet of the pump,
the pump automatically shuts off. After a programmable
period of time, the pump automatically starts up again.
High Motor Efficiency
Redi-Flo3 motors are based on a permanent magnet
rotor, which produce high efficiency within a wide
load range. The high and flat efficiency curve of the
Permanent-Magnet (PM) motor allows for coverage of
a wide power range with the same motor as compared
to conventional submersible AC motors. For Redi-Flo3
pumps, this means only three motors to cover the
horsepower range from 1/3 to 1.5Hp.
The Redi-Flo3 can operate without the status control
box much like a traditional submersible electric pump.
Some communication and program functions will not
be available in this configuration, but the internal motor
protection features are still active.
Pump and Motor Range
Product Description
Redi-Flo3 10, 22, GPM
Pump End
MSE3NE Single Phase
Motor 1/3 - 1.5 Hp
70
65
60
55
50
45
200 250 300 350 400 450 500 550 600 (W)
(%)
MS3
Conventional 3ph
Conventional 1ph

5
Features and Benefits
Wear Resistance
Redi-Flo3 pump design uses “floating” impellers. Each
impeller has its own tungsten carbide/ceramic bearing.
This design and the environmental quality of materials
make this pump an excellent choice for environmental
application projects.
Protection Against Up-Thrust
During start-up many pumps start in an up-thrust
condition. To prevent damage caused by up-thrust, a top
bearing has been placed in the motor to protect both
the pump and the motor against up-thrust.
Soft-Start
Redi-Flo3 have a soft-start feature possible because
of the integrated electronics. Soft-start reduces the
starting current and gives the pump a smooth and
steady acceleration.
High Starting Torque
Because of the permanent-magnet motor, the Redi-
Flo3 pumps have excellent starting capabilities. The
high locked rotor torque produced by the PM motor
provides a starting torque that is 1.5 times greater than
conventional submersible pump motors. Even if the
voltage is low, the PM motor will still maintain a high
starting torque.
Overvoltage and Undervoltage Protection
Overvoltage and undervoltage may occur at any time,
especially if you have an unstable voltage supply. The
integrated protection in the Redi-Flo3 motor protects itself
when voltage falls outside of permissible voltage range.
The 230V pump motor will cut out if voltage falls below
150V or above 280V. The motor will automatically start
when the voltage is within the permissible range. It is not
necessary to have additional voltage protection.
Overload Protection
When the pump load rises above the maximum amp level,
the motor will automatically compensate and reduce the
speed to maintain its maximum amp level. If the speed
drops to 65% of the nominal speed, the motor will shut
off.
Overtemperature Protection
Permanent-magnet motors emit very little heat because of
their high efficiency. Redi-Flo3 motors are designed with
an internal circulation system to effectively cool all the
internal components.
As extra protection, the electronic unit also has a built-
in temperature sensor. When the temperature rises too
high, the motor will automatically shut-off; when the
temperature drops the motor will automatically restart.
Variable Speed
The Redi-Flo3 “Smart” motor enables continuous variable
speed control within 30%-100% (3,000-10,700 rpm). The
pump can be set to operate at any duty point in the range
between 30% and 100% of the pumps performance curve.
The pump can be adapted to any specific requirement.
The variable speed control requires the status box and R100
or potentiometer.
Installation
Redi-Flo3 pumps can be installed vertically or horizontally
(Note: the pump must not fall below the horizontal level in
relation to the motor). For horizontal installations, a flow
sleeve is recommended to ensure sufficient flow past the
motor to provide proper cooling and prevent the unit from
being buried in sand or silt.
Amps
DOL
sec.
Soft start
2

