Grundfos IO 100 User manual

GRUNDFOS
PRODUCT GUIDE
SQFlex
Renewable-energy based water-supply systems
60 Hz

Contents
2
Product data
Performance range 3
Application 4
The SQFlex system 4
Type keys 5
Pumped liquids 5
Curve conditions 6
Wiring diagram for pump 6
Pump overview 6
Dry-running protection 7
High efficiency 7
Over- and undervoltage protection 7
Overload protection 8
Overtemperature protection 8
Maximum Power Point Tracking (MPPT) 8
Wide voltage range 8
Reliability 8
Installation 8
Service 8
System overview 9
Application examples
SQFlex Solar 10
SQFlex Wind 13
SQFlex Combo 15
SQFlex system 17
System components
CU 200 18
Electrical connections, CU 200 19
IO 100 20
Wiring diagram, IO 100 20
IO 101 20
Electrical connections, IO 101 20
IO 102 21
Electrical connections, IO 102 21
Generator 21
System sizing
Sizing of SQFlex system 22
Example 22
Performance curves
24
Technical data
Dimensions and weights 28
Electrical data 28
IO 100 switch box 29
IO 101 switch box 29
IO 102 breaker box 29
CU 200 control unit 30
Material specification - helical rotor pump 31
Material specification - centrifugal pump 32
Material specification - motor 33
Product numbers
Complete unit with 6 ft cable 34
Submersible drop cables 34
IO 100 35
IO 101 35
CU 200 35
IO 102 35
Wind turbine H80 Whisper 35
Tower kit for H80 Whisper 36
Tower installation kit 36
Tower pipe selection 36
Accessories
Auger / anchor 37
Grease 37
Further product documentation
WinCAPS 38
WebCAPS 39

3
Product data SQFlex
Performance range
Note: Do not use the above curves for sizing of the pump.
TM02 2433 4201
04000 8000 12000 16000 20000 Q [US GPD]
0
50
100
150
200
250
300
350
[ft]
HSQFlex Solar
A B C D E F G H
H 1200 Wp
G 900 Wp
F 700 Wp
E 500 Wp
D 400 Wp
C 300 Wp
B 200 Wp
A 100 Wp
TM02 2434 4201
04000 8000 12000 16000 20000 Q [US GPD]
0
50
100
150
200
250
300
350
[ft]
HSQFlex Wind
A B C D
D 18 mph
C 16 mph
B 14 mph
A 11 mph

4
Product data SQFlex
Application
Designed for continuous as well as intermittent opera-
tion, the SQFlex system is especially suitable for water
supply applications in remote locations, such as:
• villages, schools, hospitals, single-family houses
etc.
•farms
- watering of cattle
- irrigation of fields and greenhouses
• game parks and game farms
- watering applications
• conservation areas
- surface water pumping
• Floating pump installations for pumping of water
from ponds and lakes.
The SQFlex system
The SQFlex system is a reliable water supply system
based on renewable energy sources, such as solar and
wind energy. The SQFlex system is equipped with the
SQF submersible pump.
Very flexible as to its energy supply and performance,
the SQFlex system can be combined and adapted to
any need according to the conditions on the installation
site.
The system components are:
• SQF submersible pump
• CU 200 control unit
• IO 100 and IO 101 switch boxes
• IO 102 breaker box
• energy supply:
- solar panels
- wind turbine
- generator
- batteries.
Pump
The SQF pump range comprises two pump technolo-
gies:
• Helical rotor pump (3") for high heads and moderate
flows.
• Centrifugal pump (4") for lower heads and high
flows based on the Grundfos SP A pump.
The performance curves below illustrate pump perfor-
mance for the two pump technologies:
Motor
The SQFlex motor range comprises only one motor
size, the MSF 3 with max. power input (P1) of 900 W.
MSF 3 is a 3" motor.
The speed range for the motor is 500-3000 rpm
depending on the power input and the load.
The motor has been developed especially for the
SQFlex system.
The SQFlex motor has three internal limitations,
• max. power consumption (P1) of 900 W
• max. current of 7 A and
• max. speed of 3000 rpm.
The pump delivers its maximum performance when one
of the above limitations is reached.
The motor is available in stainless steel EN/DIN 1.4301.
The motor is designed according to the permanent-
magnet principle with built-in electronic unit.
Voltage supply
The motor can be supplied with either AC or DC
voltage.
• 30 - 300 VDC, PE
• 1 x 90 - 240 V –10%/+6%, 50/60 Hz, PE.
TM02 2425 3901
Q
H
A
B
A: Helical rotor pump
B: Centrifugal pump
/Day

