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Service instructions

SQFlex water supply systems

Table of contents
1.

SQFlex components ........................................................................................................................ 2

1.1

Pumps................................................................................................................................................ 2

1.2

Motor.................................................................................................................................................. 5

1.3

Control and switch boxes................................................................................................................... 6

1.4

Solar modules.................................................................................................................................. 13

1.5

Wind turbine..................................................................................................................................... 24

2.

Start-up ........................................................................................................................................... 28

3.

Maintenance ................................................................................................................................... 29

3.1

Solar modules.................................................................................................................................. 29

3.2

Wind turbine..................................................................................................................................... 30

4.

Trouble-shooting ........................................................................................................................... 32

4.1

Solar-powered system ..................................................................................................................... 34

4.2

Solar-powered system with CU 200 control unit and level switch ................................................... 36

4.3

Solar-powered system with generator back-up ............................................................................... 38

4.4

Wind-powered system ..................................................................................................................... 40

4.5

Wind-powered system with CU 200 control unit and level switch.................................................... 42

4.6

Combined system ............................................................................................................................ 44

4.7

Combined system with CU 200 control unit and level switch .......................................................... 46

4.8

Options with generator as back-up source ...................................................................................... 49

5.

Service of pump and motor .......................................................................................................... 51

5.1

General information ......................................................................................................................... 51

5.2

Service tools .................................................................................................................................... 52

5.3

Torques and lubricants .................................................................................................................... 54

5.4

Helical pump type ............................................................................................................................ 55

5.5

Centrifugal pump and motor ............................................................................................................ 56

5.6

Centrifugal pump type with splined shaft ......................................................................................... 57

5.7

Centrifugal pump type with cylindrical shaft..................................................................................... 58

5.8

Checking and replacing wear parts of centrifugal pumps ................................................................ 59

5.9

Testing the pump by means of CU 200 SQFlex control unit............................................................ 60

96547280 0206

US

1 / 66

1. SQFlex components
1.1 Pumps
Two pump types are used, the helical rotor pump type and the centrifugal pump type.
Nameplate, helical rotor pump
The nameplate is engraved into the pump sleeve.

1

PROD. NO.
MODEL A

2

xx SQF -x
Weight

3

96078012
P1 0110

x,x

kg

4

TM02 6973 2103

MADE IN DENMARK

Rp 1 1/4
Fig. 1 Nameplate, helical rotor pump

Key to nameplate, helical rotor pump
Pos.
1

Code

Description

PROD. NO. 96078012

Product number

MODEL A

Pump generation

P1 0110

Production code - Bjerringbro (P1) + production year and week

2

xx SQF - x

Type designation, see section Type key on page 4

3

• Weight: x,x kg

• Pump net weight

• MADE IN DENMARK

• Country of origin

• CE

• Mark of approval.

Rp 1 1/4

Type and size of connecting thread

4

2 / 66

Nameplate, centrifugal pump
The nameplate is attached to the suction interconnector.

5

1

4

7
8
9

TM02 4149 5001

3

6
984457

Weight 4,9 Kg
Type 75 SQF -3
Model A - 96078070 - 0140
m. n
min-1
m3/. H
50 Hz: Q
min-1
m. n
60 Hz: Q
GPM H

2

Fig. 2 Nameplate, centrifugal pump

Key to nameplate, centrifugal pump
Pos.

Code

Description

1

Type 75 SQF -3

Type designation, see section Type key on page 4

2

MODEL A

Pump generation

3

96078070

Product number

4

Q m³

Rated flow rate (not indicated)

5

Weight 4.9 kg

Pump net weight in kg

6

CE

Mark of approval

7

0140

Production year and week
-1

8

n min

Speed (not indicated)

9

H

Head at rated flow rate (not indicated)

3 / 66

4 / 66 .Type key The type key is common for helical rotor pump and centrifugal pump. 40 SQF-3 and 75 SQF-3 have a cylindrical shaft. X SQF - X -1 Rated flow rate in US GPM at 3000 min (approximate value) • 3 = helical rotor pump • 6 = helical rotor pump • 11 = helical rotor pump • 25 = centrifugal pump • 40 = centrifugal pump • 75 = centrifugal pump Type range Number of stages Centrifugal pumps come in two main types: with splined pump shaft and with cylindrical pump shaft. 25 SQF-3 and 25 SQF-6 have a splined pump shaft.

