Grundfos TPE 2 Series User manual

TPE2 (D), TPE3 (D)
Installation and operating instructions
GRUNDFOS INSTRUCTIONS

English (GB)
2
English (GB) Installation and operating instructions
Original installation and operating instructions
CONTENTS
Page
1. Symbols used in this document 3
2. Abbreviations and definitions 3
3. General information 4
3.1 Radio communication 4
3.2 Battery 4
4. Delivery and handling 4
4.1 Delivery 4
4.2 Handling 4
5. Applications 5
5.1 Pumped liquids 5
6. Mechanical installation 5
6.1 Pipework 6
6.2 Terminal box positions 6
6.3 Fitting of pump head 7
6.4 Base plate 7
6.5 Insulation 7
6.6 Frost protection 7
6.7 Ensuring motor cooling 8
6.8 Outdoor installation 8
7. Electrical installation 8
7.1 Protection against electric shock (indirect contact) 8
7.2 Mains supply 9
7.3 Additional protection 10
7.4 Connection terminals 10
7.5 Signal cables 14
7.6 Bus connection cable 14
8. Startup 14
8.1 Flushing the pipe system 14
8.2 Priming the pump 14
8.3 Starting the pump 15
8.4 Shaft seal run-in 15
9. Operating conditions 15
9.1 Maximum number of starts and stops 15
9.2 Alternating operation of twin-head pumps 15
9.3 Liquid temperature 15
9.4 Ambient temperature 15
9.5 Operating pressure/test pressure 15
9.6 Inlet pressure 15
9.7 Electrical data 15
9.8 Sound pressure level 15
9.9 Environment 15
9.10 Installation altitude 16
9.11 Humidity 16
9.12 Motor cooling 16
10. User interfaces 16
11. Standard control panel 17
11.1 Setpoint setting 17
12. Advanced control panel 19
12.1 Home display 19
12.2 Startup guide 19
12.3 Menu overview for advanced control panel 20
13. Grundfos GO 23
13.1 Communication 23
13.2 Menu overview for Grundfos GO main menus 24
14. Description of functions 27
14.1 Heat energy meter 27
14.2 Setpoint 27
14.3 Operating mode 27
14.4 Set manual speed 27
14.5 Control mode 28
14.6 FLOWLIMIT 33
14.7 Automatic Night Setback 33
14.8 Analog inputs 33
14.9 Built-in Grundfos sensor 34
14.10 Pt100/1000 inputs 35
14.11 Digital inputs 35
14.12 Digital inputs/outputs 36
14.13 Signal relays 1 and 2 (Relay outputs) 36
14.14 Analog output 37
14.15 Controller (Controller settings) 38
14.16 Operating range 39
14.17 External setpoint function 39
14.18 Predefined setpoints 42
14.19 Temperature influence 42
14.20 Limit-exceeded function 43
14.21 Pulse flowmeter setup 43
14.22 Ramps 44
14.23 Standstill heating 44
14.24 Motor bearing monitoring 44
14.25 Service 44
14.26 Number (Pump number) 44
14.27 Radio communication (Enable/disable radio comm.) 45
14.28 Language 45
14.29 Date and time (Set date and time) 45
14.30 Unit configuration (Units) 45
14.31 Buttons on product (Enable/disable settings) 45
14.32 Delete history 45
14.33 Define Home display 45
14.34 Display settings 45
14.35 Store settings (Store actual settings) 46
14.36 Recall settings (Recall stored settings) 46
14.37 Undo 46
14.38 Pump name 46
14.39 Connection code 46
14.40 Run start-up guide 47
14.41 Alarm log 47
14.42 Warning log 47
14.43 Assist 47
14.44 Assisted pump setup 47
14.45 Setup, analog input 48
14.46 Setting of date and time 48
14.47 Multipump setup (Setup of multi-pump system) 48
14.48 Description of control mode 50
14.49 Assisted fault advice 50
15. Selecting control mode 51
16. Changing the position of the control panel 53
17. Bus signal 54
18. Priority of settings 54
19. Grundfos Eye 55
20. Signal relays 56
21. Installation of communication interface module
(CIM) 57
22. Identifying the functional module 59
23. Identifying the control panel 59
24. Maintenance and service 60
24.1 Maintenance 60
24.2 Service 60
25. Fault finding 61
26. Megging 62
27. Technical data, single-phase motors 62
27.1 Supply voltage 62
27.2 Leakage current 62
28. Technical data, three-phase motors 62
28.1 Supply voltage 62
28.2 Leakage current 62
29. Inputs or outputs 62
30. Other technical data 63
31. Factory settings 64
32. Disposing of the product 65

