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GRUNDFOS INSTRUCTIONS

MGE model H/I


MGE 71, MGE 80, MGE 90
Service instructions
2
English (GB) Service instructions

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)

Pos. Designation For pos.


Max. torque information
Terminal Thread
[Nm]
Standard tools
L1, L2, L3, L, N M4 1.8
A Screwdriver 156, 252b Straight slot, 8 mm
NC, C1, C2, NO M2.5 0.5
B Screwdriver 273b, 502 Straight slot, 3 mm
1- 26, A, Y, B M2 0.5
273a,
Screwdriver Torx 20
277a, 288a
4. Secondary materials
152, 268,
Screwdriver Torx 25
C 251d
Quantity Product
Pos. Designation 178, 185,
[kg] number Screwdriver Torx 30
192, 289a
156c
Screwdriver 286 Torx 40
159d Castrol LMX grease 0.1 00RM4311
Ratchet spanner with
159e D J, K 17 mm
socket
E Torque screwdriver - 0.5 - 4 Nm
5. Service tools
F+G Torque wrench - 4-20 Nm

Standard tools 152, 178,


185, 251d,
A B C 268, 273a, Tx20, Tx25, Tx30,
H Bits kit
277a, 286, Tx40
287a,
288a, 289a
Plastic hammer or 1300 N
I 156
press (axial force)
J Soft jaws - For vice
D E F
Locking-ring pliers,
187 ∅50 - 65 (62) mm
internal ring
K
Locking-ring pliers,
188 ∅20 - 30 (25) mm
external ring
L Antistatic service kit - 96884939
M Bearing heater 153, 154
G H I Special tools
∅/∅37.8/20.5
Punch 156c
98394718
∅/∅44/25.5
N Punch 156c
98394719
∅/∅60/30.5
J K L Punch 156c
98394720
Puller 153, 154
O 98394731
Puller + special arms 172

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.

Caution Never measure between two terminals.

1. Disconnect the power supply.

TM05 7021 0413


2. Remove the terminal box.
See section 7.9 Replacing the terminal box.
3. Measure between terminals T1, T2, T3 and earth. As windings
are star-connected, fault in a winding will show when
measuring all terminals. Fig. 2 Removing the battery
4. Replace the entire motor unit in case of fault.
4. Insert the new battery with the positive pole upwards.
See also measurement of winding resistances in section
8.4 Power module. The new battery must comply with the battery
Note
5. Fit the terminal box. directive (2006/66/EC).
See section 7.9 Replacing the terminal box. 5. Press the battery home with a finger.
6. Switch on the power supply. 6. Fit the terminal box cover. See section 7.1 Replacing the
7. Start the pump. terminal box cover.

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.

Make sure that the antenna wire is not sharply


Caution bent or pinched when you fit the terminal box
cover.
7. Fit the terminal box cover.
See section 7.1 Replacing the terminal box cover.
TM05 1590 3211

7.4 Replacing the control panel


1. Disconnect the power supply.
2. Remove the terminal box cover.
See section 7.1 Replacing the terminal box cover.
Fig. 1 Antistatic service kit 3. Press and hold in the two locking tabs (fig. 3, pos. A) while
gently lifting the control panel (fig. 3, pos. B, and pos. 290).
7.1 Replacing the terminal box cover
1. Loosen the four screws (pos. 251d) and remove terminal box
cover (pos. 251b).
2. Clean the sealing faces of terminal box (pos. 251a) and the
terminal box cover.
3. Fit the terminal box cover and cross-tighten the screws. Make
sure that the position of the terminal box cover is correct in
relation to the control panel (pos. 290).
TM05 5353 3612

Note The control panel can be turned 180 °.

7.2 Replacing the battery


Applies only to the FM300 functional module. Fig. 3 Removing the control panel
1. Disconnect the power supply.
4. Gently remove the plug for the control panel from functional
2. Remove the terminal box cover. See section 7.1 Replacing
module (pos. 273).
the terminal box cover.
5. Connect the plug for the new control panel to the functional
3. Insert a screwdriver under the battery (pos. 273b) and prise
module.
the battery out of the isolation cover (pos. 277).
6. Turn the control panel to the desired position (0 ° / 180 °).
The old battery must be disposed off according
Caution
to the battery directive (2006/66/EC). Caution Do not twist the flat cable by more than 90 °.

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)

are placed correctly. fingers.