15 per hp 4 Code A 5 PF 1. Nameplate.9 kW Maximum input power [kW] I: 7 A Maximum input current [A] S1/40 C Suitable for continuous operation up to 40°C CONT. Rated speed 500 . 3. DUTY 104F Suitable for continuous operation at 104°F Ins Cl F Insulation class F.3000 min-1 Enclosure class: IP 68.55/14. It is a brushles. NO. 96040989 MODEL A P1 0110 Vdc: 30-300V Vac: 1x90-240V P1: 0.1.9 kW I: 7A S1/40 C CONT. 1 2 Code MSF 3 Type designation PROD. motor The nameplate is engraved into the stator sleeve. motor Key to nameplate. Nameplate.0 RPM 500 . electronically commutated DC-motor with a permanent-magnet rotor (PM-motor).55/14. Start-kVA is 0-3. Max submerged depth: 150 m Weight 6. 1 PROD.4 kg/lb Motor net weight in kg and pounds THERMALLY PROTECTED Temperature sensor built into the electronic unit MADE IN DENMARK Country of origin CE Mark of approval 5 / 66 .3000 6 IP 68 150 m 7 Power factor = 1. motor Pos. 96040989 Product number MODEL A Pump generation P1 0110 Production code . DUTY 104F Ins Cl F Code A PF 1.0 RPM: 500-3000 IP 68 150m Weight 6.4 kg/lb 2 3 4 5 6 THERMALLY PROTECTED MADE IN DENMARK 7 TM02 2452 0202 MSF3 Fig.Bjerringbro (P1) + production year and week VDC: 30-300 V VAC: 1 x 90-240 V 3 Description The motor can be supplied with either DC or AC voltage: • DC: 30-300 V or • AC: 1 x 90-240 V P1: 0. NO.2 Motor The MSF 3 motor is a sealed construction made of stainless steel.

1. Internal (and external) wiring of CU 200 SQFlex control unit 6 / 66 . Maximum load: 100 mA.3. PE. 50/60 Hz. Technical data • 30-300 VDC. PE.1 CU 200 SQFlex control unit The CU 200 SQFlex control unit offers: • system monitoring on the basis of sensor signals • system control on the basis of sensor signals • monitoring of pump operation and alarm indication. • 1 x 90-240 V –10%/+6%.3 Control and switch boxes 1.

see Trouble-shooting by means of CU 200 on page 8. F1 = overvoltage F2 = overtemperature F3 = no contact to the pump F4 = overload 7 / 66 . upon startup. • Green light on: The system has been switched on. the power consumption of the pump is indicated in steps of 10 Watt. When the fault indicator is on. • Both lights off: The system lacks the required power to light the display. Power and fault codes The display indicates 0 Watt until the power supply is sufficient to run the pump at 500 rpm. • Red light on: The system has been switched off. the maximum indication being 990 Watt.CU 200 SQFlex display and indicator lights The front cover of CU 200 features a button and various indications: ON/OFF button Full water reservoir Pump operation A running green light indicates that the pump is operating at more than 500 min-1. • Flashing green light: The system has adequate power to light the display but lacks sufficient power to start the pump. The yellow light indicates that the water reservoir is full. Fault indicator Red light indicates fault. Dry running Red light indicates lack of water. the display indicates fault codes.