Maintaining a Constant Water Table
Introduction
By monitoring the water table and controlling the pump,
the water table can be maintained at a constant level.
EXAMPLES OF APPLICATION:
For example maintaining a constant water table is
useful in the following situations:
• When the groundwater should be kept out of a
building site.
• When the salt water should be kept from penetrating
a borehole with potable water.
Remedial Pumping with Water
Quality Monitoring
Introduction
By means of sensor signals it is possible to carry
out remedial pumping where the water contains
contamination e.g. chemicals, oils, etc.
Applications
Remediation/Pollution Recovery/Dewatering
Connection of a sensor such as a submersible pressure sensor enables the pump via the status control box to
maintain a constant level by starting and stopping the pump based on a desired water level.
Description
Pos. Description
1 CU300
2 Level sensor
Description
Pos. Description
1 CU300
2 pH sensor
Detects the water quality
3 Level sensor
6

Sensor 1 (tank at top)
Pumping from One Tank to Another
Where there is a need to move water from one tank to another, the Redi-Flo3 is ideal.
Applications
Level Description
Max. (stop) When the water has reached this level,
the pump stops. Green indicator light in
on/off-button flashes.
Min. (start) When the water has dropped to this level,
the pump starts. Green indicator light in
on/off-button is constantly lit.
Description
Pos. Description
1 CU300
2 Level sensor
3 Water tank
NOTE: When the Redi-Flo3 pump is installed
horizontally, it is recommended that a flow sleeve be
fitted. The motor must be fully submerged in the water.
7
Sensor 2 (bottom tank)
Level Description
Min. (stop) When water has dropped to this level,
tank is empty, stop pump.

Status Control Box Communication
Redi-Flo3 CU300 Status Box
The CU300 status box is a control and communication
unit especially developed for the Redi-Flo3 submersible
pumps.
The CU300 status box provides:
• Easy adjustment to a specific well
• Full control of Redi-Flo3 pumps
• Two-way communication with the Redi-Flo3 pumps
• Indicator lights on the front to indicate alarms
• The ability to start and stop the pump with the push
of a button.
The CU300 communicates with the pump using the
power leads. It is not necessary to run any extra cables
between the pump and the CU300 status box.
The following alarms can be indicated by the CU300:
• No Contact
• Overvoltage
• Undervoltage
• Dry-run
• Speed Reduction
• Overtemperature
• Overload
• Sensor Alarm
The CU300 incorporates:
• External signal input for three sensors
• relay output for external alarm control
• Control according to the signals received, e.g. flow,
pressure, water level and conductivity
The CU300 can communicate with the R100 infrared
remote control or R100 PC software tool.
R100 Remote Control or PC Software Tool
The R100 allows you to monitor the installation by
reading current operating parameters, such as:
• Power Consumption
• Energy Consumption
• Number of Operating Hours
It allows you to change factory settings. A number of
settings can be made, such as:
• Speed (Performance)
• Constant Pressure Control Mode
• De-watering Function
• Automatic Restart Time
8
(Inches)

9
The CU300 Redi-Flo3 control panel communicates with
the Redi-Flo3 motors via the pump power cable to turn
the pumps on and off, set motor speed and monitor
pump status. The technique used for performing this
communication impresses a high frequency data signal
on the pump power cable that is picked off by internal
pump electronics and then decoded into command
instructions. This is the reason for assigning unique
numbers to each CU300 in a multiple unit installation.
The unique number serves as a communication address
between each CU panel/motor pair.
In situations where multiple CU300 pump power cables
are run parallel in wiring trays or conduit and less
than 10-12 inches apart, the possibility for undesired
communication between units exists. When this occurs,
intermittent or continuous NO CONTACT is typically seen.
Other unexpected errors may also be seen.
There are two approaches available to eliminating the
possibility of this occurring:
1. Physical separation of cables – maintain a
minimum distance of 10-12 inches between
pump power cables, and never place more than
one cable in a conduit.
2. Use shielded cable – The use of shielded cable
prevents cross communication between parallel
cables and allows sharing of conduit and cable
trays. Tie the cable shield to earth only at the CU
control panel.
Suitable cables:
Anixter (1-800-321-1486)
In addition, Grundfos recommends applying power to
only one CU panel/motor at a time while programming
the CU number with the R100. This will prevent the
possibility of two pumps receiving the same number
assignment command.
Multiple CU300 Installation Requirements
Manf. Part # Gage
Anixter 2A-1403S 14
Anixter 2A-1203S 12
Anixter 2A-1003S 10
K1
POWER
PE
PUMP
RELAY
DRAIN WIRE
COM NC NO
NO NC COM
AUX
RELAY
5 6 7
1 2
1098
3 4
PE
LNL N
H
SHIELDED CABLE WIRING DIAGRAM