TM05 5355 3612

TM05 7023 0413


Fig. 4 Fitting the control panel
Fig. 7 Align the CIM module with the connecting plug.
8. Fit the terminal box cover.
See section 7.1 Replacing the terminal box cover. 9. Fit the frame screw in the CIM module.
10. Fit the cover by leading the slits into the end with the plug
7.5 Replacing the CIM module connection and clicking the locking taps onto the isolation
1. Disconnect the power supply. cover.
2. Remove the terminal box cover. 11. Press down the module using your fingers. Check that the
See section 7.1 Replacing the terminal box cover. plug has been pressed home.
3. Remove the plug connection for the CIM module. 12. CIM 250 and CIM 270: Put the FCC label on the terminal box.
4. Remove the cover (pos. 287) of the CIM module by pressing
the locking tab (fig. 5, pos. A) and lifting the end of the cover
(fig. 5, pos. B). Then lift the cover off the hooks (fig. 5, pos. C).

TM05 7028 0413


A
TM05 7029 0413

Fig. 8 Position of FCC label

13. Fit the terminal box cover.


See section 7.1 Replacing the terminal box cover.
Fig. 5 Removing the cover of the CIM module

5. Remove the screw connecting the frame connection of the


CIM module to the functional module.
6. Insert a screwdriver at the three plastic holders and loosen
the CIM module from isolation cover (pos. 277). See fig. 6.
7. Gently lift the CIM module away from the isolation cover so
that the connecting plug is not damaged.

2
3
TM05 6711 5012

Fig. 6 Removing the CIM module

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.

TM05 6717 5012


See fig. 9.
6. Remove screw (pos. 277a) from the isolation cover.
7. You can now remove the isolation cover from the terminal box.

Fig. 10 Removing the connecting plug from the functional


module

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

14. Fit the isolation cover.


See section 7.6 Replacing the isolation cover.
15. Fit the CIM module.
See section 7.5 Replacing the CIM module.
Fig. 9 Removing the plug connections 16. Fit the control panel.
See section 7.4 Replacing the control panel.
8. Fit the new isolation cover on the terminal box.
Check that the isolation cover is not clamped. 17. Fit the terminal box cover.
See section 7.1 Replacing the terminal box cover.
9. Secure the isolation cover to the terminal box with the screw.
18. Calibrate the functional module with the power module.
10. Push the plug connection into the relevant terminals. They are
See section 7.14 Configuring the controller.
marked so that they only fit in the right socket of the functional
module. 7.8 Replacing the power module
11. Fit the CIM module. If the power module is replaced, the entire bottom of the terminal
See section 7.5 Replacing the CIM module. box must be replaced.
12. Fit the control panel. See section 7.4 Replacing the control 1. Disconnect the power supply.
panel.
2. Remove the terminal box cover. See section 7.1 Replacing
13. Fit the terminal box cover. the terminal box cover.
See section 7.1 Replacing the terminal box cover.
3. Remove control panel (pos. 290) from isolating cover
7.7 Replacing the functional module (pos. 277). See section 7.4 Replacing the control panel.
1. Disconnect the power supply. 4. Remove CIM module (pos. 502) from the isolation cover.
See section 7.5 Replacing the CIM module.
2. Remove the terminal box cover.
See section 7.1 Replacing the terminal box cover. 5. Remove the isolation cover.
See section 7.6 Replacing the isolation cover.
3. Remove control panel (pos. 290) from isolating cover
(pos. 277). See section 7.4 Replacing the control panel. 6. Remove the functional module.
See section 7.7 Replacing the functional module.
4. Remove CIM module (pos. 502) from the isolation cover.
See section 7.5 Replacing the CIM module. 7. Pull out plug connection (pos. 266).
5. Remove isolating cover (pos. 277). 8. Remove screws (pos. 178) from terminal box (pos. 251a) and
See section 7.6 Replacing the isolation cover. gently lift the terminal box off the motor (pos. 150).
6. Remove spacer (pos. 286) and screws (pos. 273a). 9. Fit the new terminal box on the motor. Make sure that the plug
connections are aligned.
7. Gently lift the functional module (pos. 273) out of the power
module so that the connecting plug (pos. 275a) is not 10. Cross-tighten the screws of the terminal box.
damaged. 11. Fit the plug connection for power supply.
8. Pull the connecting plug out of the functional module 12. Fit the functional module.
(or power module). See fig. 10. See section 7.7 Replacing the functional module.
13. Fit the isolation cover.
See section 7.6 Replacing the isolation cover.
14. Fit the CIM module.
See section 7.5 Replacing the CIM module.
15. Fit the control panel.
See section 7.4 Replacing the control panel.
16. Fit the terminal box cover.
See section 7.1 Replacing the terminal box cover.
17. Calibrate the functional module with the power module.
See section 7.14 Configuring the controller.

