Grundfos SCALA User manual

SCALA
Installation and operating instructions
GRUNDFOS INSTRUCTIONS
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English (GB)
2
English (GB) Installation and operating instructions
Original installation and operating instructions
These installation and operating instructions describe Grundfos
SCALA2 domestic water supply pumps.
Sections 1-5 give the information necessary to be able to unpack,
install and start up the product in a safe way.
Sections 6-14 give important information about the product, as
well as information on service, fault finding and disposal of the
product.
CONTENTS
Page
1. General information
1.1 Target group
These installation and operating instructions are intended for
professional as well as non-professional users.
1.2 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. General information 2
1.1 Target group 2
1.2 Hazard statements 2
1.3 Notes 3
2. Receiving the product 3
2.1 Inspecting the product 3
2.2 Scope of delivery 3
3. Installing the product 3
3.1 Location 3
3.2 System sizing 3
3.3 Mechanical installation 3
3.4 Electrical connection 6
4. Starting up the product 6
4.1 Priming the pump 6
4.2 Starting the pump 6
4.3 How to set the correct pressure 7
4.4 Shaft seal run-in 7
5. Handling and storing the product 7
5.1 Handling the product 7
5.2 Storing the product 7
6. Product introduction 7
6.1 Product description 7
6.2 Intended use 8
6.3 Pumped liquids 8
6.4 Identification 8
7. Control functions 9
7.1 Menu overview, SCALA2 9
8. Setting the product 10
8.1 Setting the outlet pressure 10
8.2 Locking and unlocking the operating panel 10
8.3 Expert settings, SCALA2 10
8.4 Resetting to factory settings 11
9. Servicing the product 11
9.1 Maintaining the product 11
9.2 Customer service information 12
9.3 Service kits 12
10. Starting up the product after standstill 12
10.1 Deblocking the pump 12
11. Taking the product out of operation 12
12. Fault finding the product 13
12.1 Grundfos Eye operating indications 13
12.2 Fault resetting 13
12.3 Fault finding chart 14
13. Technical data 16
13.1 Operating conditions 16
13.2 Mechanical data 16
13.3 Electrical data 16
13.4 Dimensions and weights 16
14. Disposing of the product 16
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.
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.

English (GB)
3
1.3 Notes
The symbols and notes below may appear in Grundfos
installation and operating instructions, safety instructions and
service instructions.
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
The box contains the following items:
• 1 Grundfos SCALA2 pump
• 1 quick guide
• 1 safety instructions booklet.
3. Installing the product
3.1 Location
The pump can be installed indoors or outdoors, but it must not be
exposed to frost.
We recommend that you install the pump near a drain or in a drip
tray connected to a drain in order to lead away possible
condensation from cold surfaces.
3.1.1 Minimum space
The pump requires a minimum space of 430 x 215 x 325 mm (17
x 8.5 x 12.8 inches).
Even though the pump does not require much space, we
recommend that you leave enough space for service and
maintenance access.
3.1.2 Installing the product in frosty environment
Protect the pump from freezing if it is to be installed outdoors
where frost may occur.
3.2 System sizing
The pump is factory-set to 3 bar (44 psi) outlet pressure which
can be adjusted according to the system in which it is
incorporated.
The tank precharge pressure is 1.25 bar (18 psi).
In case of suction lift of more than six metres, the pipe resistance
on the outlet side must be at least two metres water column or 3
psi at any given flow in order to obtain optimum operation.
3.3 Mechanical installation
3.3.1 Positioning the product
Always mount the pump on the base plate in a horizontal position
with a maximum inclination angle of ± 5 °.
3.3.2 Foundation
Fasten the pump to a solid horizontal foundation by means of
screws through the holes in the base plate. See figs 1and 2.
Fig. 1 Horizontal foundation
Fig. 2 Base plate
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.
Install the pump in such a way that no undesirable
collateral damage can arise due to leakage.