10
R100 Menu Structure

11
R100 Menu Structure
R100 Menu Structure for the CU300
(ref. CU300 I&O)
0. General
1. Operation
1.1 Set-point setting
1.2 Selection of operating mode
1.3 Alarm indication
2. Status
The indication of:
2.1 Actual operating mode
2.2 Actual and external set point
2.3 Actual motor temperature
2.4 Actual motor speed
2.5 Actual power input and accumulated motor
power consumption.
2.6 Accumulated number of operating hours and
accumulated number if starts.
2.7 Actual values of sensors 1 and 2 respectively
2.8 Actual values of the digital input
2.9 Accumulated flow, and the power used to
pump 1 gal.
R100 allows you to make a number of settings:
3. Limits
The setting of:
3.1 Sensor 1
3.2 Min. and max. stop limit of sensor 1
3.3 Min. and max. warning limit of sensor 1
3.4 Min. and max. alarm limit of sensor 1
3.5 Sensor 2
3.6 Min. and max. stop limit of sensor 2
3.7 Min. and max. warning limit of sensor 2
3.8 Min. and max. alarm limit of sensor 2
3.9 Filling or emptying
3.10 Setting of the function of the digital sensor
connected to the digital input
3.11 The setting of the water quantity stop limit
and the setting of the sensor to detect water
quantity
3.12 The setting of the temperature warning limits of
the motor electronics
4. Installation
4.1 Selection of controller
4.2 Setting of external set-point
4.3 Setting of automatic restart time
4.4 Allocation of individual start delays
4.5 Setting of the stop and run times for the
de-watering function
4.6 Setting of the value of the Dry-Run shutdown
4.7 Activating or deactivating the Dry-Run protection
4.8 Setting of the maximum motor speed
4.9 Activating or deactivating the on/off-button on the
CU 300
4.10 Allocation of number where more than one
CU300 is installed

12
R100
Examples of R100 displays
Menu OPERATION
Set-point Setting
From the factory, the pump
is set to maximum speed,
10,700 rpm. R100 allows
you to reduce the pump
speed by changing the
setpoint. The speed can be
set from 3,000–10,700 rpm,
at 100 rpm intervals.
The unit of the set-point is automatically changed
according to the unit of the sensor connection to sensor
input no. 1 if closed loop.
EXAMPLE: Sensor input no. 1 is connected to a
pressure sensor using the unit feet (ft.) and the range 0
– 200 (dependent on the actual sensor characteristics).
Therefore, the set-point of display 1.1 can be set to
between 0 – 200 ft.
Menu STATUS
The displays appearing
in this menu are status
displays only. You cannot
change settings in this
menu.
Example
In display 2.4, the actual speed of the pump is shown.
Accumulated Number of Operating Hours and
Number of Starts
The value of operating
hours and the number
of starts are values
accumulated from the
time of installation and
they cannot be reset.
Both values are stored in the motor electronics, and
are kept even if the CU300 is replaced.
The number of operating hours is measured every
two minutes of continuous operation, but the display
value is updated every two hours.
Menu LIMITS
The Setting of Sensor 1
Depending on the type
of sensor, the following
settings can be made:
Sensor outputs:
(not active), 0-10V, 2-10V,
0-20mA, 4-20mA.
Setting range unit: M3/h,
m, %, gpm, ft.