7
7.9 Replacing the terminal box 7.11 Replacing the fan
English (GB)

1. Disconnect the power supply. 1. Disconnect the power supply.


2. Remove the terminal box cover. 2. Remove the terminal box. See section 7.10 Replacing the
See section 7.1 Replacing the terminal box cover. stator housing.
3. Disconnect all relevant wires. 3. Remove screws (pos. 152) and lift off the fan cover (pos. 151).
4. Remove screws (pos. 178) from terminal box (pos. 251a) and 4. Insert two screwdrivers close to the shaft and remove the fan
gently lift the terminal box off the motor (pos. 150). (pos. 156).
5. Fit the new terminal box on the motor. Make sure that the plug
connections are aligned.
6. Cross-tighten the screws of the terminal box.
7. Move relevant modules to the new terminal box according to
the section above.
8. Connect all relevant wires.
9. Transfer data from the nameplate of the old terminal box to
the nameplate of the new one.

TM05 7022 0413


Type : P.C. : INPUT OUTPUT VARIANT
P.N. : Serial no : U in : P2 : kW PB :
DE : Env.Type : ~ V n max: rpm FM :
NDE : IP : CL: f in : Hz Eff : HMI : Made in Hungary
o
Wgt : kg Tamb : C PF: I 1/1 : A CIM : DK - 8850 Bjerringbro, Denmark

Fig. 12 Removing the fan

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.

7.12 Replacing the bearings


1. Disconnect the power supply.
2. Remove the stator housing from the terminal box.
See section 7.10 Replacing the stator housing.
3. Remove the fan. See section 7.11 Replacing the fan.
4. Remove seal rings (pos. 156c) from shaft (pos. 172).
5. Remove screws (pos. 185) holding the flange (pos. 156b).
6. Place the puller on the non-drive end of the stator housing
(pos. 150). See fig. 13.
7. Gently pull the rotor (pos. 172) out of the stator, holding rotor
and flange to prevent damage.

Keep metallic dust away from the rotor as the


TM05 6954

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

Fig. 13 Pushing the rotor out of the stator

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].

TM05 6928 0313


TM05 5967 4212
Fig. 15 No COM port selected

4. Select "Preferences" in the main menu under "Files".


5. Open the dropdown menu "Select interface" and select
Fig. 14 Position of configuration label "MI 301". See fig. 16.
If the terminal box, functional module or power module is
replaced or mounted on another motor, it must be reconfigured.
Use PC Tool E-products for that purpose. To establish connection
to the motor, use Grundfos GO Remote MI 301 or PC Tool Link.
7.14.1 Connection to motor by means of Grundfos GO
Remote MI 301
Configuration can be done in three ways:
• Radio Scan
• Direct Connect
• IR Connect.

If the power supply to the pump is interrupted


during configuration, the update will be lost.
Caution
This will, however, not damage the controller.
Start from the beginning.

TM05 7037 0413


Equipment
• PC Tool E-products, version 14.00.00 or newer
• MI 301 (PN 98046408) with USB cable.

Fig. 16 Selecting the user interface

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.

TM05 7132 0613

Fig. 17 IR connection via MI 301

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

9. To find the GSC file, see section 7.14.3 Configuration with PC


Tool E-products.

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].

TM05 7211 0713


TM05 6928 0313
Fig. 22 Selection of unit

Fig. 19 No COM port selected

TM05 7044 0513


5. Select "Preferences" in the main menu under "Files".
6. Open the dropdown menu "Select interface" and select
"MI 301". See fig. 20.

Fig. 23 Establish connection to the pump

10. Click the button for radio communication. See fig. 24. Status
in the PC Tool will change to "Connected". See fig. 25.

TM05 7212 0713


Fig. 24 Connection via radio communication

Click [Connect] if the pump is "Unlocked".


Note
See fig. 22.
TM05 7037 0413

Fig. 20 Selecting the user interface

TM05 7039 0412


7. Open the dropdown menu "Select port" and select the port
"PCTool-Link". See fig. 20. Click [Apply].
8. Click [Radio Scan]. See fig. 21. Wait until connection has
been established to the products the MI 301 can communicate
with (10-20 sec.). Fig. 25 Connection established

11. Find the GSC file for the motor by means of


section 7.14.3 Configuration with PC Tool E-products.
TM05 6932 0313

Fig. 21 Radio Scan

11
Direct Connect 7.14.2 Connection to motor via PC Tool Link
English (GB)

1. Switch on the power supply to the pump. Equipment


2. Connect the MI 301 to the PC. • PC Tool E-products, version 14.00.00 or newer
3. Place the MI 301 at a distance of maximum 10 metres from • Grundfos PC Tool Link
the pump.
• GENIbus cable (RS-485).
4. Start the PC Tool. The first time the program is started, the
Procedure
message "No COM port selected" will be shown. Click [OK].
1. Disconnect the power supply.
2. Remove the terminal box cover.
See section 7.1 Replacing the terminal box cover.

