Service instructions, MQ
Contents
1. Service instructions MQ 3 35 MQ 3 45 90 60 Hz Tas Contents 1 TY SVG SNC GC AIO MN aieiaa ana E ota E EAA IAEE 2 i edo ce ee ee ee ee eee S ee ere ee 2 1 2 Type Key PS psp P o AI ITS 3 2 daiekol D Sp VS 4 2 1 Special tools La ee a re 4 2 2 Standard tools A TWO TIA 4 3 Dismantling and ls www gr S 5 PS EEE Ro Ann TAS 5 3 2 Replacing the shaft seal chambers and impellers esesesesessssececececeeesesececececeessesescecececeecsesesceeceeeeeseseseees 6 3 3 Replacing the gEasure tank S8 aeneus casscsesererssse senas ananasas esamas sns 8 3 4 Replacing the electronic unit flow sensor and pressure SWITCH eeeesseetcteecececessececececeeescececececeseeseeseeeees 9 3 5 Replacing the MMRBOr unit Mm VWrrrrrRe S RS 10 4 Operation CA Agro Ser SRT Sener en ee een tT Tt 11 APC a AO MS 11 ieee sea sia A G a i a i i a A V la k rere 11 Sio STT BO ANNO Geren ere E reer er 11 Ce Cie M ie eo a a o AA e i a a o ii 11 oe AUK 1 EE Adi 11 4 6 Manual reset sssssccesereesase 1 1 sg S 11 AT ONTO NE E E A i i i i i EE EE E 12 Wa OVEN a iii A i I er eee eT 13 TMU TUNG UN ias i i a i cc eee Sees AEA 14 LO EAdlElindine OVENMIEU 22 a E O ee ree eee ee eer eee 15 5 What Selecteer ee eee ee E r A EE E ENE 24 5 1 Winding resistence measurement ee eseseseceseseseececececeeesescscecececesesescscscscesenesessscucuceseasaesesesceceacssacucecececeeeeeeseeee2. overloaded motor thermal switch in motor seized up motor pump thermal switch in motor 4 5 Auto reset If activated the auto reset function will cause the pump to restart automatically every 30 minutes for 24 hours in case of any type of fault After this period if the fault has not disappeared the pump will remain in the alarm condition and can only be reset manually see below 4 6 Manual reset The pump can be reset manually by pressing the on off button twice or interrupting the supply voltage briefly 11 24 ne S 4 7 Control panel Indicator light green Indicates that the pump is ready for operation When the indicator light is on the pump will start automatically when water is consumed The pump will stop a few seconds after the water consumption has ceases On off button The pump is started stopped by means of the on off button The on off button can also be used for manual resetting in case of an alarm condition press once for resetting and press once more for starting Indicator light red When the indicator light is on the pump is on standby Pump on green The indicator light is on when the pump is running Auto reset green As standard this function is activated on delivery When the indicator light is on the Auto reset function is activated The pump will automatically attempt to restart every 30 minutes after an alarm fault over a period of 24 hours After this period
3. the pump will remain in the alarm condition off the Auto reset function is deactivated The pump will not restart after an alarm fault The Auto reset function can be activated deactivated by pressing the on off button for 5 seconds Note When water is consumed the pump will start and stop automatically whether the Auto reset light is on or off Alarm red The indicator light is on when the pump is in alarm condition The alarm condition may have been caused by dry running overtemperature overloaded motor or seized up motor pump Note The pump settings are stored After supply failure the pump will automatically revert to its operating condition when the electricity supply is connected again 12 24 ance 4 8 Overview Before starting the fault finding procedure check the external installation conditions of the pump For this purpose see the installation and operating instructions Note It is important to read this section as well as 4 9 Fault finding and 4 10 Fault finding overview thor oughly The pictures below show the essential parts that control the MO pump Pressure switch e P lt 2bar gt open contact Tolerance 1 8 2 2 bar e P gt 2bar gt closed contact Tolerance 1 8 2 2 bar TMO2 2365 4201 Flow sensor It is important that the magnet part of the flow wheel is pointing upwards against the sensor part The sensor is positioned in the part with the wire connection
