Grundfos BoosterpaQ Hydro MPC Installation And Operating Instructions Manual Download Page 1

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BoosterpaQ -
Hydro MPC

GRUNDFOS

INSTRUCTIONS

Installation and operating instructions

www.motralec.com / [email protected] / 01.39.97.65.10

Summary of Contents for BoosterpaQ Hydro MPC

Page 1: ...BoosterpaQ Hydro MPC GRUNDFOS INSTRUCTIONS Installation and operating instructions www motralec com service commercial motralec com 01 39 97 65 10 ...

Page 2: ...ctive product must be returned to the distributor or dealer of Grundfos products from which it was purchased together with proof of purchase and installation date failure date and supporting installation data Unless otherwise provided the distributor or dealer will contact Grundfos or an authorized service station for instructions Any defective product to be returned to Grundfos or a service stati...

Page 3: ...rings 56 13 3 CU 351 56 14 Frost protection 56 15 Taking out of operation 56 16 Technical data 56 16 1 Pressure 56 16 2 Temperature 57 16 3 Relative humidity 57 16 4 Sound pressure 57 17 Electrical data 57 18 Related documents 57 19 Disposal 57 1 Symbols used in this document 2 Scope of these instructions These installation and operating instructions apply to Grundfos Hydro MPC booster sets Hydro ...

Page 4: ...ate 1 3 Suction manifold stainless steel 1 4 Isolating valve 2 per pump 5 Base frame stainless steel 1 6 Non return valve 1 per pump 7 Discharge manifold stainless steel 1 8 Pressure transmitter pressure gauge on suction and discharge manifolds 2 9 Pump 2 6 1 2 3 4 5 6 7 8 9 Control variant Description E 2 to 6 CRE pumps ED 2 CRE pumps and up to 4 mains operated CR pumps ES 1 CRE pump and up to 5 ...

Page 5: ...mps 13 Motor powr in HP 14 Nominal voltage in volts 15 Order number 16 Options 17 Options 18 Options 19 Options 20 Options 21 Options 22 Enclosure class panel P N 23 Weight in lb 24 Approval marks 25 Production location date code Type Model Serial No Mains supply Max oper press PSI Number HP P Un V T Medium ºF Q Max GPM H Min Fixed speed pumps E pumps Order No Options Encl Type NEMA PN Weight PN l...

Page 6: ...e is a configuration data file 1 Control MPC 3 Hydro MPC 5 Pump data 96586126 4 H MPC options 2 C MPC options CONFIGURATION STEPS PLEASE FOLLOW THE NUMBERS 1 2 3 4 5 Example Hydro MPC ED 2 CRE 5 10 1 CR 5 10 3 x 460 V 60 Hz Type range Subgroups Pumps with integrated frequency converter E ED ES Pumps with external frequency converter EF EDF F Mains operated pumps start stop S Number of pumps with i...

Page 7: ...and through cutting in out the required number of pumps and through parallel control of the pumps in operation Pump changeover is automatic and depends on load time and fault All pumps in operation will run at equal speed Hydro MPC ED maintains a constant pressure through continuous adjustment of the speed of two CRE pumps while the CR pump is mains operated One CRE pump always starts first If the...

Page 8: ...m performance is adjusted to the demand through cutting in out the required number of pumps and through parallel control of the pumps in operation Pump changeover is automatic and depends on load time and fault All pumps in operation will run at equal speed Hydro MPC EDF maintains a constant pressure through continuous adjustment of the speed of two CR pumps connected to external frequency convert...

Page 9: ...erated CR pumps in operation TM03 2046 3505 Hydro MPC S maintains pressure range through cutting in out the required number of pumps The operating range of the pumps will lie between Hset and Hstop cut out pressure The cut out pressure cannot be set but is calculated automatically Pump changeover is automatic and depends on load time and fault PT Q H Q H www motralec com service commercial motrale...

Page 10: ...s The right damper varies from installation to installation and a wrong damper may increase the vibration level Vibration dampers should therefore be sized by the supplier of vibration dampers If the booster set is installed on a base frame with vibration dampers expansion joints should always be fitted on the manifolds This is important to prevent the booster set from hanging in the pipework 7 1 ...

Page 11: ...tank etc If there is a fill point above the highest point of the pumps you may fill the system from this point If there is no fill point above the highest point of the pumps remove the large vent plug on each pump Fill each pump until the water is up to the vent plug then replace the vent plugs 5 Ensure all circuit breakers are in the on position 6 Make sure the discharge manifold pump isolatin va...