TM05 6928 0313


3. Connect PC Tool link to the GENIbus terminals on the motor
by means of the GENIbus cable.

Fig. 26 No COM port selected


A Y B
5. Select "Preferences" in the main menu under "Files".
6. Open the dropdown menu "Select interface" and select
"MI 301". See fig. 27.

TM05 7122 0513


Fig. 30 Connection of GENIbus

4. Connect the mains supply to the pump.


TM05 7037 0412

Fig. 27 Selecting the user interface

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

Fig. 28 Direct Connect

9. Click the motor button for radio communication.


Connection has now been established.
TM05 7212 0713

Fig. 29 Connection via radio communication

10. Find the GSC file for the motor by means of


section 7.14.3 Configuration with PC Tool E-products.

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.

Searching by configuration number

1. Select "Standard configuration".

2 3

2. Select "Number".

3. Enter a number or part of a


number.
4. Click [Search now].

5
5. Select the configuration file in the
list of search results.
6. Click [Send] to download the

TM04 2563 2608


configuration file to the MGE.
1 6

Fig. 31 Configuration of terminal box by searching by the GSC number

3. End the PC Tool and remove the MI 301.

13
8. Fault finding
English (GB)

8.1 General information


1. Check the mains supply to the pump.
2. Read fault messages by means of Grundfos Eye,
Grundfos GO Remote, PC Tool or R100.

Note Make a copy of motor settings.


3. If possible, test if the motor can run without load. Remove the
coupling to the pump (if possible) and set the operating signal

IMG_0042 & IMG_0043


to max. by means of PC Tool, Grundfos GO Remote or R100.
You can reset a fault indication in the following ways:
• When the fault cause has been eliminated and the pump is
switched on, the pump will revert to normal duty.
• If the fault disappears by itself, the fault indication will
automatically be reset.
The fault cause will be stored in the pump alarm or warning log. Fig. 33 Alarm and warning log of the MI 201
Fault indications via Grundfos Eye
For a detailed description the fault, see display "Assisted fault
See the indication of motor status by means of the Grundfos Eye advice".
and the contact positions of signal relays in the installation and
operating instructions for the MGE motor.
Fault indications via Grundfos GO Remote
See the description of the Grundfos GO Remote control panel
and possibilities of communication in the installation and
operating instructions for the MGE motor.

IMG_0047
Fig. 34 Detailed fault description

Fault indications via R100


IMG_0041

The R100 must be updated to be used for


Note
MGE 71, MGE 80 and MGE 90, model H/I.
See the description of the R100 display and possibilities of
Fig. 32 Alarms and warnings shown on the MI 201 communication in the installation and operating instructions for
the MGE motor.

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.

Grundfos Eye Condition/cause Remedy

External fault (3)


An external signal has reported an Check the parameter or the unit reporting the
"External fault" to the digital input set up external fault. Correct the fault.
Two opposite red indicator lights for this function.
flashing simultaneously. Too many restarts (4)
The pump has restarted to many times in a) Check the warning and alarm log for faults that
connection with a fault that forced the caused to many restarts.
pump to stop and restart automatically. b) Replace the pump if the fault cannot be found.
Overvoltage (32)
a) Check that the power supply is within the
Supply voltage to the pump too high.
specified range.
Undervoltage (40)
Supply voltage to the pump too low. a) Check that the power supply is within the
specified range.
Overload (49)
a) Check that the viscosity and temperature of the
pump liquid is within the limits for the pump.
If not, change the properties of the liquid.
The motor is overloaded and has
b) Dismantle the pump, and remove any foreign
automatically reduced the speed and thus
matter or impurities preventing the pump from
the pump performance.
rotating.
c) If none of the above causes are present, replace
the pump.
Blocked pump (51)
a) Dismantle the pump, and remove any foreign
The pump is blocked. matter or impurities preventing the pump from
rotating.
Pump communication fault (10)
Communication fault between this pump a) Check that all pumps of the multipump system
and the other pumps of the multipump have been correctly set up.
One yellow indicator light permanently system.
on. Forced pumping (29)
a) Check the system for defective non-return
Other pumps or sources force flow
valves and replace, if necessary. Check the
through the pump even if the pump is
system for correct position of non-return valves,
stopped.
etc.
Dry running (56, 57)
a) Prime and vent the pump before a new start-up.
No water at the pump inlet or the water
Check that the pump is operating correctly.
contains too much air.
If not, replace the pump.
Internal fault (72, 83, 85, 155, 157, 163)
a) Replace the functional module, power module or
Internal fault in the pump electronics.
terminal box.
High motor temperature (65, 66)
1. The motor temperature is too high. a) Check that the ambient temperature is within the
specified range.
One yellow indicator light permanently b) Check that the pump is not covered by dust, dirt
on. or other foreign matter which reduces the air
cooling of the pump.
c) If none of the above causes are present, replace
the motor.
Internal communication fault (76)
1. Communication fault between different a) Replace the terminal box.
parts of the electronics.
Soft pressure buildup, timeout (215)
1. The system has been in the mode a) Check the system for leakages.
"soft pressure buildup" longer than the
set time limit.