If the unlikely event of an internal leakage occurs, the
liquid will be drained through the bottom of the pump.
Make sure that the system in which the pump is
incorporated is designed for the maximum pump
pressure.
DANGER
Electric shock
Death or serious personal injury
- Switch off the power supply before starting any
work on the product. Make sure that the power
supply cannot be accidentally switched on.
TM06 5729 5315TM06 3809 1015
[mm (inches)]
A 181 (7.13)
B 130 (5.12)
C 144 (5.67)
B
A
C

English (GB)
4
3.3.3 Connecting the piping system
1. Turn the union nuts by hand to loosen the inlet and outlet
ports. See fig. 3.
2. Seal the pipe fittings with thread sealing tape.
3. Carefully screw the inlet and outlet connections to the pipe
fittings using a pipe wrench or similar tool. Keep the union nut
on the pipe fitting if you have removed it from the pump.
The pump is equipped with flexible connections, ± 5 °, to
facilitate the connection of inlet and outlet pipes.
4. Fasten the connections to the inlet and outlet. Hold the
connection with one hand and tighten the union nut with the
other hand.
Fig. 3 How to fit the connections
3.3.4 How to reduce noise in the installation
Vibrations from the pump may be transferred to the surrounding
structure and create noise in the 20-1000 Hz spectrum, also
called the bass spectrum.
Correct installation using a vibration-damping rubber pad, flexible
hoses and correctly placed pipe hangers for rigid pipes can
reduce the noise experienced by up to 50 %. See fig. 4.
Place pipe hangers for the rigid pipes close to the connection of
the flexible hose.
Fig. 4 How to reduce noise in the installation
3.3.5 Installation examples
Fittings, hoses and valves are not supplied with the pump.
We recommend to follow the installation examples in sections
3.3.6 to 3.3.8.
3.3.6 Mains water pressure boosting
Fig. 5 Mains water pressure boosting
Make sure that the pump is not stressed by the
piping system.
Always loosen and tighten the union nuts on the inlet
and outlet ports by hand. Damage to the inlet and
outlet parts increases the risk of leakage.
TM06 4318 1915
Pos. Description
1 Inlet and outlet port
2 Union nut
3 Pipe fitting
We recommend to use flexible hoses and mount the
pump on a vibration-damping rubber pad.
1
2
3
TM06 4321 1915TM06 4347 2015
Pos. Description
1 Highest tapping point
2 Pipe hangers and supports
3 Isolating valves
4 Flexible hoses
5 Bypass valve
6Optional pressure-reducing valve on the inlet side if the
inlet pressure can exceed 10 bar (145 psi)
7Optional pressure-relief valve on the outlet side if the
installation cannot withstand a pressure of 6 bar (87 psi)
8Drip tray. Install the pump on a small stand to prevent
the ventilation holes from being flooded.
9 Pressure gauge
10 Mains water pipe
Rubber pad
Pipe hanger for rigid pipe
Flexible hose
49
1
37
2
5
10
62
3
8

English (GB)
5
3.3.7 Suction from a well
Fig. 6 Suction from a well
3.3.8 Suction from freshwater tank
Fig. 7 Suction from freshwater tank
3.3.9 Inlet pipe length
The overview below shows the different possible inlet pipe
lengths, depending on the vertical pipe length.
The overview is only intended as a guide.
Fig. 8 Inlet pipe length
Preconditions:
TM06 4349 4117
Pos. Description
1 Highest tapping point
2 Isolating valve
3 Flexible hoses
4 Pipe support
5
Inlet filter.
If the water may contain sand, gravel or other debris,
please install a filter on the inlet side to protect the pump
and installation.
6 Foot valve with strainer (recommended).
H1 Maximum suction lift is 8 m (26 ft).
H2 Inlet pipe must be submersed at least 0.5 m (1.64 ft).
TM06 4348 4117
Pos. Description
1 Highest tapping point
2 Pipe hangers
3 Isolating valve
4 Flexible hoses
5 Drain to sewer
6
Inlet filter.