English (GB)
3
1. Symbols used in this document
2. Abbreviations and definitions
Warning
Prior to installation, read these installation and
operating instructions. Installation and operation
must comply with local regulations and accepted
codes of good practice.
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
The surface of the product may be so hot that it may
cause burns or personal injury.
Warning
Risk of dropping objects which may cause personal
injury.
Warning
Escaping vapour involves the risk of 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.
AI Analog input
AL Alarm, out of range at lower limit
AO Analog output
AU Alarm, out of range at upper limit
Current sinking The ability to draw current into the terminal and
guide it towards earth in the internal circuitry.
Current
sourcing
The ability to push current out of the terminal
and into an external load which must return it
to earth.
DI Digital input
DO Digital output
ELCB Earth-leakage circuit breaker
FM Functional module
GDS Grundfos Digital Sensor.
Factory-fitted sensor in some Grundfos pumps.
GENIbus Proprietary Grundfos fieldbus standard.
GFCI Ground fault circuit interrupter.
(USA and Canada).
GND Earth
Grundfos Eye Status indicator light
LIVE Low voltage with the risk of electric shock if the
terminals are touched.
OC Open collector:
Configurable open-collector output.
PE Protective earth
PELV
Protective extra-low voltage.
A voltage that cannot exceed ELV under
normal conditions and under single-fault
conditions, except earth faults in other circuits.
SELV
Safety extra-low voltage.
A voltage that cannot exceed ELV under
normal conditions and under single-fault
conditions, including earth faults in other
circuits.
TPE2 Single-head pump without factory-fitted
differential-pressure and temperature sensor.
TPE2 D Twin-head pump without factory-fitted
differential-pressure and temperature sensor.
TPE3 Single-head pump with factory-fitted
differential-pressure and temperature sensor.
TPE3 D Twin-head pump with factory-fitted
differential-pressure and temperature sensor.

English (GB)
4
3. General information
These installation and operating instructions apply to the
Grundfos TPE2, TPE2 D and TPE3, TPE3 D pumps.
The pumps are fitted with frequency-controlled
permanent-magnet motors for single-phase or three-phase mains
connection.
3.1 Radio communication
This product incorporates a radio module for remote control
which is a class 1 device and can be used anywhere in the EU
without restrictions.
For use in USA and Canada, see page 66.
This product can communicate with Grundfos GO and other
products of the same type via the built-in radio module.
In some cases, an external antenna may be required.
Only Grundfos-approved external antennas may be connected to
this product, and only by a Grundfos-approved installer.
3.2 Battery
Pumps with the advanced functional module, FM 300, incorporate
a Li-ion battery. The Li-ion battery complies with the Battery
Directive (2006/66/EC). The battery does not contain mercury,
lead and cadmium.
4. Delivery and handling
4.1 Delivery
The pump is delivered from the factory in a carton with a wooden
bottom, specially designed for transport by fork-lift truck or a
similar vehicle.
4.2 Handling
Lift the pump by means of nylon straps. See figures 1and 2.
Fig. 1 TPE2, TPE3
Fig. 2 TPE2 D, TPE3 D
Note
Some variants of these products and all products
sold in China and Korea have no possibility of radio
communication according to local legislation.
Warning
TPE2 D, TPE3 D: Do not use the centrally positioned
thread of the pump housing for lifting purposes as the
thread is placed below the centre of gravity of the
pump.
TM05 7914 1613TM05 7915 1613