4. TMO2 2388 4201 If the pump delivers water it is OK Connect the controller correctly If the pump does not deliver water continue the fault finding procedure The controller continues to be bypassed continue the fault finding TMO2 2375 4201 TMO2 2376 4201 Disconnect the electricity supply by pulling out the plug O N a N M N N Dismantle the hydraulic part and check for defects dirt and wear TMO2 2389 4201 Connect the electricity supply by plugging the pump into the mains TMO2 2390 4201 Check that the motor can rotate If the motor cannot rotate replace it If the motor can rotate the hydraulics are faulty See the exploded drawing TMO2 2391 4201 22042003 GB 22 24 a T C18 Do not forget to connect the controller correctly after completing the fault finding procedure cc O N a O o0 N N O ee E Pi CEPE A 4 10 4 Observation D D1 Replace the controller N T O o0 N N O E Ia eS CEPE 4 23 24 ne S 5 Wiring diagram Capacitor Electrical motor Ground Yellow green Phase White gt Mains Neutral Black gt Flow sensor gt Pressure switch TMO2 2424 4401 5 1 Winding resistence measurement Resistance Ambiemt temperature Q 10 230 50 230 60 120 60 The measurement can be done with or without cables connected to the PCB and the capacitor 24 24 o S
5. high ambient temperature gt 45 C overloaded motor or e seized up motor pump Check the supply voltage and correct the fault if possible stops too frequently water rings on the inlet part tank pos 42 sure must be 1 5 to 1 7 bar valve tric shocks in accordance with local regulations 6 The pumps starts a Defective non return valve or the exist Clean the valve or fit a new non return when no water is con ing pipework is leaking or defective valve sumed If the pump does not start when the fault has been corrected contact your pump supplier or GRUNDFOS for further information 14 24 ance 4 10 Fault finding overview Start the pump and allow it to run for a minimum of 5 minutes with the tap turned on Then observe how the system reacts Typical faults If the tap is opened too guickly there will be no alarm indication See 4 10 1 Observation A on page 16 If the flow is lower than 1 2 l min the pump does not start and there will Pressure be no alarm indica switch Controller Water comes out of the tap but the pump stops every 15 seconds for a short period and starts again right away The alarm indicator light is off See 4 10 2 Observation B on page 18 Pressure switch Flow sensor No water comes out of the tap The alarm indicator light is on See 4 10 3 Observation C on pag
6. 4 N TM02 6626 1103 9 Remove the stationary shaft seal part pos 103 using a screwdriver 3 2 2 Fitting the shaft seal 1 Fit the stationary shaft seal part pos 103 with the groove against the intermediate part pos 2 2 Fit the rotating shaft seal part pos 104 3 Fit the washer pos 102 2 mm the retaining ring pos 111 and the washer pos 107 6 24 anne 4 Fit the chambers pos 4 O rings pos 37 and impellers pos 49 on the motor unit shaft pos 150 see drawing Note There is no O ring on the chamber next to the intermediate part pos 2 5 Fit the washer pos 66 and the nut pos 67 and tighten it with 7 Nm screwdriver TMO02 6628 1203 MUN SSR 9 mH f SSS SSS K PET NY N J VZ RREN lt KR estes A 5 Oy KN lt gt KOS A SA Ne y all Y ZA Ole L NE NI sr DE Ke A Za NX N DESS iL 7 Al 7 R L ihe KE f KS as 4 Z or AA S LTA 1 7 ys eee A VE SS a r O Ng the hole of the pump sleeve 10 Push the pump sleeve into position and tighten the three screws pos 91 11 Fit and tighten the strap pos 92 7 24 V TMO02 6704 1403 Hold the
7. e 20 Capacitor Hydraulics No water comes out of the tap The alarm indicator light is off See 4 10 4 Observation D on page 23 Controller 15 24 ne S 4 10 1 Observation A Turn off the tap TMO2 2369 4201 The system is closed the pressure must be minimum 2 5 bar If 2 5 bar is not reached check the hydraulics If the pressure is above 2 5 bar continue the fault finding procedure TMO2 2370 4201 Wait approx 15 seconds to see what happens when the pump stops If the pump does not stop even when the start stop but ton is on replace the controller If the pressure falls below 2 5 bar check the non return valve in the suction line Non return valve If the pressure does not fall continue the fault finding procedure TMO2 2371 4201 Disconnect the electricity supply by pulling out the plug TMO2 2372 4201 Remove the pressure switch plug from the controller TMO2 2373 4201 16 24 ne S At a pressure above 2 5 bar the switch is closed and the multimeter must show approx 0 Q ny g If the multimeter shows OL or M Q the contact is open and the pressure switch must be replaced co 2 Replace O N a a m M N N O Turn on the tap The pressure is removed from the system TMO2 2375 4201 TMO2 2376 4201 At a pressure below 2 bar the switch is open and the mul timeter must show OL or M O If the multimeter sho