If the water may contain sand, gravel or other debris,
please install a filter on the inlet side to protect the pump
and installation.
7 Freshwater tank
H2 H1
6
54
23
1
A
1
2
34
6
7
8
5
8 Foot valve with strainer (recommended)
A Minimum 1 ° inclination
TM06 4372 4117
DN 32 DN 40
H
[m (ft)]
L
[m (ft)]
H
[m (ft)]
L
[m (ft)]
0 (0) 68 (223) 0 (0) 207 (679)
3 (10) 43 (141) 3 (10) 129 (423)
6 (20) 17 (56) 6 (20) 52 (171)
7 (23) 9 (30) 7 (23) 26 (85)
8 (26) 0 (0) 8 (26) 0 (0)
Maximum flow velocity: 1 l/s (16 gpm).
Inside roughness of pipes: 0.01 mm (0.0004 inch).
Size Inside pipe diameter
[mm (inches)]
Pressure loss
[m/m (psi/ft)]
DN 32 28 (1.1) 0.117 (5/100)
DN 40 35.2 (1.4) 0.0387 (1.6/100)
Pos. Description
H
L

English (GB)
6
3.4 Electrical connection
3.4.1 Motor protection
The pump incorporates current and temperature dependent
motor protection.
3.4.2 Plug connection
3.4.3 Connection without plug
4. Starting up the product
4.1 Priming the pump
1. Unscrew the priming plug and pour minimum 1.7 litres (0.45
gallons) of water into the pump housing. See fig. 9.
2. Screw the priming plug on again.
4.2 Starting the pump
1. Open a tap to prepare the pump for venting.
2. Insert the power plug into the socket or turn on the power
supply and the pump will start.
3. When water flows without air, close the tap.
4. Open the highest tapping point in the installation, preferably a
shower.
5. Adjust the pressure setpoint to the required pressure by
means of the buttons. See section 4.3 How to set the
correct pressure.
6. Close the tapping point.
Startup has been completed.
Fig. 9 Priming the pump
Carry out the electrical connection according to local
regulations.
Check that the supply voltage and frequency
correspond to the values stated on the nameplate.
DANGER
Electric shock
Death or serious personal injury
- Switch off the power supply before starting any
work on the product. Make sure that the power
supply cannot be accidentally switched on.
DANGER
Electric shock
Death or serious personal injury
- The pump must be earthed.
- The pump is supplied with a grounding conductor
and grounding-type attachment plug. To reduce
the risk of electric shock, be certain that the pump
is connected only to a properly grounded,
grounding type receptacle (protective earthing).
- If national legislation requires a Residual Current
Device (RCD), a Ground Fault Circuit Interrupter
(GFCI), or equivalent in the electrical installation,
this must be type B (according to UL/IEC
61800-5-1) or better, due to the nature of the
constant DC leakage current.
If the power supply cable is damaged, it must be
replaced by the manufacturer, his service agent or
similarly qualified persons in order to avoid hazard.
We recommend that you fit the permanent
installation with a residual-current circuit breaker
(RCCB) with a tripping current less than 30 mA.
DANGER
Electric shock
Death or serious personal injury
- Check that the power plug delivered with the
product is in compliance with local regulations.
- Make sure that the pump is connected only to a
properly grounded, grounding-type receptacle
(protective earthing).
- The protective earth of the power outlet must be
connected to the protective earth of the pump. The
plug must therefore have the same PE connection
system as the power outlet. If not, use a suitable
adapter.
The electrical connection must be carried out by an
authorised electrician in accordance with local
regulations.
DANGER
Electric shock
Death or serious personal injury
- The pump must be connected to an external main
switch with a minimum contact gap of 3 mm (0.12
inch) in all poles.
Do not start the pump until it has been filled with
liquid.
If the suction depth exceeds 6 m (20 ft), it may be
necessary to prime the pump more than once.
Always tighten priming and drain plugs by hand.