Page 12: ...12 INSTALLATION AND STARTUP NOTES www motralec com service commercial motralec com 01 39 97 65 10 ...

Page 13: ...own a list will appear see 9 1 4 The list shows the status of alarms see C in fig 7 the system see D in fig 7 and the pumps see E in fig 7 9 1 4 List The list includes one or more lines with information grouped to the left and to the right The left side shows texts and the right side shows values Headlines and empty lines cannot be selected 9 1 5 Scroll bar If the list of illustration elements exc...

Page 14: ...ue has been changed and the button is pressed the new value will not be saved For further information see 9 2 7 Ok pos 10 If the button is pressed before the button the new value will be saved For further information see 9 2 7 Ok pos 10 9 2 6 Home pos 9 Press the button to return to the Status menu 9 2 7 Ok pos 10 Use the button as an enter button The button is also used to start the setting proce...

Page 15: ...be set such as setpoint operating mode control mode and forced control Alarm The Alarm menu gives an overview of alarms and warnings Alarms and warnings can be reset in this menu Settings In the Settings menu it is possible to set various functions Primary controller Setting of setpoint setpoint influence primary sensor and redundant primary sensor Pump cascade control Setting of min time between ...

Page 16: ... AI1 IO 351 42 57 4 3 8 6 Function AI1 IO 351 42 57 4 3 8 7 Setting AI2 IO 351 42 60 4 3 8 7 Function AI2 IO 351 42 60 4 3 9 Overview of digital outputs 4 3 9 1 4 3 9 Function DO1 and DO2 CU 351 72 75 4 3 9 3 4 3 9 Function DO1 DO7 IO 351 41 77 88 4 3 9 10 4 3 9 Function DO1 DO7 IO 351 42 77 88 4 3 1 Min max and user defined duty 4 3 14 1 Min duty 4 3 14 2 Max duty 4 3 14 3 User defined duty 4 3 1...

Page 17: ...2 4 33 10 7 15 Test run 4 2 5 33 10 7 16 Secondary functions 4 3 33 10 7 17 Stop function 4 3 1 34 10 7 18 Overview of digital inputs 4 3 7 35 10 7 19 Functions of digital inputs 4 3 7 1 to 4 3 7 12 35 10 7 20 Overview of analog inputs 4 3 8 36 10 7 21 Setting of analog inputs 4 3 8 1 to 4 3 8 7 36 10 7 22 Functions of analog inputs 4 3 8 1 1 to 4 3 8 7 1 37 10 7 23 Overview of digital outputs 4 3...

Page 18: ... pumps the symbol will also be shown in front of the status line D of the pump in question At the same time the symbol will be flashing instead of the pump symbol E The symbol will be shown to the right in the top line of the display F As long as a fault is present this symbol will be shown in the top line of all displays To open a menu line mark the line with or and press The display makes it pos...

Page 19: ...nally it is possible to relate a source to an operating mode for instance External signal to Max As several digital inputs can be set to external operation at the same time the CU 351 has an order of priority of the external commands Example The source Fault may for instance relate to the function dry running protection In case of water shortage the operating mode will be Stop as this mode has fir...

Page 20: ...mance pressure Manual The pump is not controlled by the PI controller In manual operation the pump has one of the following operating modes Max The pump runs at a set maximum speed Normal The pump runs at a set speed This operating mode can only be selected for variable speed pumps Min The pump runs at a set minimum speed This operating mode can only be selected for variable speed pumps Stop The p...

Page 21: ... setting for instance System operating mode with or 3 Go to a new display with Factory setting The setpoint is a value suitable for the Hydro MPC booster set in question Typically 50 of the maximum head of the pumps The factory setting may have been changed in the start up menu 10 5 2 System operating mode 2 1 Fig 17 System operating mode Description Hydro MPC can be set to five different operatin...

Page 22: ... 1 Example 2 Example 3 Setting range There are two control modes Closed and open loop Setting via control panel 1 Mark the Operation menu with 2 Mark Control mode with or and press 3 Select the desired control mode with or and press Factory setting Closed loop control 10 5 4 Setting of setpoints 2 3 Fig 19 Setting of setpoints Description In addition to the primary setpoint 1 shown in display 2 si...

