GRUNDFOS INSTRUCTIONS

UPE Series 2000 FZService parts

Tabl

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s

3

UPE Series 2000 FZ

English (GB) Installation and operating instructions . . . . . . . . . . . . . . . . .4Dansk (DK) Monterings- og driftsinstruktion. . . . . . . . . . . . . . . . . . . . . .16Deutsch (DE) Montage- und Betriebsanleitung. . . . . . . . . . . . . . . . . . . . .28Ελληνικά (GR) Οδηγίες εγκατάστασης και λειτουργίας . . . . . . . . . . . . . . . .40Español (ES) Instrucciones de instalación y funcionamiento . . . . . . . . . .52Français (FR) Notice d'installation et de fonctionnement . . . . . . . . . . . . .64Italiano (IT) Istruzioni di installazione e funzionamento . . . . . . . . . . . . .76Nederlands (NL) Installatie- en bedieningsinstructies . . . . . . . . . . . . . . . . . .88Português (PT) Instruções de instalação e funcionamento . . . . . . . . . . . .100Русский (RU) Руководство по монтажу и эксплуатации . . . . . . . . . . .112Suomi (FI) Asennus- ja käyttöohjeet . . . . . . . . . . . . . . . . . . . . . . . . .125Svenska (SE) Monterings- och driftsinstruktion. . . . . . . . . . . . . . . . . . . .137

Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149

English (GB)

4

English (GB) Installation and operating instructions

Original installation and operating instructions.

CONTENTSPage

1. Symbols used in this document 52. General introduction 53. Replacement of control box 64. Replacement of power head 85. Replacement of differential-pressure sensor 106. Replacement of control box fan 117. Replacement of connecting cable (UPED 80-120 FZ) 128. Configuration of twin-head pumps 139. Start-up 149.1 Venting the pump 1410. Disposal 15

WarningPrior to installation, read these installation and operating instructions. Installation and operation must comply with local regulations and accepted codes of good practice.

WarningThe use of this product requires experience with and knowledge of the product.Persons with reduced physical, sensory or mental capabilities must not use this product, unless they are under supervision or have been instructed in the use of the product by a person responsible for their safety.Children must not use or play with this product.

Engl

ish

(GB)

5

1. Symbols used in this document

2. General introductionThese instructions relate to UPE Series 2000 circulator pumps, types UPE, UPED 80-120 FZ and UPE 100-120 FZ and describe how to replace the following components:• control box• power head• differential-pressure sensor• control box fan• connecting cable (UPED 80-120 FZ).See also the general installation and operating instructions and the document "Supplement to installation and operating instructions" included.All figures referred to can be found in the fold-out page at the end of this booklet. In most figures only a single-head pump is shown, but all dismantling and assembly instructions apply to both single-head and twin-head pumps.

WarningIf these safety instructions are not observed, it may result in personal injury!

WarningThe surface of the product may be so hot that it may cause burns or 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.

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6

3. Replacement of control boxDismantling

1. Check that the "Reorder No." of the new control box is identical to that of the existing control box. See fig. 1.

2. Switch off the power supply to the pump, and make sure that it cannot be accidentally switched on again during replacement.

3. Remove the four screws securing the control box cover. Remove the cover. See fig. 2.

4. Before disconnecting any leads, carefully note their position.5. Disconnect all leads from the control box.6. Unscrew the five screws securing the printed circuit board (PCB) to the

control box bottom and remove the PCB from the control box. See fig. 4.7. Remove the two rubber plugs. See fig. 6.8. Remove the two screws securing the terminal box to the power head.

See fig. 5.9. Remove the control box bottom from the power head. See fig. 6.10. Dismantle the new control box for easy mounting. See fig. 2 and fig. 4.

WarningNever make any connections in the pump control box unless the power supply has been switched off for at least 5 minutes.Make sure that voltage supplies from other external systems have been switched off as well.

Caution

Always use an antistatic service kit (Grundfos ESD, protection set prod. no. 96884939) when dismantling and assembling the terminal box as the electronics are sensitive to static electricity. Connect the antistatic service kit to the connection terminal of the protective earth lead (PE terminal).

Engl

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7

Assembly1. Mount the new control box bottom on the power head. See fig. 6.

Check that the gasket is positioned correctly. See fig. 7.Be careful not to damage the motor cable.Refer to section Wiring diagram in the general installation and operating instructions.

2. Remove the two rubber plugs. See fig. 6.3. Fit and tighten the two screws. See fig. 5.4. Mount the PCB, fit and tighten the five screws. See fig. 4.5. Connect the motor cable including screen and PE lead. See fig. 8.6. Enter the leads into the control box bottom via the cable entries.7. Connect all the leads in the same positions as before dismantling.8. Mount the cover, fit and tighten the four screws. See fig. 2.9. Twin-head pumps:

Follow the instructions given in section 8. Configuration of twin-head pumps in order to obtain the right configuration.