8. ic cable in accordance with local regulations 3 1 2 Before assembly Gaskets and O rings should always be replaced when the pump is overhauled e Clean and check all parts Order the necessary service kits e Replace defective parts by new parts 5 24 sing 3 2 Replacing the shaft seal chambers and impellers 3 2 1 Removing the shaft seal 1 Slacken and remove the strap pos 92 2 Remove the screws pos 91 3 Carefully remove the pump sleeve pos 16 using a screwdriver 4 Remove the inlet part pos 6 from the pump sleeve or the top of the chamber stack 5 Remove the nut pos 67 and the washer pos 66 Hold the shaft with a screwdriver in the shaft end r ea Tu ae i KOS f N p BBA SS a ow rd SS NST k Ley Ke ANT mH L f IA __ X y A UA D a NE ny A 15 ASS J Na Ola Za LARS 5 V ZZZZZZZZLZZZL A e eS ey Z AYL HE i ae Sa Ira EIS S SSS IIS SB T ARS N x gt a N vam E gt q of W Sf A AN i H AA A A AN AN A NAR N 4 N f D j TM02 0086 3700 6 Remove the chambers pos 4 and the impellers pos 49 7 Remove the washer pos 107 the retaining ring pos 111 and the washer pos 102 8 Remove the rotating shaft seal part pos 10
9. nic unit pos 181 Remove the capacitor pos 161 from the terminal box and disconnect the leads Remove the pressure switch pos 174a using the fingers Slacken and remove the screws pos 166a OO NAM AWN Remove the flow sensor cover pos 184 including the O ring pos 187 and flow wheel pos 185 10 Pull up the flow wheel shaft pos 186 and remove the washer pos 185a 3 4 2 Fitting the electronic unit flow sensor and pressure switch 1 Fit the flow wheel shaft pos 186 and the washer pos 185a Fit the flow wheel pos 185 with the magnet against the cover Lubricate the O ring pos 187 and fit it on the cover pos 184 Press the cover pos 184 home Check that the pin of the flow wheel chamber fits the hole in the cover Fit and tighten the screws pos 166a Lubricate the O ring pos 174b with soapy water Fit and tighten the pressure switch pos 174a using the fingers Pull the mains cable into the terminal box OO NAM AWN Lead the earth lead round the pressure switch 174a on the outside and the leads round the flow sensor pos 184 on the inside 10 Fit the capacitor pos 161 into the retainer by means of the clip pos 160 11 Fit the electronic unit pos 181 and connect the leads including the earth terminal pos 176a see 5 Wiring diagram 12 Fit the terminal box cover pos 164 including the O ring pos 165 13 Fit and tighten the screws pos 166 9 24 anne 3 5 Replacing the motor unit 3 5 1 Removing the mot
10. or unit 1 Remove the shaft seal see 3 2 1 Removing the shaft seal 2 Remove the electronic unit flow sensor and pressure switch see 3 4 1 Removing the electronic unit flow sensor and pressure switch Remove the pressure tank see 3 3 1 Removing the pressure tank Slacken and remove the screws pos 152 and washers pos 152a b and c Remove the end cover pos 51 Remove the screw for the earth lead pos 173 on the motor unit pos 50 Pull the leads to the motor unit out of the terminal box Press the motor unit pos 150 out of the motor housing pos 180 O ON DM A w Remove the screws pos 26 washers pos 27 and intermediate part pos 2 10 Remove the retainer pos 40a and the O rings pos 40 3 5 2 Fitting the motor unit 1 Lubricate the O rings pos 40 and fit the rings and the retainer pos 40 Lubricate the O ring pos pos 37a and fit it on the motor housing pos 180 Fit the motor housing pos 180 to the intermediate part pos 2 Fit the screws pos 26 and the washers pos 27 and tighten diagonally Lubricate the recess of the O ring pos 53 in the motor housing pos 180 Roll the O ring pos 53 on the motor unit pos 150 and lubricate it Fit the motor unit in the motor housing pos 180 Pull the leads from the motor unit into the terminal box OO NAM AWN Pull the earth lead into the terminal box The earth lead lug must not touch the other leads O Fit the earth lead to the motor unit and tighten the sc