Page 23: ... Pumps in manual operation are not part of the normal pump cascade and speed control The manual pumps are a disturbance of the normal control of Hydro MPC If one or more pumps are in manual operation Hydro MPC may not be able to deliver the set performance There are two displays for the function In the first display the pump to be set is selected and in the next display the operating mode is selec...

Page 24: ...4 Level 1 is the tank level where a warning is indicated in case of water shortage Level 2 is the tank level where an alarm is indicated and the pumps stop in case of water shortage For further information see 10 7 34 Dry running protection with pressure level switch 4 4 1 1 and 10 7 36 Dry running protec tion with level transmitter 4 4 1 3 TM03 2291 4005 Fault Warning alarm Change of operating mo...

Page 25: ...ult fault finding for the pump Auto Alarm Stop b Pumps are not indicating alarm Check the Genibus wires eg connection polarisation 6 External fault signal External fault signal 003 a External fault digital input activated 1 Check the external signal source 2 Check the digital input according to the wiring diagram Auto Manual Alarm Warning Stop Unchanged 7 Inconsistency between sensors Inconsistenc...

Page 26: ...g and input according to the wiring diagram 16 Communication fault Pump communication fault 010 Pump 1 6 IO 351 a No GeniBus communication with a device connected to CU 351 See actual alarms and identify the faulty device from the alarm message 1 Check power supply 2 Check GeniBus cable connection 3 Check with R100 that the device GeniBus no is correct 17 Device alarms From device Pump 1 6 a The d...

Page 27: ...he fault is and the alarm code in brackets Water shortage level 1 206 max pressure 210 etc When the fault occurred Date and time When the fault disappeared Date and time If the fault still exists date and time are shown as The latest warning alarm is shown at the top of the display Setting via control panel To open the alarm log proceed as follows 1 Mark the Alarm menu with 2 Mark Alarm log with o...

Page 28: ...ng via control panel 1 Mark the Settings menu with 2 Mark Primary controller with or and press 3 Mark PI controller with or and press 4 Select the gain Kp with or Set the value with or and save with Note Usually it is not necessary to adjust Kp 5 Select the integral time Ti with or Set the time with or and press Factory setting Kp 0 5 Ti 1 second 10 7 3 Selection of alternative setpoints 4 1 2 Fig...

Page 29: ...oint The influence values can be set individually Factory setting Setpoint influence is not activated 10 7 6 External setpoint influence 4 1 3 1 Fig 31 External setpoint influence Description This function makes it possible to make an external analog signal influence the setpoint The analog signal may be a 0 100 signal from another control unit a signal transmitter such as a flow sensor or a param...

Page 30: ...Set the value of the external input value with or and save with 10 Mark Reduce setpoint to point 1 with or 11 Set the value in per cent with or and save with 12 Repeat points 5 to 11 for all desired parameters Factory setting External setpoint influence is not activated 10 7 8 Primary sensor 4 1 4 Fig 34 Primary sensor Description In this display select the control parameter of Hydro MPC and the s...

Page 31: ...0 or more than 4 of full scale of the primary sensor but the Hydro MPC will still be controlled by the primary sensor Note The redundant primary sensor must be of the same type and size as the primary sensor and be mounted at the same position in Hydro MPC Setting range The analog input AI3 CU 351 can be set to this function Setting via control panel 1 Mark the Settings menu with 2 Mark Primary co...

Page 32: ...number of starts per hour Setting range 1 to 253 starts per hour Setting via control panel 1 Mark the Settings menu with 2 Mark Pump cascade control with or and press 3 Mark Max number of starts hour with or and press 4 Mark Max number of starts hour with or and press 5 Set the permissible number of starts per hour with or and save with Factory setting 10 7 13 Standby pumps 4 2 3 Fig 39 Standby pu...

Page 33: ...o operating mode Stop for instance in a period when the system is not needed In such situations its important to test the pumps regularly The function ensures that pumps do not seize up during a long standstill due to deposits from the pumped liquid the pumped liquid does not decay in the pump trapped air is removed from the pump Each pump is connected to a counter The pump starts automatically on...

Page 34: ...setpoint Hydro MPC S 0 9 x setpoint During each flow estimation every 2 minutes the estimating function will disturb the discharge pressure by 10 If this disturbance is not acceptable the stop function must be based on direct flow measurement with a flowmeter or flow switch The flow switch is set in the menu Go to setting of digital input see 10 7 18 Overview of digital inputs 4 3 7 and 10 7 19 Fu...