• Repair or replace pump or cable. Off light in the ON/ OFF button is on. • Press the ON/OFF button on the CU 200 to start Pump has been stopped. 4. the pump or pump cable is defective. If a supply voltage to the pump can be detected. replace the CU 200. Green indicator light tive. 5. in ON/OFF button is • Check that there is sufficient voltage on the on. CU 200 indicates ‘F3 = no contact to pump’. • Disconnect the solar modules to allow the voltage to drop. Supply voltage is above permissible range.• Check that the ‘CONTROL INDICATOR’ LED is flashing. • Ensure that the water temperature is below the maximum permissible level. • Reconfigure the modules and reconnect them. Pump is defective. Pump does not start. CU 200 or pump is defec. Position of ribbon cable connector is wrong or cable is defective. Too high water temperature. • Reestablish the voltage supply. • Repair or replace the pump. the pump. PUMP terminals. and pump does not deliver water. CU 200 is defective. 3. allow for the voltage drop in the pump cable. Note: As the voltage is detected at the motor. Possible cause Remedy No voltage supply. 2. CU 200 indicates ‘F1 = overvoltage’ 7. • Check CU 200 defective. If a different supply source is used.the end cover with socket on the pump. If not. If no voltage can be measured. No fault indicated. 10 V and 24 V internal supply voltage are on. check that the voltage is within the recommended voltage range. and the ‘CONTROL INDICATOR’ LED is not flashing. 6. Pump is defective. • Replace the CU 200.the pump cable tions defective. No light in front cover. Incrustations on motor. . • Repair or replace the pump. CU 200 indicates ‘F2 = overtemperature’. • Remove incrustations on the motor. No light in front cover. 8 / 66 . continue as follows: • Switch off the energy supply and wait for one minute.Trouble-shooting by means of CU 200 Indication/Fault 1. But the LEDs inside CU 200 indicating 5 V. • Correct the position of the cable or replace it. replace the CU 200. Pump does not deliver water.the connection in the CU 200 Pump cable or connec. . • Switch on the energy supply and observe what happens: If the green indicator light in the ON/OFF button is on and the pump still does not start.

Cable on level switch is damaged. Cable on level switch is damaged. 12. 13. cover. 200 but low wattage. Pump does not stop when water reservoir is full. • Increase the number of solar modules or connect an alternative energy supply. Level switch is defective. 11. Too low input voltage. Pumped liquid is contaminated with oil or similar substance. Pump does not stop when water reservoir is full. CU 200 indicates ‘F4 = overload’. Pump is defective. Pump delivers Ribbon cable not water. Running light on CU System not grounded. • Repair or replace the pump. batteries or generator. in ON/OFF button is flashing. 9. CU 200 is defective. • Clean the liquid and replace the pump. 10. Water reservoir indicator is on. • Replace the CU 200. • Clean the pump. If a centrifugal pump is used: Check that the riser pipe is not blocked. Pump is defective. • Replace the CU 200. • Mount the ribbon cable.Indication/Fault Possible cause 8. 14. • Clean or replace the level switch. Green indicator light Insufficient power supply. mounted. • Check system for adequate grounding • Repair or replace the pump. No light in front CU 200 is defective. to 30 VDC or higher. Level switch is dirty or defective. • Replace the level switch. • Check or refill motor liquid. CU 200 is defective. • Replace the cable. Remedy • Increase the supply voltage. 9 / 66 . Motor liquid low / Missing. Fault indicator light on CU 200 is on. Fault indicator light on CU 200 is off. Pump has seized up. Pump does not start when water reservoir is empty. • Replace the cable. • Replace the CU 200. Only helical rotor pumps. such as wind turbine.

Internal (and external) wiring of IO 100 SQFlex switch box Technical data: DC: Max. 10 / 66 . In addition.1.2 IO 100 SQFlex switch box The IO 100 enables manual starting and stopping of the pump in a solar-powered SQFlex system. PE.3. 225 V. AC: Max. 50/60 Hz. the IO 100 functions as a connection point for all necessary cables. 265 V. PE.