5
Product data SQFlex
IO 100 switch box
The IO 100 is an on/off switch box designed as a posi-
tive disconnect for the system voltage supply.
IO 101 switch box
The IO 101 is an on/off switch box designed as a posi-
tive disconnect for the system voltage supply.
The IO 101 is used with SQFlex systems supplied by
solar panels and with a generator supply backup.
IO 102 breaker box
The IO 102 is an on/off switch box designed as a posi-
tive disconnect for the system voltage supply.
The IO 102 is used with wind-powered SQFlex systems
or with SQFlex systems powered by wind and solar
energy.
IO 102 acts as a brake which makes it possible to slow
down or stop the wind turbine.
CU 200 control unit
The CU 200 control unit is a combined status and
control unit for the SQFlex pump system. Furthermore,
the CU 200 enables connection of a level switch placed
in a water reservoir or similar tank.
Solar modules
Grundfos’ solar modules have been developed espe-
cially for the SQFlex system. The solar modules are
equipped with plugs and sockets enabling easy and
simple installation.
Grundfos offers data sheets for available solar
modules. For further information please contact your
local Grundfos Company.
Generator
If the electricity supply from its primary source of
energy is temporarily insufficient, the SQFlex system
can be supplied by a generator. The generator can
either be diesel or gasoline driven.
Batteries
The SQFlex system can be supplied by batteries with a
voltage supply of 30 - 300 VDC, minimum current 7A.
Type keys
Type key for helical rotor pumps
Type key for centrifugal pumps
Pumped liquids
The SQF pumps are designed for pumping thin, clean,
non-aggressive, non-explosive liquids, not containing
solid or long-fibred particles larger than sand grains.
Sand content: max. 50 ppm.
A higher sand content will reduce the pump life consid-
erably due to wear.
pH: 5 - 9
Liquid temperature: 32°F to +104°F
The pump can run at free convection (~ 0 ft/sec) at max.
+104°F.
Salt content
The table below shows the resistance of stainless steel
to Cl-. The figures in the table are based on a pumped
liquid with a pH-value of 4 - 9.
Example 6 SQF -2 x
Rated flow at 3000 rpm [US
GPM]
Type range
Number of stages
Blank = Stainless steel
AISI 304
Example 25 SQF -3 x
Rated flow at 3000 rpm [US GPM]
and pump generation
Type range
Number of stages
Blank = Stainless steel
AISI 304
Stainless steel Cl-content
[ppm]
Liquid
temperature
[°F]
EN/DIN AISI
1.4301 304 0 - 300 < 104
300 - 500 < 86

6
Product data SQFlex
Curve conditions
The SQFlex Solar performance range shown on page 3
is based on:
• solar radiation on a tilted surface
•H
T= 6 kWh/m2per day
• 20° tilt angle
• ambient temperature: +86°F
• 20° northern latitude
• panel voltage: 120 VDC
• an 11 hour standard solar day.
The SQFlex Wind performance range shown on page 3
is based on:
• average wind speed
• calculations according to Weibull’s factor k = 2
• continuous operation over 24 hours.
The performance charts on pages 24 to 27 are based
on the following guidelines:
• All curves show mean values.
• The curves must not be used as guarantee curves.
• Typical deviation: +/–15%.
• The measurements were made at a water tempera-
ture of +86°F.
• The curves apply to a kinematic viscosity of 1 mm2/
s (1 cSt). If the pump is used for liquids with a vis-
cosity higher than that of water, this will reduce the
head and increase the power consumption.
• The performance curves are inclusive of inlet and
valve losses at the actual speed.
• Supply to pump: 120 VDC.
Wiring diagram for pump
Connection of the MSF motor to the power supply must
be done according to the wiring diagram shown below.
As the intelligent motor electronics can handle both
connection possibilities, it makes no difference how the
wires "+" and "–" or "N" and L" are connected.
Pump overview
The SQF pump is available as a complete unit.
TM02 2437 3901
NL
30 - 300 VDC 1 x 90 - 240 VAC
Element Drawing Description
SQF pump complete
TM02 2217 3901
SQF pump complete with ...
•motor
• 6 ft cable with water level electrode, end cover,
socket and
• cable guard.