11. rew pos 173 Lubricate and fit the O ring pos 52 to the end cover pos 51 N Fit the end cover pos 51 The leads from the motor must fit into the slot UJ Fit the screws pos 152 and washers pos 152a b and c and tighten Fit the pressure tank see 3 3 2 Fitting the pressure tank Fit the electronic unit flow sensor and pressure switch see 3 4 2 Fitting the electronic unit flow sensor and pressure switch Fit the shaft seal see 3 2 2 Fitting the shaft seal m v A Ov 10 24 ane 4 Operation 4 1 Priming Before initial start up pour approx 5 litres of water into the pump through the priming port see the installa tion and operating instructions When started the pump will start to evacuate the air contained in the system Once it starts to deliver water the pump will change over to normal operation start stop It no water is delivered within 5 minutes after start up the pump will stop automatically as protection against dry running and alarm will be indicated 4 2 Start The pump starts when the consumption is higher than 1 2 min or the pressure is lower than 2 bar 4 3 Stop The pump stops when e the consumption is lower than 1 2 l min 4 4 Alarm The pump stops in case of dry running if the pressure falls below 2 bar and the consumption below 1 2 min an alarm will be given after 60 seconds overtemperature thermal switch in motor
12. s TMO2 2366 4201 Capacitor Note the wiring of the capacitor Blue wire from the control panel together with the red wire from the motor The white wire is solitary m O O r O ci A N ci O N a WO M N N O Motor see 5 Wiring diagram TMO2 2368 4201 Electricity supply Flow sensor Controller and connections Pressure switch TMO2 2466 4301 13 24 ence 4 9 Fault finding 1 The pump does not a Insufficient water Check the water supply suction pipe start b Overheating due to excessive liguid Supply cold liguid to the pump temperature above 35 C c Overheating due to seized up choked Contact your pump supplier up pump d Too low or too high supply voltage Check the supply voltage and correct the fault if possible e No electricity supply Connect the electricity supply y supply y supp y f No water consumption Turn on a tap Check that the height be tween the top point of the discharge pipe and the pump does not exceed 15 metres g The pump is in alarm condition Reset the pump by means of the on off but ton See the table in section 4 7 2 The pump does not a The existing pipework is leaking or Repair the pipework stop oe 3 The pump cuts out Check the water supply suction pipe during operation 5 Sa S due to excessive liguid Supply cold liguid to the pump temperature above 35 C c Overheating caused by Contact your pump supplier
13. s 24 1 24 ance 1 Type identification 1 1 Nameplate D O wo N OA VI 11 12 13 14 15 Description Type designation Rated flow rate m h Model Characters 1 8 Production number 9 10 Factory code 11 14 Production year and week Operating pressure m Rated voltage V Max head m Max current A Frequency Hz Insulation class Power input P Max system pressure liquid temperature bar Cmax Marks of approval Enclosure class Country of origin Serial number Example MQ 3 35 A O A BVBP 3 0 96440338 P7 0127 22 1x220 240 V 35 4 0 50 B 850 7 5 35 CE 54 Made in Italy Serial number 000001G 2 24 TMO2 2363 4201 M GRUNDFOS 794 1 2 Type key Example MO 3 35 A O A Pump range Rated flow rate m h Max head m Code for pump version A Standard Code for pipework connection O External thread Code for materials A Standard Code for shaft seal 3 24 ance 2 Service tools 2 1 Special tools H vos Begins eros escipion Petra 2 2 Standard tools Part no SV2011 SV2010 SV0055 4 24 anne 3 Dismantling and assembly 3 1 General information Position numbers of parts digits refer to exploded views sectional drawings and parts lists position numbers of tools letters refer to section 2 Service tools 3 1 1 Before dismantling e Disconnect the electricity supply to the motor e Remove the electr