Page 35: ...panel Setting range The digital input to be set is selected in display Overview of digital inputs 4 3 7 Note DI1 CU 351 cannot be selected Setting via control panel 1 Mark the Settings menu with 2 Mark Secondary functions with or and press 3 Mark Digital inputs or and press 4 Select the digital input with or and press 10 7 19 Functions of digital inputs 4 3 7 1 to 4 3 7 12 Fig 46 Functions of digi...

Page 36: ...lue for instance discharge pressure Measuring range of the sensor signal transmitter for instance 0 16 bar Setting range It is possible to set the following parameters in each display Input deactivated Range of input signal 0 10 V 0 20 mA 4 20 mA Measured input value Sensor range Setting via control panel 1 Mark the Settings menu with 2 Mark Secondary functions with or and press 3 Mark Analog inpu...

Page 37: ... and save with 10 Set the maximum sensor value with or and save with 10 7 23 Overview of digital outputs 4 3 9 Fig 50 Overview of digital outputs Description In this menu the digital relay outputs of the Hydro MPC can be set Each output can be activated and related to a certain function As standard the Hydro MPC has two digital outputs If the Hydro MPC incorporates an IO 351B module option the num...

Page 38: ...he CU 351 makes it possible to change between three operating modes 1 Min duty 4 3 14 1 2 Max duty 4 3 14 2 3 User defined duty 4 3 14 3 10 7 26 Min duty 4 3 14 1 Fig 53 Min duty Description In all booster sets apart from Hydro MPC S min duty is only possible for variable speed pumps In Hydro MPC S systems only the number of pumps running at 100 speed can be set Setting range Number of pumps in op...

Page 39: ...peration Speed as percentage for variable speed pumps Note In Hydro MPC booster sets with only variable speed pumps the speed can be set between 25 and 100 in booster sets with both variable speed pumps and mains operated pumps the speed can be set between 70 and 100 Setting via control panel 1 Mark the Settings menu with 2 Mark Secondary functions with or and press 3 Mark Min max and user defined...

Page 40: ...n option see 10 8 2 GENIbus The setpoint and operating mode are then set via the bus connection In this display the control source CU 351 or the external bus connection is selected 1 Mark the Settings menu with 2 Mark Secondary functions with or and press 3 Mark Control source with or and press 4 Select the desired control source with or and save with Factory setting The control source is CU 351 1...

Page 41: ...ctory setting If a pressure switch or pressure transmitter is fitted on the suction manifold the relevant function has been selected and set 10 7 34 Dry running protection with pressure level switch 4 4 1 1 Fig 61 Dry running protection with pressure level switch Description Dry running protection can take place by means of a pressure switch on the suction manifold or a level switch in a possible ...

Page 42: ...der The function is activated Restart Automatic 10 7 36 Dry running protection with level transmitter 4 4 1 3 Fig 63 Dry running protection with level transmitter Description Dry running protection can take place by means of a level transmitter measuring the level in a tank on the suction side It is possible to set two levels Warning level 1 and alarm stop level 2 In the display it is possible to ...

Page 43: ... or and press to activate deactivate the function 5 Mark Min pressure with or Set the pressure with or and save with 6 Mark Stop at min pressure with or and press to activate deactivate the function 7 Mark Time delay of function at start up with or Set the time with or and save with 8 Mark Time delay of function during operation with or Set the time with or and save with Factory setting The functi...

Page 44: ...unction with 8 Mark Manual or Auto with or Activate the function with Factory setting The function is deactivated If the function is activated the following values have been set from factory Time delay 5 seconds Operating mode in case of alarm Stop Restart Manual per order default if active DI 3 10 7 40 Functions CU 351 4 5 Fig 67 Functions CU 351 Description In this submenu it is possible to make...

Page 45: ...th or and press 4 Select the unit with or and save with A check mark shows that the unit has been selected 5 Select the measuring parameter with or and press to open the display for the measuring parameter See the example Fig 70 Example of setting of display units 6 Select the unit with or and save with A check mark shows that the unit has been selected Factory setting CU 351 has been set to US un...

Page 46: ...te and time may have been changed during the setting of Hydro MPC 10 7 44 Passwords 4 5 4 Fig 72 Passwords Description In this display it is possible to limit the access to the Operation and Settings menus by means of a password If the access is limited it is not possible to view or set any parameters in the menus The password must consist of four digits and may be used for both menus Note If you ...

