Grundfos TPE 2 Series User manual

TPE2 (D), TPE3 (D)
Installation and operating instructions
GRUNDFOS INSTRUCTIONS
Other languages
http://net.grundfos.com/qr/i/98450210

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 4
3. General information 4
4. General description 4
4.1 Radio communication 4
4.2 Battery 4
5. Receiving the product 5
5.1 Delivery 5
5.2 Transporting the product 5
5.3 Inspecting the product 5
5.4 Handling the product 5
6. Applications 5
6.1 Pumped liquids 6
7. Mechanical installation 6
7.1 Pipes 7
7.2 Terminal box positions 8
7.3 Fitting of pump head 8
7.4 Base plate 9
7.5 Insulation 10
7.6 Frost protection 10
7.7 Cable entries 10
7.8 Ensuring motor cooling 10
7.9 Outdoor installation 10
8. Electrical installation 11
8.1 Protection against electric shock,
indirect contact 11
8.2 Cable requirements 11
8.3 Mains supply 12
8.4 Additional protection 13
8.5 Connection terminals 13
8.6 Signal cables 16
8.7 Bus connection cable 16
9. Startup 17
9.1 Flushing the pipe system 17
9.2 Priming the pump 17
9.3 Starting the pump 17
9.4 Shaft seal run-in 17
10. Operating conditions 18
10.1 Maximum number of starts and stops 18
10.2 Alternating operation of twin-head
pumps 18
10.3 Liquid temperature 18
10.4 Ambient temperature 18
10.5 Operating pressure or test pressure 18
10.6 Inlet pressure 18
10.7 Electrical data 18
10.8 Sound pressure level 18
10.9 Environment 18
10.10 Installation altitude 19
10.11 Humidity 19
10.12 Motor cooling 19
11. User interfaces 20
12. Standard control panel 20
12.1 Setpoint setting 21
13. Advanced control panel 23
14. Home display 24
14.1 Start-up guide 24
14.2 Menu overview for advanced control
panel 25
15. Grundfos GO 28
15.1 Communication 28
15.2 Menu overview for Grundfos GO main
menus 29
16. Description of functions 32
16.1 "Heat energy monitor" 32
16.2 Setpoint 32
16.3 Operating mode 32
16.4 Set manual speed 33
16.5 "Set user-defined speed" 33
16.6 Control mode 33
16.7 "Proportional-pressure setup" 40
16.8 FLOWLIMIT 40
16.9 Automatic Night Setback 41
16.10 Analog inputs 41
16.11 Built-in Grundfos sensor 43
16.12 Pt100/1000 inputs 43
16.13 Digital inputs 44
16.14 Digital inputs/outputs 45
16.15 "Signal relays 1 and 2" (Relay outputs) 47
16.16 Analog output 47
16.17 "Controller" ("Controller settings") 48
16.18 Operating range 50
16.19 External setpoint function 50
16.20 "Predefined setpoints" 52
16.21 "Temperature influence" 53
16.22 Limit-exceeded function 53
16.23 "Pulse flowmeter setup" 54
16.24 "Ramps" 55
16.25 "Standstill heating" 55
16.26 Motor bearing monitoring 55
16.27 "Service" 56
16.28 "Number" (Pump number) 56
16.29 "Radio communication" (Enable/disable
radio comm.) 56
16.30 Language 56
16.31 "Date and time" (Set date and time) 57
16.32 "Unit configuration" (Units) 57
16.33 "Buttons on product" (Enable/disable
settings) 57
16.34 Delete history 57
16.35 Define Home display 58
16.36 Display settings 58
16.37 "Store settings" (Store actual settings) 58
16.38 "Recall settings" (Recall stored settings) 58
16.39 "Undo" 58

English (GB)
3
1. Symbols used in this document
The text accompanying the three hazard symbols
DANGER, WARNING and CAUTION is structured in
the following way:
16.40 "Pump name" 58
16.41 "Connection code" 59
16.42 Run start-up guide 59
16.43 Alarm log 59
16.44 Warning log 60
16.45 Assist 60
16.46 Assisted pump setup 60
16.47 Setup, analog input 60
16.48 Setting of date and time 61
16.49 "Multipump setup" (Setup of multi-pump
system) 61
16.50 Description of control mode 64
16.51 Assisted fault advice 64
17. Selecting control mode 65
18. Bus signal 67
19. Priority of settings 68
20. Grundfos Eye 69
21. Signal relays 70
22. Installing a communication interface
module 71
23. Identification of functional module 73
24. Identification of control panel 73
25. Changing the position of the control
panel 74
26. Servicing the product 75
26.1 Maintenance 75
26.2 Service 75
27. Cleaning the product 76
28. Fault finding 76
29. Megging 78
30. Technical data, single-phase motors 78
30.1 Supply voltage 78
30.2 Leakage current 78
31. Technical data, three-phase motors 78
31.1 Supply voltage 78
31.2 Leakage current, AC 78
32. Inputs and outputs 79
33. Other technical data 80
33.1 Torques 81
33.2 Sound pressure level 81
34. Factory settings 82
35. Disposing of the product 83
Read this document before installing the
product. Installation and operation must
comply with local regulations and accepted
codes of good practice.
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.
Tips and advice that make the work easier.
If these instructions are not observed, it
may result in malfunction or damage to the
equipment.
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.