TM06 4204 1615

English (GB)
7
4.3 How to set the correct pressure
The pump can be set to provide a water pressure between 1.5 to
5.5 bar (22 to 80 psi) at intervals of 0.5 bar (7 psi).
The factory setting is 3 bar (44 psi). See section 3.2 System
sizing.
4.3.1 Boosting from a well or a tank
If you are boosting from a well or a tank, make sure not to set the
pressure setpoint too high. The difference between the inlet
pressure and outlet pressure must not exceed 3.5 bar (51 psi).
Fig. 10 Boosting from a well or a tank
4.3.2 Boosting from the mains
The pressure settings 4.5, 5.0 and 5.5 bar (65, 73 and 80 psi)
require a positive inlet pressure and these settings must only be
used when boosting from the water mains.
Fig. 11 Boosting from the mains
4.3.3 Self-learning setpoint
If the pump cannot reach the user-defined pressure setpoint, the
self-learning function will automatically lower the setpoint. See
section 8.3.2 Self-learning function.
4.4 Shaft seal run-in
The shaft seal faces are lubricated by the pumped liquid. A slight
leakage from the shaft seal of up to 10 ml per day or 8 to 10 drops
per hour may occur.
When the pump is started up for the first time, or when the shaft
seal has been replaced, a certain run-in period is required before
the leakage is reduced to an acceptable level. The time required
for this depends on the operating conditions, that is, every time
the operating conditions change, a new run-in period will be
started.
Under normal conditions, the leaking liquid will evaporate. As a
result, no leakage will be detected.
The leakage is visible where the screws are mounted on the base
plate. If the unlikely event of an internal leakage occurs, the liquid
will be drained through the bottom of the pump. Install the pump
in such a way that no undesirable collateral damage can arise.
5. Handling and storing the product
5.1 Handling the product
5.2 Storing the product
If the pump is to be stored for a period of time, for example during
the winter, drain it and store it indoors in a dry location. See
section 10. Starting up the product after standstill.
Temperature range during storing must be -40 to 70 °C (-40 to
158 °F).
6. Product introduction
6.1 Product description
Fig. 12 Grundfos SCALA2 pump
The inlet and outlet openings include flexible connections of ± 5 °.
We recommend to use the default pressure of 3.0 bar
(44 psi) which will suit most applications.
The difference between the inlet pressure and outlet
pressure must not exceed 3.5 bar (51 psi).
Example: If the inlet pressure is 0.5 bar (7 psi), the
maximum outlet pressure is 4 bar (58 psi).
If you set the pressure too high, this might cause the
pump to operate for up to three minutes after the tap
is turned off.
Maximum setpoint [bar (psi)]
Well application 3.0 (44)
Tank below ground level 3.5 (51)
Tank above ground level 4.0 (58)
TM07 0075 4117 TM07 0076 4117
TM07 0074 4117
Take care not to drop the pump as it may break.
Maximum relative humidity during storing: 95 % RH.
TM06 3818 1015
Pos. Description
1 Air valve for built-in pressure tank
2 Operating panel. See section 7. Control functions.
3 Nameplate. See section 6.4.1 Nameplate.
4Plug for access to pump shaft. See section
10.1 Deblocking the pump.
5 Priming plug. See section 4.1 Priming the pump.
6Outlet opening. See section 3.3.3 Connecting the piping
system.
7Inlet opening. See section 3.3.3 Connecting the piping
system.
8 Drain plug. See section 6.4 Identification.
9 Ventilation holes. They must not be flooded.
15
6
7
8
2
3
4
9

English (GB)
8
6.2 Intended use
The pump is suitable for pressure boosting of fresh water in
domestic water supply systems.
6.3 Pumped liquids
The pump is designed for fresh water with a maximum chloride
content of 300 ppm and a free chlorine content below 1 ppm.
The pump is not suitable for these liquids:
• liquids containing long fibres
• flammable liquids (oil, petrol, etc.)