15
Grundfos Eye Condition/cause Remedy
English (GB)

Replace motor bearings (30)


1. The bearings must be replaced. a) Follow the instructions for the pump.
See section 7.12 Replacing the bearings.
Internal sensor fault (88)
One yellow indicator light rotating in
the direction of rotation of the motor 1. The pump is receiving a signal from a) Check that the plug and cable are connected
when seen from the non-drive end. the internal sensor which is outside correctly to the sensor. The sensor is on the
the normal range. back of the pump housing.
b) Replace the sensor.
Pt100/1000 sensor 1 (91) and 2 (175)
1. Pt100/1000 input 1 is receiving a a) Check that the sensor resistance corresponds to
signal which is outside the normal ≈ 100 or 1000 ohm. If not, replace the sensor.
range. b) Check the sensor cable for damage.
c) Check the cable connection at the pump and at
the sensor. Correct the connection, if required.
d) Replace the sensor.
Supply fault, 5 V (161)
1. Fault in the output voltage to sensor or a) Check the output voltage and wire to sensor or
potentiometer. potentiometer.
Supply fault, 24 V (162)
1. Fault in the output voltage. a) Check the output voltage and wire.
Signal fault, LiqTec-sensor (164)
1. The pump is receiving a signal from a) Check that the plug and cable are connected
the LiqTec sensor which is outside the correctly to the sensor.
normal range. b) Replace the sensor.
Signal fault, sensor 1 (165), 2 (166) and 3 (167)
1. Analog input 1, 2 or 3 is receiving a a) Check the setup of the analog input corresponds
signal which is outside the normal to the sensor output as regards electrical
range. (0.5 - 3.5 V, 0-5 V, 0-10 V, 0-20 mA or 4-20 mA).
If not, change the setting, or replace the sensor
with one that matches the setup.
b) Check the sensor cable for damage.
c) Check the cable connection at the pump and at
the sensor. Correct the connection, if required.
d) Check if the sensor has been removed, but the
input was not deactivated.
e) Replace the sensor.
Limit 1 exceeded (190) and limit 2 exceeded (191)
1. Limit 1 or 2 has reached the limit for a) Identify and remove the fault cause.
warning/alarm.

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

TM05 7124 0513

Fig. 35 Status diode of functional module

2. If the light diode is flashing, the functional module is working


correctly. The fault may then be in the control panel.
See section 7.4 Replacing the control panel.

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)

VFE plug connection between functional module and power


module. If no voltage is measured, the connection between
the modules or the power module is defective.
If the VFE voltage to the functional module is okay, check if
the voltage between the reference point and the other
measuring points is okay. The voltage values apply to an
operating motor.

1
5
6
5
VFE

J15
6
ref.
2

TM05 7121 0613


4

Fig. 36 Measuring voltage on the functional module

Note Use a correctly calibrated measuring instrument.

Control voltage [VDC]


Pos.
Minimum Nominal Maximum
VFE
8.5
(J15)
1 14.5 15.1 15.7
2 4.8 5 5.2
3 4.8 5 5.2
4 3.2 3.3 3.4
5 23 23.9 24.8
6 4.8 5 5.2
ref. GND
Replace the functional module if the voltage is not correct.
See section 7.7 Replacing the functional module.