English (GB)
5
5. Applications
The pumps are designed to circulate hot or cold water in
residential, institutional and industrial applications:
• heating systems
• district heating plants
• central heating systems for blocks of flats
• air-conditioning systems
• cooling systems.
In addition, the pumps are used for liquid transfer and water
supply in for instance:
• washing systems
• domestic hot-water systems
• industrial systems in general.
To ensure optimum operation, the dimensioning range of the
system must fall within the performance range of the pump.
5.1 Pumped liquids
The pump is suitable for thin, clean, non-aggressive and
non-flammable liquids, not containing solid particles or fibres that
may attack the pump mechanically or chemically.
Examples:
• Central heating system water (the water must meet the
requirements of accepted standards on water quality in
heating systems)
• cooling liquids
• domestic hot water
• industrial liquids
• softened water.
The pumping of liquids with a density and/or kinematic viscosity
higher than that of water will have the following effects:
• a considerable pressure drop
• a drop in hydraulic performance
• a rise in power consumption.
In such cases, fit the pump with a bigger motor. If in doubt,
contact Grundfos.
The EPDM O-rings fitted as standard are primarily suitable for
water.
If the water contains mineral/synthetic oils or chemicals or if other
liquids than water are pumped, chose the O-rings accordingly.
6. Mechanical installation
Install the pump in a dry well-ventilated, but frost-free position.
When installing pumps with oval bolt holes in the pump flange
(PN 6/10), use washers as shown in fig. 3.
Fig. 3 Use of washers for oval bolt holes
Arrows on the pump housing show the direction of flow of liquid
through the pump.
The pump can be installed in horizontal or vertical pipes.
For inspection and removal of motor or pump head, a clearance
of 300 mm is required above the motor. See fig. 4.
Fig. 4 Required clearance above the motor
Twin-head pumps installed in horizontal pipes must be fitted with
an automatic air vent in the upper part of the pump housing. See
fig. 5.
The automatic air vent is not supplied with the pump.
Fig. 5 Automatic air vent
Warning
If the pump is used for a liquid which is injurious to
health, it will be classified as contaminated. In such
cases, take proper precautions to avoid injury to
health when operating or working on the pump.
Warning
When pumping hot or cold liquids, make sure that
persons cannot accidentally come into contact with
hot or cold surfaces.
Note
In order to maintain the UL mark, follow the
additional installation procedures. See page 66.
TM01 0683 1997
Caution
The motor must never fall below the horizontal plane.
TM05 7916 1613TM05 7983 1713
Installation
Washer Pump
300 mm

English (GB)
6
If the liquid temperature falls below the ambient temperature,
condensation may form in the motor during standstill. In this case,
make sure that one of the drain holes in the motor flange is open
and points downwards. See fig. 6.
Fig. 6 Drain hole in motor flange
If twin-head pumps are used for pumping liquids with a
temperature below 0 °C (32 °F), condensed water may freeze
and cause the coupling to get stuck. You can solve the problem
by installing heating elements. Whenever possible, install the
pump with the motor shaft in horizontal position. See fig. 5.
6.1 Pipework
Fit isolating valves on either side of the pump to avoid draining
the system if the pump needs to be cleaned or repaired.
The pump is suitable for pipeline mounting, provided that the
pipework is adequately supported on either side of the pump.
Single-head pumps are designed for pipeline mounting only.
Twin-head pumps are prepared for installation on a mounting
bracket or base plate.
When installing the pipes, make sure that the pump housing is
not stressed by the pipework.
The inlet and outlet pipes must be of an adequate size, taking the
pump inlet pressure into account.
To avoid sediment build-up, do not fit the pump at the lowest point
of the system.
Install the pipes so that air locks are avoided, especially on the
inlet side of the pump. See fig. 7.
Fig. 7 Correct pipework on the inlet side of the pump
If there is any risk of the pump running against a closed outlet
valve, ensure a minimum liquid flow through the pump by
connecting a bypass or a drain to the outlet pipe. The drain can
for instance be connected to a tank. A minimum flow rate of 10 %
of the flow rate at maximum efficiency is needed at all times.
Flow rate and head at maximum efficiency are stated on the
pump nameplate.
6.2 Terminal box positions
You can turn the terminal box to any position. Change the
terminal box position as follows:
1. Loosen the clamp securing the pump head to the pump
housing. See fig. 8.
Fig. 8 Clamp (A)
2. Turn the pump head to the required position.
3. Check the following before the clamp is tightened:
– The contact face of the pump housing and that of the pump
head must be in full contact.
– The clamp must be positioned correctly in the flange recess
of both the pump head and the pump housing. See fig. 11.
Torque: 8 Nm (± 1 Nm).
TM05 7917 1613
Caution
Observe the conditions in section 9. Operating
conditions.
TM00 2263 0195
Caution
The pump must not run against a closed outlet valve
or this will cause an increase in
temperature/formation of steam in the pump which
may cause damage to the pump.
Warning
Before starting work on the pump, make sure that the
power supply has been switched off for at least 5
minutes. Make sure that the power supply cannot be
accidentally switched on.
Warning
If the pump head has been lifted partly or completely
from the pump housing, pay special attention when
fitting the pump head again. See section 6.3 Fitting
of pump head.
Warning
When loosening the clamp, do not drop the pump
head. See fig. 8.
Warning
When loosening the clamp, there is a risk of
escaping vapour. See fig. 8.
TM06 0721 0814
A