• aggressive liquids.
6.4 Identification
6.4.1 Nameplate
Fig. 13 Example of nameplate
6.4.2 Type key
This pump has been evaluated for use with water
only.
Only use SCALA2 pumps according to the
specifications stated in these installation and
operating instructions.
If the water can contain sand, gravel or other debris,
there is a risk of pump blockage.
Please install a filter on the inlet side or apply a
floating strainer to protect the pump.
TM06 4340 2015
Pos. Description
1 Type designation
2 Product number
3 Serial number
4 Production code, year and week
5 Maximum head
6 Minimum head
7 Rated head
8 Rated flow rate
9 Maximum ambient temperature
10 Enclosure class
11 Maximum operation pressure
12 Maximum liquid temperature
13 Minimum and maximum rated power
14 Model
15 Voltage and frequency
16 Approvals
17 Minimum and maximum rated current
DK-8850 Bjerringbro, Denmark
SCALA2 3-45 AKCHDE
Model A
200-240V 50/60Hz
Made in Serbia
P/N 99999999
S/N 
P/C 1519
Hmax
Hmin
Hnom
Qnom
45 m
16 m
27 m
3m /h
3
45 C/
55 C
Tamb.max
IPX4D
I(A)
Min.
Max.
P1(W)
0.01
2.8 550
2
Tliq.max/Psyst.max:
1MPa
NRP XXX-XXX-XXXXXX
PCS XXXXX.XX.XX 04-6292.2.41-2003
LSPr-022-IDN
1
2
3
4
5
6
7
8
9
10
11
13
14
15
16
17
12
SCALA2 3 -45 A K C H D E
Type range
SCALA2
Rated flow rate
3: [m3/h]
Maximum head
45: [m]
Material code
A: Standard
Supply voltage
K: 1 x 200-240 V, 50/60 Hz
M: 1 x 208-230 V, 60 Hz
V: 1 x 115 V, 60 Hz
W: 1 x 100-115 V, 50/60 Hz
Motor
C: High-efficiency motor with frequency converter
Mains cable and plug
A: Cable with plug, IEC type I, AS/NZS3112, 2 m
B: Cable with plug, IEC type B, NEMA 5-15P, 6 ft
C: Cable with plug, IEC type E&F, CEE7/7, 2 m
D: Cable without plug, 2 m
G: Cable with plug, IEC type G, BS1363, 2 m
H: Cable with plug, IEC type I, IRAM 2073, 2 m
J: Cable with plug, NEMA 6-15P, 6 ft
K: Cable with plug, IEC type B, JIS C 8302, 2 m
L: Cable with plug, IEC type L, CEI 23-16/VII, 2 m
O: Cable with plug, IEC type O, TIS 166-2549, 2 m
Controller
D: Integrated frequency converter
Thread
E: R 1" composite material
F: NPT 1" composite material

English (GB)
9
7. Control functions
7.1 Menu overview, SCALA2
Fig. 14 SCALA2 operating panel
7.1.1 Pressure indicator, SCALA2
The pressure indicator shows the required outlet pressure from
1.5 to 5.5 bars (22 to 80 psi) in 0.5 bar (7.5 psi) intervals.
The illustration below shows a pump set to 3 bar (44 psi)
indicated by two green lights, and a pump set to 3.5 bar (51 psi)
indicated by one green light.
Flashing green lights indicate that the pump has automatically
lowered the pressure. See section 4.3.3 Self-learning setpoint.
Fig. 15 SCALA2 outlet pressure indication
Fig. 16 Pressure indication table
7.1.2 Indicator lights for SCALA2
* For fault number 4, dry running, the pump must be reset
manually.
For fault number 4, water shortage, and the remaining faults,
1, 2, 3, 5, 6 and 7, the pump will reset whenever the cause has
disappeared or been remedied. See section 8.3.3 Auto reset.
For further information about system status, see section 12. Fault
finding the product.