The pump is now ready for operation. See section 9. Start-up.

English (GB)

8

4. Replacement of power headDismantling

1. Note the pump type of the faulty power head and find the corresponding service nameplate delivered together with the new power head. Fit the service nameplate on the new power head. See fig. 9.

2. Switch off the power supply to the pump, and make sure that it cannot be accidentally switched on again during replacement.

3. Close the isolating valves on either side of the pump or empty pipe system for water.

4. Remove the four screws securing the control box cover. Remove the cover. See fig. 2.

5. Before disconnecting any leads, carefully note their position. 6. Disconnect all leads from the control box. 7. Unscrew the five screws securing the PCB to the control box bottom and

remove the PCB from the control box. See fig. 4.8. Remove the two rubber plugs. See fig. 6.9. Remove the two screws securing the terminal box to the power head.

See fig. 5.

WarningPlease note that the pump may be hot for a while after being switched off and that hot liquid may escape from the pump during dismantling.

WarningNever make any connections in the pump control box unless the power supply has been switched off for at least 5 minutes.Make sure that voltage supplies from other external systems have been switched off as well.

Caution

Always use an antistatic service kit (Grundfos ESD, protection set prod. no. 96884939) when dismantling and assembling the terminal box as the electronics are sensitive to static electricity. Connect the antistatic service kit to the connection terminal of the protective earth lead (PE terminal).

Engl

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9

10. Remove the control box bottom from the power head. See fig. 6.11. Hold the power head, and remove the four screws securing the power

head to the pump housing. See fig. 10.

12. Pull off the power head. See fig. 11.

Assembly1. Check that the O-ring is in place. See fig. 12.2. Fit the new power head in the same position as old power head.

See fig. 11.3. Fit and tighten the four screws diagonally (20 Nm). See fig. 10. 4. Mount the control box bottom on the power head. See fig. 6.

Check that the gasket is positioned correctly. See fig. 7.Be careful not to damage the motor cable.

5. Fit and tighten the two screws. See fig. 5.6. Mount the PCB, fit and tighten the five screws. See fig. 4.7. Connect the motor cable including screen and PE lead. See fig. 8.8. Enter the leads into the control box bottom via the cable entries.9. Connect all the leads in the same positions as before dismantling.10. Mount the cover, fit and tighten the four screws. See fig. 2.11. Open the isolating valves on either side of the pump.12. Twin-head pumps:

Follow the instructions given in 8. Configuration of twin-head pumps in order to obtain the right configuration.

The pump is now ready for operation. See section 9. Start-up.

WarningTake care that escaping liquid does not cause personal injury or damage to components.

English (GB)

10

5. Replacement of differential-pressure sensorDismantling

1. Switch off the power supply to the pump, and make sure that it cannot be accidentally switched on again during replacement.

2. Close the isolating valves on either side of the pump or empty pipe system for water.

3. Remove the four screws securing the control box cover. Remove the cover. See fig. 2.

4. Disconnect the plug from the terminal block (D). See fig. 13. Refer to section Wiring diagram in the general installation and operating instructions.

5. Unscrew the cable entry. See fig. 14.6. Remove the two screws securing the metal block with the differential

pressure sensor to the pump housing. See fig. 15.7. Remove the metal block with the sensor from the pump. See fig. 15.8. Dispose of the faulty differential pressure sensor according to

section 10. Disposal.

Assembly1. Place the O-ring from the sensor kit on the pump housing. See fig. 17.1. Fit the metal block holding the sensor on the pump housing without

damaging the O-ring. See fig. 16.2. Tighten the two screws. See fig. 15.3. Enter the lead into the control box bottom.4. Fit the plug into the terminal block (D). See fig. 13.5. Tighten the cable entry. See fig. 14.6. Mount the cover, fit and tighten the four screws. See fig. 2.7. Open the isolating valves on either side of the pump.The pump is now ready for operation. See section 9. Start-up.

WarningPlease note that the pump may be hot for a while after being switched off and that hot liquid may escape from the pump during dismantling.

WarningNever make any connections in the pump control box unless the power supply has been switched off for at least 5 minutes.Make sure that voltage supplies from other external systems have been switched off as well.

Engl

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(GB)

11

6. Replacement of control box fanDismantling

1. Switch off the power supply to the pump, and make sure that it cannot be accidentally switched on again during replacement.

2. Remove the four screws securing the control box cover. Remove the cover. See fig. 2.

3. Remove the fan from the heat sink in the control box. See fig. 19.4. Disconnect the fan plug from the fan socket in the PCB. See fig. 19.5. Dispose of the faulty fan according to section 10. Disposal.