7
Product data SQFlex
Dry-running protection
The SQF pump is protected against dry running in order
to prevent damage to the pump. The dry-running
protection is activated by a water level electrode placed
on the motor cable 12 - 24 inches above the pump
depending on the pump type.
The water level electrode measures the contact resis-
tance to the motor sleeve through the water. When the
water level falls below the water level electrode the
pump will be cut out. The pump will automatically cut in
again 5 min. after the water level is above the water
level electrode.
High efficiency
The MSF 3 motor is a permanent-magnet motor (PM
motor) featuring a higher efficiency within the power
range compared to a conventional asyncronous motor.
In addition to this the segmented motor stator contrib-
utes considerably to the high efficiency.
The MSF 3 motor is characterized by a high locked-
rotor torque even at low power supply.
Over- and undervoltage protection
Overvoltage and undervoltage may occur in the case of
unstable voltage supply or a faulty installation.
The pump will be cut out if voltage falls outside the
permissible voltage range. The motor is automatically
cut in again when the voltage is again within the permis-
sible voltage range. Therefore no extra protection relay
is needed.
Note: The MSF 3 motor is protected against transients
from the the voltage supply according to IEC 60664-1
"overvoltage category III" (4 kV). In areas with high
lightning intensity, external lightning protection is
recommended.
TM02 2436 3901TM02 2435 3901
12 - 24 in
12 - 24 in

8
Features and benefits SQFlex
Overload protection
If the upper load limit is exceeded, the motor will auto-
matically compensate for this by reducing the speed. If
the speed falls below 500 rpm, the motor will be cut out
automatically.
The motor will remain cut out for 10 sec. after which
period the pump will automatically attempt a restart.
The overload protection prevents burnout of the motor.
Consequently, no extra motor protection is required.
Overtemperature protection
A permanent-magnet motor gives off very little heat to
its surroundings. An efficient internal circulation system
leads the heat away from the rotor, stator and bearings
ensuring optimum operating conditions for the motor.
As an extra protection, the electronic unit has a built-in
temperature sensor. When the temperature rises above
+185°F, the motor is automatically cut out; when the
temperature has dropped to +167°F, the motor is auto-
matically cut in again.
Maximum Power Point Tracking (MPPT)
The built-in electronic unit gives the SQFlex system a
number of advantages compared to conventional prod-
ucts. One of these advantages is the built-in micropro-
cessor with MPPT (MPPT = Maximum Power Point
Tracking).
Thanks to the MPPT-function, the pump duty point is
continuously optimised according to the input power
available. MPPT is only available for pumps connected
to DC supply.
Wide voltage range
The wide voltage range enables the motor to operate at
any voltage from 30-300 VDC or 90-240 VAC. This
makes installation and sizing especially easy.
Reliability
The MSF 3 has been developed to provide optimum
reliability which is achieved through the following
features:
• carbon/ceramic bearings
• excellent starting capabilities
• various protection facilities.
Installation
The following features ensure simple installation of the
SQF pump:
• low weight ensuring user-friendly handling
• installation in 3", 4" or larger boreholes
• only an on/off switch is needed, which means that
no extra motor starter / starter box is necessary,
• comes with cable and cable cover pre-installed.
Note: Horizontal installation requires the water level
electrode to be placed min. 12 to 24 inches above the
pump to ensure the dry-running protection.
Service
The modular pump and motor design facilitates instal-
lation and service. The cable and the end cover with
socket are fitted to the pump with nuts which enable
replacement in the field.
TM02 2246 3901TM02 2435 3901
Allowed
Not allowed
12 - 24 in

