Grundfos BoosterpaQ PFU 2000 Instructions Manual
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Grundfos BoosterpaQ PFU 2000 Instructions Manual

Cr-booster systems 60 hz
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BpaQ IO INDD.indd
BoosterpaQ
Grundfos CR-Booster Systems
60 Hz
1
GRUNDFOS INSTRUCTIONS
®
Installation and operating instructions
Factory settings are documented in this manual.
Please leave these instructions with the BoosterpaQ
for future reference.
For technical support, call your supplier or contact
Grundfos Pumps Corporation at 913 227 3400 (USA).
1/28/2005, 11:00 AM

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  • Page 1 Installation and operating instructions Factory settings are documented in this manual. Please leave these instructions with the BoosterpaQ for future reference. For technical support, call your supplier or contact Grundfos Pumps Corporation at 913 227 3400 (USA). BpaQ IO INDD.indd 1/28/2005, 11:00 AM...
  • Page 2 Model: Part Number: PFU 2000 Eprom P/N: PMU 2000 Eprom P/N: Serial Number: Production Date: Your BoosterpaQ was factory assembled and tested with the factory set control parameters listed at the beginning of one of the following sections as marked. Standard PFU 2000 System Controller (See pages 6 and 7 for Installation and Start-up) Standard PMU 2000 System Controller...

  • Page 3: Table Of Contents

    Technical information ......34 as described in Article 250-80 of the National Electrical Code. Application BoosterpaQ System Types Grundfos BoosterpaQ systems are designed for transfer System System and boosting of clean water in commercial buildings, Type...

  • Page 4: Control Modes

    BoosterpaQs offer the following functions: • Closed-loop control Grundfos BoosterpaQ systems consist of 1-8 pumps with all necessary fittings and a Grundfos Control 2000 • Automatic shut-off at zero flow mounted on a common base frame, ready for installation. • Automatic cascade control of pumps The Control 2000 has its own base for large BoosterpaQs.
  • Page 5 Grundfos BoosterpaQ MSH maintains a pressure range by cutting in/out the half-size pump and the full-size pumps. The half-size pump will always start first. The half-size pump will be cut out again when a full-size pump is cut in. The operating range of the pumps will lie between the lines Hset and Hstop (cut-out pressure).

  • Page 6: Installation

    VFD failure or other system causes, a pressure relief device must be installed. Another option is to install a pressure sustaining valve to return discharged fluid back to the suction manifold. Grundfos offers this option. BpaQ IO INDD.indd 1/28/2005, 11:01 AM...

  • Page 7: Startup

    PFU 2000 PFU 2000 Startup 7. Turn Function Selector (small knob Setpoint 1. Have a qualified person Function Selector on the PFU Controller) in the PFU 2000 check for proper power on the PFU 2000 to supply plumbing 100% “Max” (see drawing STOP connections.
  • Page 8 3 phase pumps, switch any 2 of the 3 power main wires supplied to the control panel (L1, L2, L3). If that 4. Prime the system as follows. doesn’t correct the rotation, call your Grundfos repre- Suction Pressure System (pumps are flooded at least as sentative.

  • Page 9: Troubleshooting

    Call your Grundfos dis- 16. There should be no more faults. If there are, you will tributor or the Grundfos factory if you believe you have need to review the Troubleshooting section beginning discovered incorrect wiring or documentation.
  • Page 10 12 depending or whether your system has only a below the set-point. If the system stops and starts PFU 2000 or a PMU 2000. Call your Grundfos distribu- frequently the tank pre-pressure may be too low or too tor or the Grundfos factory if you believe you have high.
  • Page 11 Troubleshooting/Fault-finding chart Fault Cause Remedy 1. Motor does not run when a) Electricity supply disconnected or loose Connect the electricity supply. Check for loose started. wires. wires. DO NOT over tighten terminal screws. b) Automatic circuit breakers cut out. Correct the fault and cut in the automatic circuit breakers.
  • Page 12 PMU fault indication menu Press the button on the PMU to see the following faults. The PMU will keep the last 10 faults in memory. Alarm type: Zone, Pump, Detail of alarm: See chart PFU, System. below. Alarm zone A min.
  • Page 13 Faults, general Automatic resetting (restarting of PFU 2000) Fault conditions in the system are indicated by: When a fault has been corrected, the system will attempt • Red indicator light (LED) on PFU or PMU to restart automatically at the following intervals: •...