English (GB)
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6.3 Fitting of pump head
If for some reason the pump head has been lifted from the pump
housing, follow the following procedure in order to mount the
pump head correctly:
1. Visually check that the neck ring is centred in the pump
housing. See fig. 9.
Fig. 9 Centring of neck ring
2. Gently lower the pump head with rotor shaft and impeller into
the pump housing. See fig. 10.
Fig. 10 Lowering of pump head
3. Check the following before you tighten the clamp:
– The contact face of the pump housing and that of the pump
head must be in full contact.
– The clamp must be positioned correctly in the flange recess
of both the pump head and the pump housing. See fig. 11.
Torque: 8 Nm (± 1 Nm).
Fig. 11 Positioning of clamp ring
6.4 Base plate
Twin-head pumps have tapped holes in the bottom of the pump
housing. You can use the holes for mounting a base plate.
6.5 Insulation
Follow the guidelines in fig. 12 when insulating the pump.
Fig. 12 Insulation of TPE2, TPE3 pumps
6.6 Frost protection
Drain pumps which are not being used during periods of frost to
avoid damage.
Warning
Before starting work on the pump, make sure that the
power supply has been switched off for at least 5
minutes. Make sure that the power supply cannot be
accidentally switched on.
Warning
If the pump head has been lifted partly or completely
from the pump housing, pay special attention when
fitting the pump head again. See instructions below.
Warning
Do not drop the pump head. See fig. 8.
Warning
When loosening the clamp, there is a risk of
escaping vapour. See fig. 8.
TM06 0722 0814TM06 0723 0814
TM06 0724 0814
Caution
Do not insulate the motor stool as this will trap any
vapour escaping from the shaft seal, thus causing
corrosion. Covering the motor stool with insulation
will also make inspection and service difficult.
TM05 7918 1613
Pos. Description
A Without insulation
B Correct insulation
C Incorrect insulation
A
BC

English (GB)
8
6.7 Ensuring motor cooling
Fig. 13 Minimum distance (D) from the motor to a wall or other
fixed objects
6.8 Outdoor installation
When you install the motor outdoors, provide the motor with a
suitable cover to avoid condensation on the electronic
components. See fig. 14.
The cover must be sufficiently large to ensure that the motor is
not exposed to direct sunlight, rain or snow. Grundfos does not
supply covers. We therefore recommend that you have a cover
built for the specific application. In areas with high humidity, we
recommend that you enable the built-in standstill heating
function.
Fig. 14 Examples of covers
7. Electrical installation
Carry out the electrical connection according to local regulations.
Check that the supply voltage and frequency correspond to the
values stated on the nameplate.
7.1 Protection against electric shock (indirect contact)
Protective earth conductors must always have a yellow/green
(PE) or yellow/green/blue (PEN) colour marking.
7.1.1 Protection against mains voltage transients
The motor is protected against mains voltage transients in
accordance with EN 61800-3.
7.1.2 Motor protection
The motor requires no external motor protection. The motor
incorporates thermal protection against slow overloading and
blocking.
Note
In order to ensure sufficient cooling of the motor, the
distance (D) between the end of the fan cover and a
wall or other fixed objects must always be at least 50
mm (irrespective of motor size). See fig. 13.
TM05 5236 3512
Note
When fitting a cover to the motor, observe the
guideline in section 6.7 Ensuring motor cooling.
TM05 7919 1613
D
Warning
Before making any connections in the terminal box,
make sure that the power supply has been switched
off for at least 5 minutes. Make sure that the power
supply cannot be accidentally switched on.
Connect the motor to an external all-pole mains
switch according to local regulations.
Earth and protect the motor against indirect contact
in accordance with local regulations.
If the power supply cable is damaged, it must be
replaced by the manufacturer, the manufacturer's
service partner or a similarly qualified person.
Note
The user or the installer is responsible for the
installation of correct earthing and protection
according to local regulations. All operations must be
carried out by a qualified electrician.
Warning
Earth and protect the motor against indirect contact
in accordance with local regulations.