9
System overview
The SQFlex system can be used in a number of combinations as shown in the table below.
System ... ... consists of the following components
Pump Solar panel  Wind turbine Generator/ supply network Switch box CU 200 Control unit Level switch
SQFlex Solar
See page 10.
SQFlex Solar
- with CU 200 control unit and level switch
See page 11.
SQFlex Solar
- with generator as power supply back-up
See page 12.
SQFlex Wind
See page 13.
SQFlex Wind
- with CU 200 control unit and level switch
See page 14.
SQFlex Combi
- combination of solar and wind energy
See page 15.
SQFlex Combi
- with CU 200 and level switch
See page 16.
SQFlex system
- with generator as power supply
See page 17.
()()()()
 For the number of solar modules required, please consult the sizing tool in WinCAPS.
 Can be excluded from the installation.
 May be a component in the system.
IO 100
CU 200 ()
IO 101
IO 102
IO 102 CU 200 ()
IO 102
IO 102 CU 200 ()
IO 101
Features and benefits SQFlex

10
Application examples SQFlex
SQFlex Solar
The SQFlex Solar system is the simplest of the range
of SQFlex systems.
Benefits
• Easy to install
• Maintenance confined to periodic cleaning of the
solar panels
• Few and simple components.
The protective circuit incorporated in the motor elec-
tronic unit cuts out the pump in case of dry running or
similar situations.
By using the IO 100 switch box, the voltage supply to
the pump can be closed manually, e.g. when ...
• there is no need for water supply
• the system requires service.
TM02 2304 4101
2
3
4
5
1
6
7
12
5
1 SQF pump
2Cable
3Cableclips
4 Straining wire
5 Wire clamp
6 Solar panels
7 Support structure
12 IO 100 switch box
Note: For the number of solar modules
required, please consult the Sizing tool.

11
Application examples SQFlex
SQFlex Solar
- with CU 200 control unit and level switch
The SQFlex Solar system allows energy from the sun to
be stored as water in a reservoir.
SQFlex Solar water supply systems with a water reser-
voir are used where ...
• there is a need for night-time water supply
• for short periods, the solar energy is insufficient to
run the pump
• there is a need for a back-up water source.
Benefits
Combined with the CU 200, the level switch acts as a
pump cut-out function when the water reservoir is full.
CU 200 offers indication of ...
• full water reservoir (level switch activated)
• pump operation
• input power.
CU 200 indicates operational stoppage in case of ...
• dry running
• service (see page 18)
• insufficient energy supply.
In addition, the system features ...
• easy installation
• maintenance confined to periodic cleaning of the
solar panels.
TM02 2305 4101
2
3
4
5
1
6
7
11
14
5
15 1 SQF pump
2Cable
3Cableclips
4 Straining wire
5 Wire clamp
6 Solar panels
7 Support structure
11 CU 200 control unit
14 Water reservoir
15 Level switch
Note: For the number of solar modules
required, please consult the Sizing tool.

12
Application examples SQFlex
SQFlex Solar
- with generator as power supply back-up
During periods of limited solar energy, the SQFlex
Solar water supply system provides a safe supply of
water. The system is connected to an external gener-
ator as back-up via the IO 101 switch box.
The system enables operation ...
• via generator when ...
- the energy supply from the solar panels is
insufficient
• via solar energy when ...
- the generator is stopped manually
- the generator runs out of fuel.
Benefits
• Offers water supply at night or when the solar
energy is insufficient
• Easy to install
• Maintenance confined to periodic cleaning of the
solar panels
• Few and simple components
• Flexible in terms of energy supply.
TM02 2309 4101
2
3
4
5
1
6
7
13
5
10
1 SQF pump
2Cable
3Cableclips
4 Straining wire
5 Wire clamp
6 Solar panels
7 Support structure
10 Generator
13 IO 101 switch box
Note: For the number of solar modules
required, please consult the Sizing tool.