  • Page 14: Factory Settings

    Controller” was marked). The factory settings cover most standard booster applications. Please contact your DIP/Switch #1 DIP/Switch #2 Grundfos representative if you believe the settings should be changed to match your application or the system is not operating properly. PFU 2000 front cover "X"...
  • Page 15 2 of this manual (if “Optional” PMU 2000 system control- ler” was marked). The factory settings cover most standard booster applications. Please contact your Grundfos repre- sentative if you believe the settings should be changed to match your application or the system is not operating properly.
  • Page 16 PMU factory settings All Pumps Set to Zone A Other ( Alarm Suppression Pump Communication Configuration Pre-Setting Other ( 8 With Pre-Pressure Monitoring Set-point Max _______ Clock Program - See Below Set-point Influence Set-point Influence ____% System Time _____ seconds Min Sequence _____seconds Medium Sequence* ______seconds On/Off Band _______...
  • Page 17 201 clock program Daily Sa-Su Time Set-point Time Set-point Time Set-point 219 discharge sensor 227 pump priority Pump 1 Pump 4 4-20mA Other ( __________ ) Pump 2 Pump 5 _____ to _____PSI Other (________________) Pump 3 Pump 6 220 suction sensor 227 pump maximum head 4-20mA Other ( __________ )
  • Page 18 Danfoss VLT 2800 Factory Settings Field changes Parameter Description Factory setting New value Date Local/Remote Operation Local Reference Default Torque Characteristics Motor Power, kW Motor Voltage Motor Frequency, Hz Motor Current, SFA Rated Motor Speed, RPM Automatic Motor Adaptation Thermal Motor Protection Minimum Reference Maximum Reference Ramp Type...
  • Page 19 Danfoss VLT 8000 Factory Settings Factory Setting Field Changes Item Number Parameter Value Value # New Value Date 001 Language English 102 Motor Power 103 Motor Voltage 104 Motor Frequency 105 Motor Current 106 Motor Speed 201 Minimum Freq. 202 Maximum Freq. 206 Ramp Up Time 207 Ramp Down Time 323 Relay 1 Function...
  • Page 20 Danfoss VLT 8000 Factory Settings (continued) Extended Menu Programming Factory Setting Field Changes Item Number Parameter Value Value # New Value Date Level 0 007 Large Readout 008 Small Display Readout 009 Small Display Readout 010 Small Display Readout Level 1 101 Torque Characteristics VT Low 112 Motor Preheater...
  • Page 21 Baldor SmartMotor Settings Factory Setting Field Changes Section Parameter Value New Value Date Level 2 Blocks Output Limits Min Output Freq. 12 Hz Output Limits Max Output 60 Hz Output Limits PK Current Limit Output Limits PWM Frequency 6 kHz Miscellaneous Restat Aut/Man Auto...

  • Page 22: Pre-Pressure Measuring

    PMU 2000 LCD display overview WITH pre-pressure measuring The following PMU 2000 LCD Display Overview illus- trates the LCD Menus and Displays for the Optional PMU 2000. To return to Display 100, repeatedly press “Esc.” Refer to page 24 for “PMU 2000 LCD Display Notes.” Pump status menu Zone status menu Zone A...
  • Page 23 Basic menu Zone A 8 press. Fault indication menu On/off menu Setting menu Set A medium sequence Set A Setting of hydraulic parallel control parameters pump priority Set A min. speed Available only when service code is activated (Display 106). Moves one display up in menu...