English (GB)
9
7.2 Mains supply
7.2.1 Single-phase supply voltage
• 1 x 200-240 V - 10 %/+ 10 %, 50/60 Hz, PE.
Check that the supply voltage and frequency correspond to the
values stated on the nameplate.
The wires in the motor terminal box must be as short as possible.
Excepted from this is the separated earth conductor which must
be so long that it is the last one to be disconnected in case the
cable is inadvertently pulled out of the cable entry.
For maximum backup fuse, see section 27.1 Supply voltage.
Fig. 15 Example of a mains-connected motor with mains
switch, backup fuse and additional protection
Fig. 16 Mains connection, single-phase motors
7.2.2 Three-phase supply voltage
• 3 x 380-500 V - 10 %/+ 10 %, 50/60 Hz, PE.
Check that the supply voltage and frequency correspond to the
values stated on the nameplate.
The wires in the motor terminal box must be as short as possible.
Excepted from this is the separated earth conductor which must
be so long that it is the last one to be disconnected in case the
cable is inadvertently pulled out of the cable entry.
For maximum backup fuse, see section 28.1 Supply voltage.
Fig. 17 Example of a mains-connected motor with mains
switch, backup fuses and additional protection
Fig. 18 Mains connection, three-phase motors
Note
If the motor is supplied through an IT network, use a
dedicated IT network motor. Contact Grundfos.
TM05 4034 1912TM05 3494 1512
Caution
In order to avoid loose connections, ensure that the
terminal block for L1, L2 and L3 is pressed home in
its socket when you have connected the supply
cable.
Note
Corner grounding is not allowed for supply voltages
above 3 x 480 V, 50/60 Hz.
Note
If the motor is supplied through an IT network, use a
dedicated IT network motor. Contact Grundfos.
TM05 3942 1812TM05 3495 1512
L1
L2
L3
L2
L1
L3
PE

English (GB)
10
7.3 Additional protection
7.3.1 Single-phase motors
If the motor is connected to an electric installation where an earth
leakage circuit breaker (ELCB) or ground fault circuit interrupter
(GFCI) is used as additional protection, this circuit breaker or
interrupter must be marked with the following symbol:
You find the leakage current of the motor in section 27.2 Leakage
current.
7.3.2 Three-phase motors
If the motor is connected to an electric installation where an earth
leakage circuit breaker (ELCB) or ground fault circuit interrupter
(GFCI) is used as additional protection, this circuit breaker or
interrupter must be of the following type:
• It must be suitable for handling leakage currents and cutting-in
with short pulse-shaped leakage.
• It must trip out when AC fault currents and fault currents with
DC content, i.e. pulsating DC and smooth DC fault currents,
occur.
For these motors, use an earth leakage circuit breaker or ground
fault circuit interrupter, type B.
The circuit breaker or interrupter must be marked with the
following symbols:
You find the leakage current of the motor section 28.2 Leakage
current.
Protection against phase unbalance
Connect the motor to a power supply with a quality corresponding
to IEC 60146-1-1, class C, to ensure correct motor operation at
phase unbalance.
This also ensures long life of the components.
7.4 Connection terminals
The descriptions and terminal overviews in this section apply to
both single-phase and three-phase motors.
For maximum tightening torques, see section Torques, page 63.
The number of terminals depends on the functional module. See
section 22. Identifying the functional module.
7.4.1 Connection terminals, advanced functional module, FM
300
The advanced functional module is only available as an option.
The advanced module has these connections:
• three analog inputs
• one analog output
• two dedicated digital inputs
• two configurable digital inputs or open-collector outputs
• Input and output for Grundfos Digital Sensor
• two Pt100/1000 inputs
• two LiqTec sensor inputs
• two signal relay outputs
• GENIbus connection.
See fig. 19.
• Inputs and outputs
All inputs and outputs are internally separated from the
mains-conducting parts by reinforced insulation and
galvanically separated from other circuits.
All control terminals are supplied by safety extra-low voltage
(SELV), thus ensuring protection against electric shock.
• Signal relay outputs
– Signal relay 1:
LIVE:
Mains supply voltages up to 250 VAC can be connected to
this output.
SELV:
The output is galvanically separated from other circuits.
Therefore, you can connect the supply voltage or safety
extra-low voltage to the output.
– Signal relay 2:
SELV:
The output is galvanically separated from other circuits.
Therefore, you can connect the supply voltage or safety
extra-low voltage to the output as desired.
• Mains supply, terminals N, PE, L or L1, L2, L3, PE
A galvanically safe separation must fulfil the requirements for
reinforced insulation including creepage distances and
clearances specified in EN 61800-5-1.
Note
When an earth leakage circuit breaker or ground
fault circuit interrupter is selected, take the total
leakage current of all the electrical equipment in the
installation into account.
Note
When an earth leakage circuit breaker or ground
fault circuit interrupter is selected, take the total
leakage current of all the electrical equipment in the
installation into account.
ELCB
(GFCI)
ELCB
(GFCI)
Note
Digital input 1 is factory-set to be start/stop input
where open circuit will result in stop.
A jumper has been factory-fitted between terminals 2
and 6. Remove the jumper if digital input 1 is to be
used as external start/stop or any other external
function.
Note
As a precaution, the wires to be connected to the
connection groups below must be separated from
each other by reinforced insulation in their entire
lengths.