13
Application examples SQFlex
SQFlex Wind
The SQFlex Wind system is based on wind energy as
the only energy source for pump operation.
The system is suitable for installation in areas where
the wind is almost constant seen over a period of time.
As the turbine noise level increases with the wind
speed, siting of the wind turbine near a residence is not
recommended.
The IO 102 breaker box makes it possible to brake the
wind turbine when ...
• there is no need for water supply
• the system requires service.
Benefits
• Easy to install
• A minimum of maintenance required
• Few and simple components.
TM02 2306 4101
2
3
4
5
1
8
5
9
1 SQF pump
2Cable
3Cableclips
4 Straining wire
5 Wire clamp
8 Wind turbine
9 IO 102 breaker box

14
Application examples SQFlex
SQFlex Wind
- with CU 200 control unit and level switch
The SQFlex Wind system allows energy from the wind
to be stored as water in a reservoir.
SQFlex Wind water supply systems with a water reser-
voir are used where ...
• for short periods, the wind energy is insufficient to
run the pump
• there is a need for a back-up water source.
As the turbine noise level increases with the wind
speed, siting of the wind turbine near a residence is not
recommended.
Benefits
Combined with the CU 200, the level switch acts as a
pump cut out function when the water reservoir is full.
CU 200 offers indication of ...
• full water reservoir (level switch activated)
• pump operation
• input power.
CU 200 indicates operational stoppage in case of ...
• dry running
• service (see page 18)
• insufficient energy supply.
The IO 102 breaker box makes it possible to interrupt
the supply voltage in the system and to slow down or
stop the wind turbine when ...
• there is no need for water supply
• the system requires service.
In addition, the system features ...
• easy installation
• a minimum of maintenance.
TM02 2308 4101
2
3
4
5
1
14
5
15
8
11
9
1 SQF pump
2Cable
3Cableclips
4 Straining wire
5 Wire clamp
8 Wind turbine
9 IO 102 breaker box
11 CU 200 control unit
14 Water reservoir
15 Level switch

15
Application examples SQFlex
SQFlex Combo
- combination of solar and wind energy
The SQFlex Combi water supply system is ideal in
areas where the solar or wind energy is sufficient to run
the pump.
The energy supply to the pump is a combination of solar
and wind energy.
As the turbine noise level increases with the wind
speed, siting of the wind turbine near a residence is not
recommended.
Benefits
• Offers water supply at night or when the solar
energy is insufficient
• Easy to install
• Maintenance confined to periodic cleaning of the
solar panels
• Few and simple components.
The IO 102 breaker box makes it possible to interrupt
the supply voltage in the system and to slow down or
stop the wind turbine when ...
• there is no need for water supply
• the system requires service.
In addition, the system features ...
• easy installation
• a minimum of maintenance.
TM02 2307 4101
2
3
4
5
1
5
9
7
6
8
1 SQF pump
2Cable
3Cableclips
4 Straining wire
5 Wire clamp
6 Solar panels
7 Support structure
8 Wind turbine
9 IO 102 breaker box
Note: For the number of solar modules
required, please consult the Sizing tool.

16
Application examples SQFlex
SQFlex Combo
- with CU 200 and level switch
The SQFlex Combi system allows solar and wind
energy to be stored as water in a reservoir.
SQFlex Combi water supply systems with a water
reservoir are used where ...
• for short periods, the solar or wind energy is insuffi-
cient to run the pump
• there is a need for a back-up water source.
As the turbine noise level increases with the wind
speed, siting of the wind turbine near a residence is not
recommended.
Benefits
Combined with the CU 200, the level switch acts as a
pump cut-out function when the water reservoir is full.
CU 200 offers indication of ...
• full water reservoir (level switch activated)
• pump operation
• input power.
CU 200 indicates operational stoppage in case of ...
• dry running
• service (see page 18)
• insufficient energy supply.
The IO 102 breaker box makes it possible to interrupt
the supply voltage in the system and to slow down or
stop the wind turbine when ...
• there is no need for water supply
• the system requires service.
In addition, the system features ...
• easy installation
• a minimum of maintenance.
TM02 2310 4101
2
3
4
5
1
14
5
15
7
8
9
6
11
1 SQF pump
2Cable
3Cableclips
4 Straining wire
5 Wire clamp
6 Solar panels
7 Support structure
8 Wind turbine
9 IO 102 breaker box
11 CU 200 control unit
14 Water reservoir
15 Level switch
Note: For the number of solar modules
required, please consult the Sizing tool in
WinCAPS.