  • Page 24: Pmu 2000 Lcd Display Notes

    [-] under all other pump numbers. Press “Enter” to Grundfos for service. If this display does not come up, the store each entry and advance to the next pump number.
  • Page 25 111 - Presetting Possible settings for days: See Display 102. 1 - [daily] The same switching times apply to each day of the week. SETTING MENU (“SET BUTTON”) 2 - [Mon, Tue, Wed, Thu, Fri, Sat, Sun] 200 - Setting of Set-point Max. Different switching times for each day.
  • Page 26 From 12:31 to the next time, the set-point will be 55 psi. The First of all the progressive influence needs to be switched next time is at 6:30 am, which was the first entry. “on”. Once this is done the PMU display should look like the following: 202 - Set-point Influence Set A...
  • Page 27 Approximately every 30 seconds or when the operating Notice that the temperature will most likely shoot past the new set-point because of the 0.4 setting, but now point changes (consumption changes), the PMU 2000 will you will change the system time constant to 0.7 times the estimate the flow by reducing the speed for a short while.
  • Page 28 Other influences are available for applications other than [invers] If the actual value is higher than the set-point, the pressure boosting. Please consult Grundfos if you want to pump performance is increased. This might be used in a use one of the other influences.
  • Page 29 PMU 2000 LCD display notes (continued) operate under “reduced op” is set in this display. The selec- tion range is from 0 pumps to one pump less than the total 220 - Suction Pressure Sensor Measuring Range, Input 2 number of pumps on the BoosterpaQ. The default value is (AI 2) 0, resulting in all pumps stopping when a switch is closed The suction pressure sensor signal output is recorded here.
  • Page 30 This function can be used to check for a broken pipe. The START/STOP MENU system designer must confirm what the limit should be to indicate a broken pipe to avoid nuisance tripping. If a pipe 300 - Start/Stop of Zones has actually broken, the pressure won’t rise and the system The top line indicates the specific zone (“A”...
  • Page 31 403 - Actual Value [invers] If the actual value is smaller than the set-point, the This display indicates the actual discharge pressure. pump performance will be reduced. 404 - Speed 413 - Medium Sequence This display indicates the performance sum of all the oper- Timing function, only available when service code is ating pumps.
  • Page 32 425 - Min. Limit Operation FAULT INDICATION MENU Indicates whether “min. limit operation” is active or inac- tive as selected in Display 230. 600 - Examples of Fault Indications Examples of fault indications for the PFU 2000: [on] No pumps are switched off if the value falls below the minimum limit, but a fault is indicated.

  • Page 33: Maintenance

    PMU 2000 GRUNDFOS BUS PFU 2000 Maintenance PMU 2000 Care must be taken to ensure that escaping water does not cause injury to persons or damage to the motor or other components. In hot water installations, special attention GRUNDFOS BUS should be paid to the risk of injury caused by scalding hot water.

  • Page 34: Technical Information

    Technical information DIP Switch Setting for PFU 2000. See the factory settings sections of this manual. DIP Switch DIP 1 DIP 2 Setting of On/Off Band Very Small 7 psi Small 10 psi Normal 15 psi Large 22 psi Setting of system time, minimum switching sequence and medium switching sequence Quick...
  • Page 35 Technical information (continued) Expansion module - PFU Expansion module - Control Board, 2000/9 Only. PFU 2000/4 PFU 2000/9 & PFU 2000/4 on MS and MSH systems do not have an expansion board. Expansion module - Control Board, PFU 2000/9 & PFU 2000/4 AI 2 AI 1 Also refer...
  • Page 36 Recommended Diaphragm Tank Size (gallons) more than 5%. Pump Type CR(E) 3 Sound pressure level CR(E) 5 For individual pump sound pressure values, call Grundfos. The sound pressure level for a number of pumps can be CR(E) 10 calculated as follows: CR(E) 15 Lmax...
  • Page 37 Maximum inlet pressure Discharge pressure must not exceed the tank, sensor and gauge ratings. Pump psi (bar) CR, CRI, CRN 1s 1s-2 1s-27 145 (10) CR(E), CRI(E), CRN(E) 1 1-25 145 (10) 1-27 218 (15) CR(E), CRI(E), CRN(E) 3 3-15 145 (10) 3-17 3-25...
  • Page 38 1 x 230-240V + 6% / -10%, 60 Hz, PE A, Y, B Communication among the units in the GRUNDFOS BUS, RS-485, GRUNDFOS BUS protocol Grundfos Pump Management System 2000 Analog/digital input for motor protection PTC or thermal switch (NC)
  • Page 39 GRUNDFOS’ liability under this warranty shall be limited to repairing or replacing at GRUNDFOS’ option, without charge, F.O.B. GRUNDFOS’ factory or authorized service sta- tion, any product of GRUNDFOS’ manufacture. GRUNDFOS will not be liable for any costs of removal, installation, transportation, or any other charges which may arise in connection with a warranty claim.
  • Page 40 Innovation is the essence L-BP-TL-001 Rev. 1/05 PRINTED IN USA GRUNDFOS Pumps Corporation GRUNDFOS Canada, Inc. Bombas GRUNDFOS de Mexico, S.A. de C.V. 17100 W. 118th Terrace 2941 Brighton Road Boulevard TLC #15 Olathe, KS 66061 Oakville, Ontario, Canada L6H 6C9...

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