13
Technical Data Redi-Flo3 10gpm
Model # HP Size Disch. Dimensions in Inches Approx.
Size Ship Wt.
A B C D E (pounds)
10Redi-Flo3-100 1/3A 3" 1 1/4" NPT 30.4 19.8 10.6 2.6 2.9 12
10Redi-Flo3-140 1/2A 3" 1 1/4" NPT 30.4 19.8 10.6 2.6 2.9 12
10Redi-Flo3-180 1/2B 3" 1 1/4" NPT 31.5 19.8 11.6 2.6 2.9 13
10Redi-Flo3-220 3/4B 3" 1 1/4" NPT 33.6 19.8 13.7 2.6 2.9 13
10Redi-Flo3-260 1C 3" 1 1/4" NPT 35.0 21.3 13.7 2.6 2.9 16
10Redi-Flo3-300 1C 3" 1 1/4" NPT 36.1 21.3 14.8 2.6 2.9 16
10Redi-Flo3-340 1 1/2C 3" 1 1/4" NPT 38.2 21.3 16.9 2.6 2.9 16
Note: Weights include pump ends with motors
0 2 4 6 8 10 12 14
0
100
200
300
400
500
600
CAPACITY (GPM)
HEAD (FEET)
-340
-300
-260
-220
-180
-140
-100
1 1/4" NPT

14
Technical Data Redi-Flo3 22gpm
Model # HP Size Disch. Dimensions in Inches Approx.
Size Ship Wt.
A B C D E (pounds)
22Redi-Flo3-40 1/3A 3" 1 1/2" NPT 30.4 19.8 10.6 2.6 2.9 12
22Redi-Flo3-80 1/2A 3" 1 1/2" NPT 30.4 19.8 10.6 2.6 2.9 12
22Redi-Flo3-110 1/2B 3" 1 1/2" NPT 31.5 19.8 11.6 2.6 2.9 13
22Redi-Flo3-140 3/4B 3" 1 1/2" NPT 33.6 19.8 13.7 2.6 2.9 13
22Redi-Flo3-180 1C 3" 1 1/2" NPT 38.2 21.3 16.9 2.6 2.9 16
22Redi-Flo3-210 1 1/2C 3" 1 1/2" NPT 38.2 21.3 16.9 2.6 2.9 16
Note: Weights include pump ends with motors
0 4 8 12 16 20 24 28 32
0
50
100
150
200
250
300
350
CAPACITY (GPM)
HEAD (FEET)
-210
-180
-140
-110
-80
-40
1 1/2" NPT

15
Redi-Flo3 Technical Specifications
Pos. Component Material DIN W. AISI
Nr.
1 Valve Casing PVDF
1a Discharge Chamber Stainless Steel 1.4401 316
1d O-Ring FPM Rubber
2 Valve Cone PVDF
3 Valve Seat FPM Rubber
9b Top Chamber PVDF
4a Empty Chamber PVDF
6 Top Bearing FPM Rubber
7 Neck Ring PVDF
7a Lock Ring Stainless Steel 1.4401 316
32 Guide Vanes PVDF
9c Bottom Chamber PVDF
13 Impeller w/ tungsten PVDF
carbide bearing
14 Suction Interconnector PVDF
14a Ring Stainless Steel 1.4401 316
16 Shaft w/ Stainless Steel 1.4401 316
coupling Sintered Steel
18 Cable Guard Stainless Steel 1.4401 316
18a-b Cable Guard Screws Stainless Steel 1.4401 316
30 Pressure Equalization Cone PVDF
39 Valve Spring Stainless Steel 1.4406 316LN
55 Pump Sleeve Stainless Steel 1.4401 316
70 Valve Guide PVDF
64 Priming Screw PVDF
86 Lip Seal Ring FPM Rubber
MATERIAL SPECIFICATION – REDI-FLO3 PUMP END
1d
7a
1
70
2
39
3
1a
55
16
30
86
87
64
18
18b
18a
6
4a
9b
32
13
9c
7
14
14a