English (GB)
4
2. Abbreviations and definitions 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.
4. General description
The pumps are fitted with frequency-controlled
permanent-magnet motors for single-phase or
three-phase mains connection.
4.1 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 member states without
restrictions.
For use in USA and Canada, see page 84.
Some variants of the product and products sold in
China and Korea have no radio module.
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.
4.2 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.
AI Analog input
AL Alarm, out of range at lower limit
AO Analog output
AU Alarm, out of range at upper limit
CIM Communication interface module
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.
RCD Residual-current device
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)
5
5. Receiving the product
5.1 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.
5.2 Transporting the product
5.3 Inspecting the product
Before you install the product, do the following:
• Check that the product is as ordered.
• Check that no visible parts have been damaged.
If parts are damaged or missing, contact your local
Grundfos sales company.
5.4 Handling the product
Observe local regulations setting limits for manual
lifting or handling. The motor weight is stated on the
nameplate.
Lift the pump by means of nylon straps. See figures
1and 2.
Fig. 1 TPE2, TPE3
Fig. 2 TPE2 D, TPE3 D
6. 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.
WARNING
Falling objects
Death or serious personal injury
- Secure the product during
transportation to prevent it from tilting or
falling down.
CAUTION
Crushing of feet
Minor or moderate personal injury
- Wear safety shoes when moving the
product.
CAUTION
Back injury
Minor or moderate personal injury
- Use lifting equipment.
CAUTION
Crushing of feet
Minor or moderate personal injury
- Wear safety shoes and attach lifting
equipment to the motor eyebolts when
handling the product.
Do not lift the product by the terminal box.
TM05 7914 1613TM05 7915 1613

English (GB)
6
6.1 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 or synthetic oils or
chemicals or if other liquids than water are pumped,
chose the O-rings accordingly.
7. 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.
You can install the pump 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
WARNING
Contact with hazardous liquids
Death or serious personal injury
- 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.
- Wear personal protection equipment.
WARNING
Hot or cold surface
Death or serious personal injury
- Make sure that no one can accidentally
come into contact with hot or cold
surfaces.
In order to maintain the UL mark,
additional requirements apply to the
equipment. See page 84.
TM01 0683 1997
The motor must never fall below the
horizontal plane.
TM05 7916 1613
Installation
Washer Pump
300 mm

English (GB)
7
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
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.
7.1 Pipes
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 pipes are 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 pipes.
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 pipes 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.
TM05 7983 1713TM05 7917 1613
Observe the conditions in section
10. Operating conditions.
TM00 2263 0195
The pump must not run against a closed
outlet valve as this will cause an increase
in temperature or formation of steam in the
pump, which may cause damage to the
pump.

English (GB)
8
7.2 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 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).
7.3 Fitting of pump head
DANGER
Electric shock
Death or serious personal injury
- Switch off the power supply to the motor
and to the signal relays. Wait at least 5
minutes before you make any
connections in the terminal box. Make
sure that the power supply cannot be
accidentally switched on.
WARNING
Hazardous liquids
Death or serious personal injury
- 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.
- Wear personal protection equipment.
WARNING
Falling objects
Death or serious personal injury
- If the pump head has been lifted partly
or completely from the pump housing,
pay special attention when fitting the
pump head again.
CAUTION
Crushing of feet
Minor or moderate personal injury
- Wear safety shoes.
- Pay special attention that the pump
head does not fall down when loosening
the clamp. See fig. 8.
WARNING
Pressurised system
Death or serious personal injury
- Pay special attention to any escaping
vapour when loosening the clamp. See
fig. 8.
- Wear personal protection equipment.
TM06 0721 0814
DANGER
Electric shock
Death or serious personal injury
- Switch off the power supply to the motor
and to the signal relays. Wait at least 5
minutes before you make any
connections in the terminal box. Make
sure that the power supply cannot be
accidentally switched on.
WARNING
Falling objects
Death or serious personal injury
- If the pump head has been lifted partly
or completely from the pump housing,
pay special attention when fitting the
pump head again.
A

English (GB)
9
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
7.4 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.
CAUTION
Crushing of feet
Minor or moderate personal injury
- Wear safety shoes.
- Pay special attention that the pump
head does not fall down when loosening
the clamp. See fig. 8.
WARNING
Pressurised system
Death or serious personal injury
- Pay special attention to any escaping
vapour when loosening the clamp. See
fig. 8.
- Wear personal protection equipment.
TM06 0722 0814
TM06 0723 0814TM06 0724 0814

English (GB)
10
7.5 Insulation
Follow the guidelines in fig. 12 when insulating the
pump.
Fig. 12 Insulation of TPE2, TPE3 pumps
7.6 Frost protection
Drain pumps which are not being used during
periods of frost to avoid damage.
7.7 Cable entries
See the size of the cable entries in section 33. Other
technical data.
7.8 Ensuring motor cooling
Leave at least 50 mm between the end of the fan
cover and a wall or other fixed objects. See fig. 13.
Fig. 13 Minimum distance, D, from the motor to
a wall or other fixed objects
7.9 Outdoor installation
If you install the motor outdoors, provide the motor
with a cover and open the drain holes 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 connect the motor
permanently to the mains supply and activate the
built-in standstill heating function. See section
16.25 "Standstill heating".
Fig. 14 Examples of covers, not supplied by
Grundfos
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
TM05 5236 3512
When fitting a cover to the motor, observe
the guidelines in section 7.8 Ensuring
motor cooling.
TM05 3496 3512
In order to maintain the UL mark,
additional requirements apply to the
equipment. See page 84.
D