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

TM05 7118 0613


for the processor.
Measure the voltage across the input and read the current in the
circuit by means of Grundfos GO Remote or PC Tool. The current GND
value must be equal to voltage divided with resistance.
Alternatively, a milliammeter can be connected in series with the Fig. 40 Testing the digital input
circuit.
Digital output, DO/open collector, OC
P See the settings of the output in PC Tool.
Measure on the output. If the value in PC Tool differs from the
value measured with the measuring instrument, remove the load.
If the values still differ, the module is defective.
The voltage of an active output is approx. 5 V.
V
DO
TM05 7115 0613

V 0-5 V
A

Fig. 37 Measuring on analog input

TM05 7118 0613


Next step is to test the input in voltage state. Change the setup of
the input to voltage state (0-10 V). Fit a jumper between terminal
5 (+5 V) and the analog input. 5 V must now be read be means of GND
PC Tool.
Fig. 41 Measuring voltage on the digital output
TM05 7116 0613

+5V AI LiqTec sensor


Connect a new LiqTec sensor to check the input. Immerse the
sensor into water and take it up. The motor must now report fault
within 20 seconds.
Fig. 38 Testing the input during voltage state Signal relay
See the settings of the output in PC Tool.
Change the setup of the input to current state and measure on
Check if the relay reacts to the signals of the controller according
the input using an ohmmeter. The resistance must be 292 Ω.
to the configuration of the controller.
In voltage state the resistance will be 122 kΩ.
CIM
Test the CIM module according to its manual.
Radio
If there are problems in the radio connection between
Grundfos GO Remote and the motor, remove the terminal box
cover. See section 7.1 Replacing the terminal box cover.
Replace the control panel if there is still no connection.
TM05 7117 0613

See section 7.4 Replacing the control panel.


Battery
ȍ Make the motor dead for a short period. When you switch on the
power to the pump again, the clock must show correct time in
relation to how long it was dead.
Fig. 39 Measuring resistance in current and voltage state
Control panel (HMI)
Analog output, AO Check the flat cable to the functional module. Replace the control
The analog input is protected against short-circuit and will shut panel if the connection is correct, and it did not solve the problem.
down the signal in case of short-circuit. If you suspect a
short-circuit, remove the load and compare the value read via
PC Tool with the value measured by means of the measuring
instrument.
If the values are not identical, the module is defective.

19
8.4 Power module
Status, three-phase Fault
English (GB)

• The microprocessor is frozen.


Warning
• No initialising message from
The terminals of the power module are live.
the functional module.
D7 is permanently on. Switch the power supply off and
Warning on. If this does not solve the
Measuring equipment must be free of static problem, replace the power
electricity or have same potential as the motor module. See section 7.8.
before being used for measurement without The power module is defective.
isolation cover. D7 is off.
See section 7.8.
If reading of fault codes does not provide a clear answer as to D7 is flashing The processor of the power
whether the power module is functioning correctly, you can 40-80 times/minute. module is functional.
proceed as described below.
The processor of the power
1. Check that the voltage to the module is within the limit values D54 is permanently on.
module is functional.
stated on the nameplate. Check all phases of a three-phase
motor. The power module is defective.
D54 is off.
See section 7.8.
2. If there are signs of moisture in the terminal box, take
necessary precautions to prevent similar faults.
3. Check the two status diodes of the power module
(the functional module must be connected) by looking under
the power module from the side. Status diode D54 must be
permanently on when connected to mains. Status diode D7
(three-phase model) or D19 (single-phase model) flashes
when the functionality is correct. See table below.

Note It may be necessary to dim the light as the diode


light is weak.

Status, single-phase Fault


• The microprocessor is frozen.
• No initialising message from
the functional module.
D19 is permanently on. Switch the power supply off and
on. If this does not solve the
problem, replace the power
module. See section 7.8.

TM05 7125 0613


The power module is defective.
D19 is off.
See section 7.8.
D19 is flashing
40-80 times/minute, and The power module is functional. LED D7 Micro Controller LED D54 5V
D54 is permanently on.
Fig. 43 Status diodes of power module, three-phase
The power module is defective.
D54 is off.
See section 7.8.
Short-circuit in the connection to
D19 and D54 are flashing
the functional module or in the
40-80 times/minute.
functional module.
TM05 7126 0613

LED D19 Micro Controller LED D54 5V

Fig. 42 Status diode of power module, single-phase

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.

_
+

TM05 7127 0613


Fig. 44 Measuring the DC voltage on single-phase power board

21
5. The DC voltage across the capacitors of the intermediate
circuit on the three-phase power module can be measured to
English (GB)

make sure that the capacitors are not short-circuited. If the


function is correct, the voltage must be ≥ 566 V (at a mains
voltage of 400 V). See fig. 45. If not, the module is defective.

GND

TM05 7421 0913


GND DC+
DC+

Fig. 45 Measuring the DC voltage on three-phase power board

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.