16
Redi-Flo3 Technical Specifications
Pos. Component Material DIN W. AISI
Nr.
1 Stator Stainless Steel 1.4401 316
2 Rotor Stainless Steel 1.4401 316
2a Stop Ring PP
2b Filter Polyester
3 Thrust Bearing Carbon
5 Radial Bearing Ceramic/
tungsten carbide
20 Motor Cable Tefzel
w/ plug PVDF
22a Filling Plug FPM Rubber
24 O-Ring FPM Rubber
24a O-Ring FPM Rubber
25 Top Cover PPS
27 Filter Polyester
32 Shaft Seal FPM Rubber
Motor Liquid SML-2
MATERIAL SPECIFICATION – REDI-FLO3 PUMP MOTOR

17
Redi-Flo3 Technical Data
ELECTRIC
Supply Voltage: 1x200-240V +6%/-10%, 50/60 Hz, PE
1x100-115V
Operation via Generator: As a minimum, the generator output
must be equal to the motor P1[KW] +10%
Starting Current: The motor starting current is equal to the
highest value stated on the motor nameplate
Starting: Soft-start
Run-up Time: Maximum: 2 seconds
Motor Protection: The motor is protected against:
Dry running, overvoltage, undervoltage,
overload, overtemperature
Power Factor: PF=1
Service Factor: 0.33-0.50A[Hp]-1.75 at 115V/230V
0.50-0.75B[Hp]-1.4 at 230V
1.0-1.5C[Hp]-1.15 at 230V
Motor Cable: 3 Wire, Tefzel Cable Kit
Motor Liquid: Type SML 2
pH Values: 2-13
Liquid Temperature: The temperature of the pumped liquid should
not exceed 104ºF.
Note: If liquids with a viscosity higher than that of water are to be pumped,
please contact GRUNDFOS
Minimum Ambient Temperature: -4° F
Maximum Ambient Temperature: +140° F
Frost Protection: If the pump is to be stored after use, it must be stored
in a frost-free location or it must be ensured that the
motor liquid is frost-proof. Otherwise motor must be
stored without being filled with motor liquid.
OPERATING CONDITIONS
Minimum Ambient Fluid Temperature: -4° F
Maximum Ambient Fluid Temperature: +104° F
APPROXIMATE DIMENSIONS AND WEIGHT
Motor Dimensions (MSE - NE 3):
0.33-0.50A[Hp] 20.9" length x 2.68" diameter
0.50-0.75B[Hp] 20.9" length x 2.68" diameter
1.0-1.5C[Hp] 22.3" length x 2.68" diameter
Pump Diameter, incl. cable guard: 2.91"
Motor Weights (MSE - NE 3):
0.33-0.50A[Hp] 6.0 lbs
0.50-0.75B[Hp] 7.1 lbs
1.0-1.5C[Hp] 8.2 lb
Pump End Dimensions:
Pump Diameter: 2.68"
Pump Diameter, incl. cable guard: 2.91"
Pump End Dimensions (min. and max.):
10 Redi-Flo3 10.6" to 16.9"
22 Redi-Flo3 10.6" to 16.9"
Pump End Weights (min. and max.):
All 2.2 lbs to 3.5 lbs
Well Diameter (minimum): 3"
Installation Depth (maximum): 500 feet, below static water level

18
CU300 Status Box
Description Product no.
CU300 Status Box 96422776
Description Product no.
CU 300 PC Tool Software 96432875
CU 300 PC Tool Software
R100 Remote Control
Description Product no.
The R100 is used for wireless infrared 625333
communication with the CU300
Potentiometer
Description Version Product no.
External potentiometer with cabinet for wall mounting. Grundfos potentiometer, SPP1 655468
Screened cables, 4-wire cable, max. length of cable: 100m Enclosure class: IP 55
Redi-Flo3 - Flow Sleeve
Description Product no.
Flow Sleeve Complete 96037505
Redi-Flo3 Accessories
No contact
Overvoltage
Undervoltage
Dry running
Speed reduction
Overtemperature
Overload
Sensor alarm

19
Notes

20
Notes