TM06 3301 5114
SCALA2 Function
On/off
Increases the outlet pressure.
Decreases the outlet pressure.
Resets alarms.
Indicates the required outlet pressure.
Indicates that the pump has been stopped manually.
Indicates that the operating panel is locked.
TM06 4345 2015
TM06 4187 4117
Indications Description
Operating indications
The operating panel is locked.
Power supply failure
The pump is blocked, for instance the shaft seal
has seized up.
Leakage in the system
Dry running or water shortage*
The maximum pressure has been exceeded or
the setpoint cannot be reached.
The maximum runtime has been exceeded.
The temperature is outside the range.
BAR PSI Water colum kPa MPa
[m]
5.5 80 55 550 0.55
5.0 73 50 500 0.50
4.5 65 45 450 0.45
4.0 58 40 400 0.40
3.5 51 35 350 0.35
3.0 44 30 300 0.30
2.5 36 25 250 0.25
2.0 30 20 200 0.20
1.5 22 15 150 0.15
}
}
}
}

English (GB)
10
8. Setting the product
The pump will remember the controller settings even if it is turned
off.
8.1 Setting the outlet pressure
Adjust the outlet pressure by pressing .
8.2 Locking and unlocking the operating panel
The operating panel can be locked, which means that the buttons
do not function and no settings can be changed accidentally.
How to lock the operating panel
1. Hold down the buttons simultaneously for 3 seconds.
2. The operating panel is locked when symbol lights up.
How to unlock the operating panel
1. Hold down the buttons simultaneously for 3 seconds.
2. The operating panel is unlocked when symbol turns off.
8.3 Expert settings, SCALA2
The expert setting menu allows the installer to toggle between the
following functions:
• self-learning
• auto reset
• anti cycling
• maximum continuous operating time.
8.3.1 Accessing the expert settings
Proceed as follows:
1. Hold down the button for 5 seconds.
2. The symbol will start flashing to indicate that the expert
settings are active.
The pressure indicator now acts as the expert menu. A flashing
green diode is the cursor. Move the cursor using the
buttons, and toggle the selection on or off using the button.
The diode for each setting will light up when the setting is active.
Fig. 17 Expert menu overview
8.3.2 Self-learning function
The factory setting for this function is "on".
On
If the pump cannot reach the user-defined pressure setpoint, the
self-learning function will automatically adjust the setpoint.
The pump will lower the setpoint to either 4.5, 3.5 or 2.5 bar (65,
51 or 36 psi).
The self-learned setpoint is indicated on the operating panel by
one flashing green light.
After every 24 hours, the pump will automatically attempt to revert
to the original user-defined setpoint. If this is not possible, the
pump will again return to the self-learned setpoint. The pump will
continue to operate with the self-learning setpoint, until the
user-defined setpoint can be reached.
Example:
The user-defined pressure is set to 5 bar (72 psi), indicated by
constant green lights on the pressure indicator panel.
The pump is unable to reach this pressure due to negative
pressure on the inlet side.
The self-learning function automatically adjusts the setpoint to 3.5
bar (51 psi), indicated by one flashing green light on the pressure
indicator panel.
After 24 hours, the pump will automatically try to adjust the
setpoint back to 5 bar (72 psi).
Fig. 18 User-defined setpoint (left) and self-learned setpoint
(right)
How to reset the self-learned setpoint
1. You can manually reset the settings by pressing any button on
the operating panel. The pump will immediately try to reach
the original setpoint.
2. If the pump keeps reducing the setpoint due to self-learning,
we recommend to reduce the setpoint manually on the
operating panel.
Off
If you set the self-learning function to off and the pump is unable
to reach the desired setpoint, the pump will show alarm 5.
Expert settings are for installers only.
Move cursor up.
Move cursor down.
Toggle settings.
TM06 4346 4117
Auto reset
Anti cycling
Maximum continuous
operating time
Exit expert menu
Self-learning
TM07 0078 4117 TM07 0079 4117