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MGE Model H I Service Instruction MGE71, 80 e 90
MGE Model H I Service Instruction MGE71, 80 e 90
English (GB)
Original service instructions. 2. General information
These service instructions apply to MGE 71, MGE 80 and
CONTENTS MGE 90, models H and I.
Page
The installation and operating instructions for
1. Symbols used in this document 3 Note this product and for the system which it is part of
2. General information 3 must be available during service of the product.
3. Torques 3 Position numbers of parts (digits) refer to drawings and parts lists;
4. Secondary materials 4 position numbers of tools (letters) refer to section 5. Service
5. Service tools 4 tools.
6. Megging 5 Electrical parts must only be serviced by Grundfos or an
authorised service workshop.
7. Replacing hardware 5
7.1 Replacing the terminal box cover 5 Warning
7.2 Replacing the battery 5 Use personal protective equipment if there is a
7.3 Fitting the antenna 5 risk of getting into contact with the pumped
7.4 Replacing the control panel 5 liquid.
7.5 Replacing the CIM module 6
Observe local regulations.
7.6 Replacing the isolation cover 7
7.7 Replacing the functional module 7 Before dismantling
7.8 Replacing the power module 7
Warning
7.9 Replacing the terminal box 8
7.10 Replacing the stator housing 8 Switch off the power supply and make sure that it
7.11 Replacing the fan 8 cannot be accidentally switched on. The power
7.12 Replacing the bearings 8 supply must be switched off for at least five
7.13 Replacing IP55 seal rings with IP66 rings minutes before you start working on the motor.
9
7.14 Configuring the controller 10 Check that other pumps or sources do not force
flow through the pump even if the pump is
8. Fault finding 14
stopped. This will cause the motor to act like a
8.1 General information 14
generator, resulting in voltage on the terminals.
8.2 Fault indications 15
8.3 Functional module 17 • Close the isolating valves, if fitted, and make sure that they
8.4 Power module 20 cannot be accidentally opened.
8.5 Winding resistance 23 • Before starting work on the product, let the product and
9. Exploded view 25 pumped liquid cool off.
10. Disposal 26 During assembly
• Lubricate and tighten screws and nuts according to
Warning section 3. Torques and 4. Secondary materials.
Prior to service work, read these service After assembly
instructions carefully. Installation and service • If analog or digital inputs, the relay output or the CIM module
work must comply with local regulations and has been removed from the functional module, you must
accepted codes of good practice. check the communication with external units after service. See
Observe the safety instructions in the installation section 7.14 Configuring the controller.
and operating instructions for the product.
3. Torques
1. Symbols used in this document
Dimensions Torque
Pos. Designation Type
Warning [mm] [Nm]
If these safety instructions are not observed, 152 Tx25 12 x M5 3.5 - 4
it may result in personal injury.
178 Tx30 16/10 x 60 5 - 6*
Warning 185 Tx30 16 x M6 5-6
If these instructions are not observed, it may lead 192 Tx30 14 x 6 5 - 6*
to electric shock with consequent risk of serious 251d Tx25 50 x M5 5 - 6*
personal injury or death.
268 Torx screw Tx 25 12 x M5 3.5 - 4
Warning 273a Tx20 32 x M4 1 - 1.3
The surface of the product may be so hot that 277a Tx20 32 x M4 1 - 1.3
it may cause burns or personal injury. 286 Tx40 21 x M7 2.2 - 2.7
288a Tx20 M4 1 - 1.3
If these safety instructions are not observed,
Caution
289a Tx30 14 x 6 5-6
it may result in malfunction or damage to the
equipment. 291 Union M20 M20 x 1.5 1 - 1.3
Notes or instructions that make the job easier * Screws of new terminal boxes must be tightened to 7-8 Nm.
Note
and ensure safe operation.
3
Torques for terminals
Further
English (GB)
Special tools
N O
4
6. Megging
English (GB)
An installation with MGE motors must not be
megged as this may damage the built-in
Caution electronic parts.