Min. / max. resistance across two phases


Type
[Ω]

Motor Min-1 Voltage [VAC] Power [kW/hp] 20 °C 60 °C 80 °C


0.25 / 0.33 12 / 14 13.8 / 16.2 14.8 / 17.3
1 x 200-240
0.37 / 0.5 12 / 14 13.8 / 16.2 14.8 / 17.3
1500-2000
0.25 / 0.33 40.5 / 47.5 46.8 / 55 50 / 58.7
3 x 380-500
0.37 / 0.5 40.5 / 47.5 46.8 / 55 50 / 58.7
0.25 / 0.33 3 / 3.6 3.5 / 4.1 3.8 / 4.4
1 x 200-240 0.37 / 0.5 3 / 3.6 3.5 / 4.1 3.8 / 4.4
0.55 / 0.75 3 / 3.6 3.5 / 4.1 3.8 / 4.4
3000-4000
0.25 / 0.33 10.4 / 12.2 12 / 14.1 12.8 / 15.1
MGE 71, MLE 71
3 x 380-500 0.37 / 0.5 10.4 / 12.2 12 / 14.1 12.8 / 15.1
0.55 / 0.75 10.4 / 12.2 12 / 14.1 12.8 / 15.1
0.25 / 0.33 1.5 / 1.7 1.7 / 2 1.8 / 2.1
1 x 200-240 0.37 / 0.5 1.5 / 1.7 1.7 / 2 1.8 / 2.1
0.55 / 0.75 1.5 / 1.7 1.7 / 2 1.8 / 2.1
4000-5900
0.25 / 0.33 4.6 / 5.4 5.3 / 6.2 5.7 / 6.7
3 x 380-500 0.37 / 0.5 4.6 / 5.4 5.3 / 6.2 5.7 / 6.7
0.55 / 0.75 4.6 / 5.4 5.3 / 6.2 5.7 / 6.7
0.55 / 0.75 6.9 / 8.1 8 / 9.4 8.5 / 10
1 x 200-240
0.75 / 1 4.3 / 5.1 5 / 5.9 5.3 / 6.3
1500-2000
0.55 / 0.75 21.2 / 24.8 24.5 / 28.7 26.1 / 30.7
3 x 380-500
0.75 / 1 13.5 / 15.9 15.6 / 18.4 16.7 / 19.6
0.75 / 1 1.5 / 1.7 1.7 / 2 1.8 / 2.1
1 x 200-240
1.1 / 1.5 1.6 / 1.8 1.8 / 2.1 1.9 / 2.3
MGE 80, MLE 80 3000-4000
0.75 / 1 4.6 / 5.4 5.3 / 6.2 5.7 / 6.7
3 x 380-500
1.1 / 1.5 5.3 / 6.3 6.2 / 7.2 6.6 / 7.7
0.75 / 1 1.5 / 1.7 1.7 / 2 1.8 / 2.1
1 x 200-240
1.1 / 1.5 1.5 / 1.7 1.7 / 2 1.8 / 2.1
4000-5900
0.75 / 1 4.6 / 5.4 5.3 / 6.2 5.7 / 6.7
3 x 380-500
1.1 / 1.5 4.6 / 5.4 5.3 / 6.2 5.7 / 6.7
1500-2000 3 x 380-500 1.1 / 1.5 8.9 / 10.5 10.3 / 12.1 11 / 12.9
1 x 200-240 1.5 / 2 1.1 / 1.3 1.3 / 1.5 1.4 / 1.6
3000-4000 1.5 / 2 3.8 / 4.4 4.4 / 5.1 4.7 / 5.5
3 x 380-500
MGE 90, MLE 90 2.2 / 3 2.2 / 2.6 2.6 / 3 2.7 / 3.2
1 x 200-240 1.5 / 2 0.8 / 1 1 / 1.1 1 / 1.2
4000-5900 1.5 / 2 2.4 / 2.8 2.8 / 3.2 3 / 3.5
3 x 380-500
2.2 / 3 1.6 / 1.8 1.8 / 2.1 1.9 / 2.3

23
Measure between terminals T1 and T2, and between T2 and T3.
English (GB)

Terminal Description
T1, T2, T3 Input for the three phases

TM05 7024 0413


Fig. 46 Motor terminals

T1 T2 T3
TM05 7025 0413

Fig. 47 Wiring diagram

24
9. Exploded view

English (GB)
TM05 7026 0413

Fig. 48 MGE 90

25
10. Disposal
English (GB)

This product or parts of it must be disposed of in an environmen-


tally 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.