17
Application examples SQFlex
SQFlex system
- with generator as power supply
The SQFlex water supply system is connected to a
gene-rator, which can be diesel or gasoline driven.
Benefits
• Offers water supply 24 hours a day independent of
the weather.
• Easy installation.
• Few and simple components.
TM02 2311 4101
2
3
4
5
1
5
10
1 SQF pump
2Cable
3Cableclips
4 Straining wire
5 Wire clamp
10 Generator

18
System components SQFlex
CU 200
The CU 200 control unit is a combined status, control
and communication unit specifically developed for the
SQFlex system. Furthermore, the CU 200 enables
connection of a level switch.
The CU 200 incorporates cable entries for ...
• power supply connection (pos. 6),
• pump connection (pos. 7),
• earth connection (pos. 8),
• level switch connection (pos. 9).
(The position numbers shown in brackets refer to the
drawing to the right).
Communication between the CU 200 and the pump
takes place via the pump power supply cable. This is
called mains borne signalling (or Power Line Communi-
cation), and this principle means that no extra cables
between the CU 200 and the pump are required.
It is possible to start, stop and reset the pump by means
of the on/off button (pos. 1).
The CU 200 control unit offers:
• System monitoring
• Alarm indication.
The following indications allow the operation of the
pump to be monitored:
• Water reservoir is full (level switch) (pos. 2)
• Pump is running (pos. 3)
• Input power (pos. 11).
The CU 200 offers the following alarm indications:
• Dry running (pos. 10)
• Service needed (pos. 5) in case of:
- No contact to pump
- Overvoltage
- Overtemperature
- Overload.
In addition, the CU 200 shows the symbols of the
energy supply options (pos. 4).
Dimensions, CU 200
Dimensions stated in inches.
TM02 2325 4101TM02 8730 0804
1
2
3
11
4
5
10
8
7
69
7.75"
3.75"
10.5"

19
System components SQFlex
Electrical connections, CU 200
TM02 2515 4401
GND IN
F1 = OVERVOLTAGE
F2 = OVERTEMP
F3 = NO CONTACT
F4 = OVERLOAD
CONTROL INDICATOR
MAX SPEED
+24 V
+10 V
+5 V
LEVEL SWITCH
POWER PUMP PE PE PE
GND IN
F1 = OVERVOLTAGE
F2 = OVERTEMP
F3 = NO CONTACT
F4 = OVERLOAD
CONTROL INDICATOR
MAX SPEED
+24 V
+10 V
+5 V
LEVEL SWITCH
High water level:
Contact is closed
Low water level:
Contact is open
Level switch input:

20
System components SQFlex
IO 100
The IO 100 switch box is designed specifically for solar
powered SQFlex systems.
The IO 100 enables manual starting and stopping of the
pump in an SQFlex Solar system and functions as a
connection box joining all necessary cables.
The dimensions and wiring diagram of IO 100 are
shown below.
Dimensions, IO 100
Dimensions stated in inches.
Wiring diagram, IO 100
IO 101
The IO 101 switch box is designed specifically for solar
powered SQFlex systems.
The IO 101 enables the connection of a generator
supply back-up in case of insufficient solar radiation.
The switching between solar power and generator must
be made manually.
When the generator is stopped manually or runs out of
fuel, the IO 101 will automatically switch to the solar
energy supply.
The IO 101 functions as a connection box joining all
necessary cables.
The dimensions and electrical connections of IO 101
are shown below.
Dimensions, IO 101
Dimensions stated in inches.
Electrical connections, IO 101
TM02 8731 0804TM02 4058 4701
7.75"
4.5"10.5"
TM02 8732 0804TM02 4162 5001
7.75"
10.5" 4.5"
Ground
Generator
PE
Power Pump