Motor windings may, however, be megged if the
terminal box has been removed.
Max. test voltage Max. leakage current [mA] 7.3 Fitting the antenna
1000 VAC/1500 VDC 35 1. Disconnect the power supply.
2. Remove the terminal box cover.
7. Replacing hardware See section 7.1 Replacing the terminal box cover.
3. Remove blanking plug (pos. 252b) from the terminal box.
Always use an antistatic service kit when 4. Fit union (pos. 291) in the terminal box.
handling electronic components. This will
5. Lead the antenna into the union from above and tighten the
prevent static electricity from damaging
Caution top part (close to the wire).
components.
6. Click the antenna wire onto the control panel (pos. 290).
When unprotected, the component must be
The antenna wire is long enough to be fitted in both positions
placed on the antistatic cloth.
of the control panel.
5
7. Position the control panel correctly on the four rubber pins 8. Fit the new CIM module by aligning it with the plastic holders
(fig. 4, pos. C). Make sure that the locking tabs (fig. 4, pos. A) and the connecting plug. Press home the module using your
English (GB)
2
3
TM05 6711 5012
6
7.6 Replacing the isolation cover
English (GB)
The example below shows a three-phase motor.
1. Disconnect the power supply.
2. Remove the terminal box cover. See section 7.1 Replacing
the terminal box cover.
3. Remove control panel (pos. 290) from isolating cover
(pos. 277). See section 7.4 Replacing the control panel.
4. Remove CIM module (pos. 502) from the isolation cover.
See section 7.5 Replacing the CIM module.
5. Pull up/out plug connections (pos. 266) using your fingers.
9. Insert the connecting plug into the new functional module with
the long end towards the module. Lead it through the module
and home.
10. Fit the functional module on the power module by means of
the five screws. See the order of the screws on the functional
module.
11. Fit the spacer on the module.
12. Gently push the connecting plug home.
13. FM300: Put battery in the module.
TM05 6712 5012
7
7.9 Replacing the terminal box 7.11 Replacing the fan
English (GB)
5. Push the fan on the shaft. Alternatively, gently knock the fan
onto the shaft (pos. 172) by means of a plastic hammer while
holding the drive end of the shaft against a solid surface.
6. Fit the fan cover on stator housing (pos. 150) and tighten
screws (pos. 152).
7. Fit the terminal box on the stator housing and cross-tighten
the screws.
Caution
rotor is magnetic.
8. Remove gasket (pos. 156d) from the flange.
9. Wrap a piece of cardboard or similar material around the
Fig. 11 Transferring data to new nameplate magnetic rotor part to protect it against damage and dirt.
10. Fit the terminal box cover. 10. Put the flange in a vice with soft jaws.
See section 7.1 Replacing the terminal box cover. 11. Remove bearing (pos. 154) with a puller.
12. MGE 90: Remove locking ring (pos. 187) from the flange.
7.10 Replacing the stator housing
13. Remove the rotor from the flange and place the rotor in the
1. Disconnect the power supply. vice.
2. Remove screws (pos. 178) and take terminal box (pos. 251a
and 251b) out of stator housing (pos. 150). Caution Do not tighten the vice on the bearing journal.
Support the terminal box when you remove the 14. MGE 90: Remove locking ring (pos. 188) from the shaft.
Note
motor. 15. Remove bearing (pos. 153) with a puller.
3. Remove the stator housing according the service instructions
of the system.
4. Install the stator housing in the system according to the
service instructions of the system.
5. Fit the terminal box on the stator housing and cross-tighten
the screws.
TM05 7027 0413
8
16. Clean the bearing journal with a clean cloth. 7.13 Replacing IP55 seal rings with IP66 rings
English (GB)
17. Heat the new bearing (pos. 153) to maximum 110 °C. 1. Disconnect the power supply.
Follow the instructions of bearing and bearing 2. Remove the stator housing from the terminal box.