Assembly1. Fit the plug of the new fan into the socket in the PCB. See fig. 19.2. Mount the new fan. See fig. 19.

3. Mount the cover, fit and tighten the four screws. See fig. 2.The pump is now ready for operation. See section 9. Start-up.

WarningNever make any connections in the pump control box unless the power supply has been switched off for at least 5 minutes.Make sure that voltage supplies from other external systems have been switched off as well.

Caution

Always use an antistatic service kit (Grundfos ESD, protection set prod. no. 96884939) when dismantling and assembling the terminal box as the electronics are sensitive to static electricity. Connect the antistatic service kit to the connection terminal of the protective earth lead (PE terminal).

Note The arrows marked on the side of the fan shows the direction of rotation and the direction of the cooling air. See fig. 20.

English (GB)

12

7. Replacement of connecting cable (UPED 80-120 FZ)Dismantling

1. Switch off the power supply to the pump, and make sure that it cannot be accidentally switched on again during replacement.

2. Remove the 2 x 4 screws securing the control box covers on the two control boxes. Remove the covers. See fig. 2.

3. Disconnect the connecting cable from the sockets. See fig. 21.4. Unscrew the two cable entries on the two control boxes.5. Remove the connecting cable.

Assembly1. Enter the connecting cable into the control box bottoms.2. Mount plugs of the new connecting cable in the sockets of the two control

boxes. See fig. 21.3. Fit and tighten the two cable entries.4. Mount the covers, fit and tighten the 2 x 4 screws. See fig. 2.The pump is now ready for operation. See section 9. Start-up.

WarningPlease note that the pump may be hot for a while after being switched off and that hot liquid may escape from the pump during dismantling.

WarningNever make any connections in the pump control box unless the power supply has been switched off for at least 5 minutes.Make sure that voltage supplies from other external systems have been switched off as well.

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8. Configuration of twin-head pumpsUse the procedure below to establish the correct master/slave configuration in case one of the control boxes or both have been replaced.

Configuration1. Switch off the power supply to the pump.2. Switch on the power supply and press the two arrow buttons on the front

simultaneously for 15 seconds (two flashing light fields indicate that the pump is in configuration mode).

3. Keep the buttons depressed, and the flashing light fields will change. See the meaning of the different settings in the table below.

4. Release the buttons when the control box is in the appropriate mode.

Refer to the general installation and operating instructions and the document Supplement to installation and operating instructions for further information about setting of the pump.

Configuration Light fields

Single pump

TM04

683

4 10

10

Master pump, marked (1)

TM04

683

5 10

10

Slave pump, marked (2)

TM04

683

3 10

10

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9. Start-upDo not start the pump until the system has been filled with liquid and vented. Furthermore, the required minimum inlet pressure must be available at the pump inlet. See the general installation and operating instructions.

9.1 Venting the pumpVent the pump before start-up. See figure below.

Due to air remaining in the pump, the pump may be noisy when first switched on. This noise should cease after a few minutes of operation.After start-up, set the desired operating mode and head.

Note The system cannot be vented through the pump.

WarningWhen the air vent screw is loosened, scalding hot liquid under high pressure may escape. Take care that escaping liquid does not cause personal injury or damage to components.

TM04

463

5 18

09 -

TM04

463

6 18

09

Air vent screw

Venting the pump

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10. DisposalThis product or parts of it must be disposed of in an environmentally sound way:1. Use the public or private waste collection service.2. If this is not possible, contact the nearest Grundfos company or service

workshop.

Subject to alterations.

Appendix

149

Appendix

Fig. 1

TM04

685

6 10

10

Appendix

150

Fig. 2

Fig. 3

TM04

685

7 10

10TM

04 6

858

1010

Appendix

151

Fig. 4

Fig. 5

TM04

685

9 10

10TM

04 6

860

1010

Appendix

152

Fig. 6

Fig. 7

TM04

686

1 10

10TM

04 6

862

1010

Appendix

153

Fig. 8

Fig. 9

TM04

686

3 10

10TM

04 6

864

1010

Appendix

154

Fig. 10

Fig. 11

TM04

686

5 10

10TM

04 6

866

1010

Appendix

155

Fig. 12

Fig. 13

TM04

686

7 10

10TM

04 6

868

1010

Appendix

156

Fig. 14

Fig. 15

TM04

686

9 10

10TM

04 6

870

1010

Appendix

157

Fig. 16

Fig. 17

TM04

687

1 10

10TM

04 6

872

1010

Appendix

158

Fig. 18

Fig. 19

TM04

687

3 10

10TM

04 6

874

1010

Appendix

159

Fig. 20

Fig. 21

TM04

687

5 10

10TM

04 6

876

1010

Gru

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ArgentinaBombas GRUNDFOS de Argentina S.A.Phone: +54-3327 414 444Telefax: +54-3327 411 111

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