26
Argentina Finland Lithuania Spain

Grundfos companies
Bombas GRUNDFOS de Argentina S.A. OY GRUNDFOS Pumput AB GRUNDFOS Pumps UAB Bombas GRUNDFOS España S.A.
Ruta Panamericana km. 37.500 Centro Mestarintie 11 Smolensko g. 6 Camino de la Fuentecilla, s/n
Industrial Garin FIN-01730 Vantaa LT-03201 Vilnius E-28110 Algete (Madrid)
1619 Garín Pcia. de B.A. Phone: +358-(0)207 889 900 Tel: + 370 52 395 430 Tel.: +34-91-848 8800
Phone: +54-3327 414 444 Telefax: +358-(0)207 889 550 Fax: + 370 52 395 431 Telefax: +34-91-628 0465
Telefax: +54-3327 45 3190
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GRUNDFOS Pumps Pty. Ltd. Parc d’Activités de Chesnes 7 Jalan Peguam U1/25 Box 333 (Lunnagårdsgatan 6)
P.O. Box 2040 57, rue de Malacombe Glenmarie Industrial Park 431 24 Mölndal
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Phone: +61-8-8461-4611 Télécopie: +33-4 74 94 10 51 Phone: +60-3-5569 2922
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Hongqiao development Zone Ballymount Road Lower ООО Грундфос sentative Office of Grundfos Kazakhstan in
Shanghai 200336 Dublin 12 Россия, 109544 Москва, ул. Школьная Uzbekistan
PRC Phone: +353-1-4089 800 39 38a, Oybek street, Tashkent
Phone: +86 21 612 252 22 Telefax: +353-1-4089 830 Тел. (+7) 495 737 30 00, 564 88 00 Телефон: (+998) 71 150 3290 / 71 150
Telefax: +86 21 612 253 33 Факс (+7) 495 737 75 36, 564 88 11 3291
Italy E-mail grundfos.moscow@grundfos.com Факс: (+998) 71 150 3292
Croatia GRUNDFOS Pompe Italia S.r.l.
GRUNDFOS CROATIA d.o.o. Via Gran Sasso 4 Serbia Addresses Revised 06.05.2013
Cebini 37, Buzin I-20060 Truccazzano (Milano) GRUNDFOS Predstavništvo Beograd
HR-10010 Zagreb Tel.: +39-02-95838112 Dr. Milutina Ivkovića 2a/29
Phone: +385 1 6595 400 Telefax: +39-02-95309290 / 95838461 YU-11000 Beograd
Telefax: +385 1 6595 499 Phone: +381 11 26 47 877 / 11 26 47 496
www.grundfos.hr
Japan Telefax: +381 11 26 48 340
GRUNDFOS Pumps K.K.
Czech Republic Gotanda Metalion Bldg., 5F, Singapore
GRUNDFOS s.r.o. 5-21-15, Higashi-gotanda GRUNDFOS (Singapore) Pte. Ltd.
Čajkovského 21 Shiagawa-ku, Tokyo 25 Jalan Tukang
779 00 Olomouc 141-0022 Japan Singapore 619264
Phone: +420-585-716 111 Phone: +81 35 448 1391 Phone: +65-6681 9688
Telefax: +420-585-716 299 Telefax: +81 35 448 9619 Telefax: +65-6681 9689
Denmark Korea Slovenia
GRUNDFOS DK A/S GRUNDFOS Pumps Korea Ltd. GRUNDFOS d.o.o.
Martin Bachs Vej 3 6th Floor, Aju Building 679-5 Šlandrova 8b, SI-1231 Ljubljana-Črnuče
DK-8850 Bjerringbro Yeoksam-dong, Kangnam-ku, 135-916 Phone: +386 1 568 0610
Tlf.: +45-87 50 50 50 Seoul, Korea Telefax: +386 1 568 0619
Telefax: +45-87 50 51 51 Phone: +82-2-5317 600 E-mail: slovenia@grundfos.si
E-mail: info_GDK@grundfos.com Telefax: +82-2-5633 725
www.grundfos.com/DK South Africa
Latvia GRUNDFOS (PTY) LTD
Estonia SIA GRUNDFOS Pumps Latvia Corner Mountjoy and George Allen Roads
GRUNDFOS Pumps Eesti OÜ Deglava biznesa centrs Wilbart Ext. 2
Peterburi tee 92G Augusta Deglava ielā 60, LV-1035, Rīga, Bedfordview 2008
11415 Tallinn Tālr.: + 371 714 9640, 7 149 641 Phone: (+27) 11 579 4800
Tel: + 372 606 1690 Fakss: + 371 914 9646 Fax: (+27) 11 455 6066
Fax: + 372 606 1691 E-mail: lsmart@grundfos.com
ECM: 1106756
98413121 0513

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