Caution See section 7.10 Replacing the stator housing.
heater.
18. Fit the heated bearing (pos. 153) on the shaft (pos. 172). 3. Remove the fan. See section 7.11 Replacing the fan.
4. Remove seal rings (pos. 156c) from shaft (pos. 172).
5. Lubricate gamma ring (pos. 159d) and fit it on the drive end of
Warning
the shaft.
Use heat-resistant gloves.
6. Lift the motor so that the non-drive end of the shaft rests on a
solid, vibration-free surface.
19. MGE 90: Fit locking ring (pos. 188) on the shaft.
7. Gently knock the ring home with the relevant punch.
20. Place the flange in the vice and clean the bearing seat with a The distance between flange (pos. 156b) and ring must be 0.8
clean cloth. to 1.3 mm.
21. Clean the bearing and fit the rotor in the flange.
22. MGE 90: Fit locking ring (pos. 187) so that the bearing is held The design of the punch ensures correct
Note
by the flange. tolerances.
23. Clean the bearing journal in the non-drive end with a clean 8. Support the motor so that it rests on the drive end of the shaft.
cloth. 9. Lubricate gamma ring (pos. 159e) and fit it on the non-drive
24. Heat bearing (pos. 154) to maximum 110 °C. end of the shaft.
10. Gently knock the ring home with the relevant punch.
Follow the instructions of bearing and bearing The distance between stator housing (pos. 150) and ring must
Caution
heater. be 0.8 to 1.3 mm.
25. Fit the heated bearing (pos. 154) on the shaft (pos. 172). 11. Fit fan and cover.
See section 7.11 Replacing the fan.
Warning 12. Fit the terminal box.
See section 7.10 Replacing the stator housing.
Use heat-resistant gloves.
26. Remove the cardboard from the rotor when the bearings have
cooled down.
27. Fit the gasket (pos. 156d) on the flange.
28. Check that the corrugated spring water (pos. 158) is correctly
fitted in the stator housing.
29. Gently insert the rotor into the stator.
Warning
Watch your fingers when you insert the rotor, as
the magnet will pull rotor and stator together with
big force.
30. Unscrew the puller to slowly insert the rotor into the stator.
Press flange and stator together when the bearing (pos. 154)
has engaged with the stator housing. Check that the drain
hole of the flange faces downwards.
31. Remove the puller and cross-tighten screws (pos. 185).
32. Lubricate shafts ends and fit seal rings.
33. Check that the shaft can rotate freely.
34. Fit fan and cover.
See section 7.11 Replacing the fan.
35. Fit the terminal box.
See section 7.10 Replacing the stator housing.
9
7.14 Configuring the controller IR Connect
English (GB)
The terminal box is configured from factory for the intended 1. Switch on the power supply to the pump.
application and pump type. The configuration file number appears 2. Connect the MI 301 to the PC.
from the terminal box configuration label which is placed inside 3. Start the PC Tool. The first time the program is started, the
the terminal box. See fig. 14. message "No COM port selected" will be shown. Click [OK].
6. Open the dropdown menu "Select port" and select the port
"PCTool-Link". See fig. 16. Click [Apply].
7. Point the MI 301 at the IR eye of the pump.
Distance: max. 20 cm. See fig. 17.
8. Click [IR Connect]. See fig. 18. Wait while connection to the
pump is established (10-20 seconds).
TM05 6930 0313
Fig. 18 IR Connect
10
Radio Scan 9. Mark the pump to be connected and click [Connect].
See figures 22 and 23.
English (GB)
1. Switch on the power supply to the pump.
2. Connect the MI 301 to the PC.
3. Place the MI 301 at a distance of maximum 10 metres from
the pump.
4. Start the PC Tool. The first time the program is started, the
message "No COM port selected" will be shown. Click [OK].
10. Click the button for radio communication. See fig. 24. Status
in the PC Tool will change to "Connected". See fig. 25.