Page 47: ...ermore status about important parameters such as current value and input power and fault indications can be read from the CU 351 Contact Grundfos for further information Setting range The number can be set between 1 and 64 Setting via control panel 1 Mark the Settings menu with 2 Mark Functions CU 351 with or and press 3 Mark GENIbus number with or and press 4 Select the number with or and save wi...

Page 48: ... in the CU 351 or via the web server See the example in fig 77 Fig 77 Example of setting of Ethernet Dynamic assignment of an IP address for the CU 351 requires a DHCP server in the network The DHCP server assigns a number of IP addresses to the electrical units and makes sure that two units do not receive the same IP address A traditional Internet browser is used for connection to the web server ...

Page 49: ...e JavaScript program The Java Runtime Environment application will then export the CU 351 user interface including display and operating panel to the computer screen It is now possible to monitor and control the CU 351 from the computer Fig 80 Network setting Change of network setting When connection to the web server of the CU 351 has been established it is possible to change the network setting ...

Page 50: ... to an external network The connection can take place via a GENIbus based network or a network based on another protocol via a gateway see fig 76 For further information contact Grundfos The gateway may be a Grundfos G100 gateway or a third party gateway For further information on the G100 gateway see the G100 data booklet publication number V7139522 TM03 2051 3505 www motralec com service commerc...

Page 51: ...n Value or number in the display of VLT Function Value or number in the display of VLT 2 Local remote operation Local remote operation 0 3 Local reference Local reference Default 101 Torque characteristics Torque characteristics 2 102 Motor power Motor power Motor nameplate in kW 103 Motor voltage Motor voltage Motor nameplate 104 Motor frequency Motor frequency Motor nameplate Hz 105 Motor curren...

Page 52: ...equency Hz 3 008 Small display readout Motor voltage V 16 009 Small display readout Motor current 5 010 Small display readout Power Hp 6 101 Torque characteristics VT low 2 113 Motor Preheater DC Current 0 117 Motor Thermal Protection ETR Trip 1 4 208 Automatic ramp down Disable 0 210 Reference type External preset 2 302 Pin 18 Start 1 303 Pin 19 Reverse and start 2 304 Pin 27 Safety interlock 3 3...

Page 53: ...Restart aut man Auto Motor data Motor voltage 230 V Motor data Motor rated amps SFA on nameplate Level 1 blocks Preset speed Preset speed 1 60 Hz Accel Accel 1 CR 3 CR 10 1 5 sec CR 15 CR 90 2 0 sec Decel rate Decel 1 CR 3 CR 10 3 0 sec CR 15 CR 90 4 0 sec Output Opto output 1 Ready Input Operating mode 1 2 wire 7 spd Input ANA CMD select Pot 0 10 V V Hz and Boost V Hz profile 67 sqr law www motra...

Page 54: ...54 Variable frequency drive setting notes www motralec com service commercial motralec com 01 39 97 65 10 ...

Page 55: ...red by the Hydro MPC Cable is broken or short circuited Repair or replace the cable CU 351 fault Electricity supply disconnected Connect the electricity supply CU 351 defective Contact Grundfos Unstable water delivery from Hydro MPC applies to unstable water supply Inlet pressure is too low Check the suction pipe and possible suction strainer Suction pipe or pumps partly blocked by impurities Clea...

Page 56: ...low the pump will be delivering Hv Vapor pressure in feet NPSH Net Positive Suction Head in feet NPSH can be read from the NPSH curve at the maximum capacity at which the pump will run See installation and operating instructions for CR CRI CRN HS Safety margin minimum 2 feet If H is calculated as positive the pump can operate at a suction of maximum H feet If H is calculated as negative an inlet p...

Page 57: ... contact the nearest Grundfos company or service workshop Open circuit voltage 24 VDC Closed circuit current 5 mA DC Frequency range 0 4 Hz Note All digital inputs are supplied with PELV voltage Protective Extra Low Voltage Input current and voltage 0 20 mA 4 20 mA 0 10 V Tolerance 3 3 of full scale Repetitive accuracy 1 of full scale Input resistance current 250 Ω Input resistance voltage CU 351 ...

Page 58: ...58 www motralec com service commercial motralec com 01 39 97 65 10 ...

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