14. shaft end using a Fit the O rings pos 37 to the back of the inlet parts and fit the inlet parts to the chamber stack Fit the O ring pos 37b and lubricate it Fit the O ring pos 37a on the intermediate part pos 2 and lubricate it Lubricate and fit the pump sleeve pos 16 Check that the pin at the bottom of the intermediate part fits M GRUNDFOS 794 3 3 Replacing the pressure tank 3 3 1 Removing the pressure tank 1 Remove the cover pos 43 2 Remove the pressure tank pos 42 including the O ring pos 44 It can be loosened using the fingers 3 If the union nut including O ring pos 44 is not removed with the pressure tank remove it using a 42 mm socket 3 3 2 Fitting the pressure tank 1 If the pressure tank pos 42 has been screwed out of the union nut lubricate the threads of the pressure tank with Loctite 5331 and screw the tank into the union nut 2 Fit the O ring pos 44 and screw the pressure tank pos 42 into the motor housing pos 180 by hand 3 Fit the cover pos 43 8 24 sing 3 4 Replacing the electronic unit flow sensor and pressure switch 3 4 1 Removing the electronic unit flow sensor and pressure switch 1 Slacken the screws pos 166 and remove the terminal box cover pos 164 Disconnect the leads and pull them out of the terminal block on the electronic unit pos 181 Disconnect the flow sensor and pressure switch from the electronic unit pos 181 Disconnect the earth lead Remove the electro
15. tions are satisfactory TMO2 2383 4201 Prime the pump TMO1 9696 2600 Disconnect the electricity supply by pulling out the plug TMO2 2372 4201 Check if the pump is seized up by means of a screwdriver If it is impossible to turn the motor and pump the hydrau lics must be checked See the exploded drawing TMO2 2384 4201 Bypass the controller by connecting the motor lead to the mains cable TMO2 2385 4201 TMO2 2386 4201 22042003 GB 20 24 a Fix the cover on the pump and connect the electricity sup ply TMO2 2387 4201 Max 5 m n Wait approx 5 min or until water comes out of the tap TMO2 2388 4201 If the pump delivers water the controller must be replaced If the pump delivers no water continue the fault finding procedure Replace the Continue the controller fault finding TMO2 2375 4201 TMO2 2376 4201 Disconnect the electricity supply by pulling out the plug TMO2 2372 4201 Replace the capacitor If available a measuring instru ment capable of measuring 25 microfarad can be used to measure the capacitor for failures before it is replaced The blue wire from the capacitor must be connected with the red wire to the motor The white wire is not connected to other wires TMO2 2367 4201 Fix the cover on the pump and connect the electricity sup ply TMO2 2387 4201 oaos GB 21 24 _ a T jii R min Wait approx 5 min or until water comes out of the tap
16. ws approx 0 Q the contact is closed and the pressure switch must be replaced If the pressure switch is OK replace the controller TMO2 2377 4201 22042003 GB 17 24 ance 4 10 2 Observation B Turn off the tap TMO2 2369 4201 If the pump enters an alarm condition after 60 sec replace the pressure switch Ifthe pump stops within 15 sec and does not enter an alarm condition continue the fault finding procedure TMO2 2371 4201 Disconnect the electricity supply by pulling out the plug TMO2 2372 4201 Turn on the tap Remove the pressure from the system O N a ie m M N N O ci O N a LA M N N O Controller Remove the controller TMO2 2378 4201 18 24 o S Flow sensor Check for impurities in the flow wheel housing Replace the flow sensor if defect TMO2 2379 4201 Make sure that the magnet on the flow wheel is fitted against the sensor in the flow sensor cover TMO2 2366 4201 L d i i orj Am Fit the controller and the cover P Connect the electricity supply Fs ee Le ee T TMO2 2380 4201 Press the on off button Do not forget to turn on the tap TMO2 2381 4201 TM02 2382 4201 If the pump delivers water without stopping starting at intervals of 15 seconds the pump is OK Otherwise the controller must be replaced TMO2 2375 4201 19 24 ne S 4 10 3 Observation C C1 Non return valve Check that the inlet condi
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