11
Direct Connect 7.14.2 Connection to motor via PC Tool Link
English (GB)
7. Open the dropdown menu "Select port" and select the port
"PCTool-Link". See fig. 27. Click [Apply].
8. Click [Direct Connect]. See fig. 28. Wait until connection has
been established to the products the MI 301 can communicate
with (10-20 sec.).
TM05 7208 0713
12
7.14.3 Configuration with PC Tool E-products
English (GB)
Find the desired configuration file in PC Tool E-products in this
way:
1. Start the PC Tool.
2. Find the desired configuration file in PC Tool E-products in
one of these ways:
• Search by the configuration number. See fig. 31.
• Search on the basis of the application that MGE is part of.
• Choose the file position on the PC hard disk via the PC Tool
E-products browser.
2 3
2. Select "Number".
5
5. Select the configuration file in the
list of search results.
6. Click [Send] to download the
13
8. Fault finding
English (GB)
IMG_0047
Fig. 34 Detailed fault description
14
8.2 Fault indications
English (GB)
The fault indication below can be read by means of the number in
brackets, as text or as status indications on the control panel,
depending on the equipment available.
15
Grundfos Eye Condition/cause Remedy
English (GB)
16
8.3 Functional module
English (GB)
Warning
The terminals of the power module are live.
Relay RL1 may also be live.
Warning
Measuring equipment must be free of static
electricity or have same potential as the motor
before being used for measurement without
isolation cover.
1. The status diode of the functional module flashes
40-80 times/minute when the software is running correctly.
See fig. 35. The functional module can only function if the
power module is in operation, as the power module supplies
voltage to the functional module.
See section 8.3 Functional module.
Status Fault
The microprocessor is frozen.
The functional module is
Permanently on.
defective.
See section 7.7.
The functional module is
Light off. defective.
See section 7.7.
Flashing The processor of the functional
40-80 times/minute. module is functional.
D26
D41
17
3. If the status diode of the functional module is off, check if the
power module supplies voltage by measuring 8.5 VDC on the
English (GB)
1
5
6
5
VFE
J15
6
ref.
2
18
8.3.1 Checking input and outputs Digital input, DI
English (GB)
See the settings of the input in PC Tool.
Note Make a copy of motor settings. Connect the digital input to frame (GND) by means of an
Pt100/1000 ammeter. The value measured must now be approximately
12 mA. Check that PC Tool shows a corresponding value.
Use a 100 Ω resistance and decide on the basis on the motor
settings which value this resistance will show in the display when
DI
connected to the terminals instead of the Pt100/1000 sensor.
Analog input, AI
It is possible to measure on the analog input to determine if its
function is correct. A 12 mA
During current state, a 292 Ω resistance in the input converts a
current signal (e.g. 0-20 mA) from the sensor to a voltage signal
V 0-5 V
A
19
8.4 Power module
Status, three-phase Fault
English (GB)
20
4. The DC voltage across the capacitor of the intermediate
circuit on the single-phase power module can be measured to
English (GB)
make sure that the capacitor is not short-circuited. If the
function is correct, the voltage must be ≥ 350 V (at a mains
voltage of 230 V). See fig. 44. If not, the module is defective.
_
+
21
5. The DC voltage across the capacitors of the intermediate
circuit on the three-phase power module can be measured to
English (GB)
GND
22
8.5 Winding resistance
English (GB)
As the motor is star-connected, the easiest way to measure the
winding resistance is to measure across two phases. Measure at
the coil temperatures stated in the table below. It may be
necessary to let the motor cool off if it has been running or if it
was stopped because of short-circuit or overload.
23
Measure between terminals T1 and T2, and between T2 and T3.
English (GB)
Terminal Description
T1, T2, T3 Input for the three phases
T1 T2 T3
TM05 7025 0413
24
9. Exploded view
English (GB)
TM05 7026 0413
Fig. 48 MGE 90
25
10. Disposal
English (GB)
Subject to alterations.
26
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