265 V. 11 / 66 .1. A back-up generator is useful in periods of insufficient solar energy or in case of an immediate requirement for water supply or a need for water at night. 50/60 Hz.3 IO 101 SQFlex switch box The IO 101 SQFlex switch box makes it possible to • switch off the voltage supply to the pump and • connect a back-up generator. 50/60 Hz. PE. PE. 225 V. PE. The internal relay in the IO 101 has the following rated voltage: • 115 V –15%/+10%. • AC: Max. Internal (and external) wiring of IO 101 SQFlex switch box Technical data: • DC: Max.3.

50/60 Hz. PE. 225 V. and • Stop the wind turbine blades • connect solar modules as well as a wind turbine. Internal (and external) wiring of IO 102 SQFlex breaker box 12 / 66 .4 IO 102 SQFlex breaker box The IO 102 is applicable in SQFlex systems powered exclusively by a wind turbine The IO 102 SQFlex breaker box makes it possible to • switch off the voltage supply to the pump.1. PE IO 102 • AC: Max. 265 V. The IO 102 is applicable in SQFlex systems provided the system voltages mentioned below are not exceeded. Technical data: • DC: Max.3.

turn the modules some degrees to the west. In case of positive declination. The map illustrates the differences in magnetic declination in different parts of the world. in case of negative declination. make sure that the module frames overlap in order to allow for rain water to run off.1. turn the modules some degrees to the west. In case of positive declination. turn the modules some degrees to the east. Due to the magnetic declination it may be necessary to turn the modules some degrees away from the direction of the compass. For further information on the installation of solar modules. 13 / 66 . See Fig. Due to the magnetic declination it may be necessary to turn the modules some degrees away from the direction of the compass. Use a compass to position the modules as precisely as possible. When mounting the solar modules.4 Solar modules Positioning Solar modules located in the northern hemisphere should face south. Fig. Use a compass to position the modules as precisely as possible. see installation and operating instructions for the modules. turn the modules some degrees to the east. Tilt angle For maximum utilisation of the solar radiation the tilt angle of the support structure can normally be adjusted from 15° to 45°. How much appears from the map. 4. Declination is caused by the fact that the geographic north pole and the magnetic north pole are not located in the same place. 4. Solar modules located in the southern hemisphere should face north. Depending on your location on the globe you must turn the solar modules away from the direction of the compass. 4. See Fig. Mounting The solar modules must be mounted on a support structure. in case of negative declination.

cell temperature 25 C) All values are nominal unless designated as tested Peak Power (Pmax) Warranted Minimum Pmax Voltage (Vmp) Current (Imp) Open Circuit Voltage (Voc) Short Circuit Current (Isc) Minimum Bypass Diode Maximum Series Fuse : : : : : : : : 43 38.2 T = 50°C T = 75°C 0. 14 / 66 mA A COM V .1.4 150 0.40 6 15 W W V A V A A A Example of GF 43 nameplate Solar module current [A] Solar module voltage [VDC] 0.7 140 0.: 96467737 This module is designed only for GRUNDFOS pumping systems GF 43 MODEL: PART #: 901050 SERIAL #: Product of USA Manufactured in ISO9001 certified facility Electrical Ratings at STC (1000 W/m 2. GF 50 solar modules The GF solar modules consist of amorphous silicon thin-film solar cells. • Make sure that trees. 0.5 spectrum. bushes. grass.3 190 mV mV OFF A mA A V A OFF A mA A V mA A V V A COM V Measurement of voltage by means of multimeter Measurement of current by means of multimeter Visual inspection of solar modules • Check that the solar modules are intact.5 200 0. GRUNDFOS PART NO.31 194 0.1 GF 43. etc. Each solar module is equipped with plugs and sockets for easy connection of several modules in parallel. tilted at an angle ensuring optimum utilisation of the solar energy. buildings.1 0 0 0 0 1000 500 1000 500 Irradiance [W/m2 ] Irradiance [W/m2 ] A = current read on the graph must be multiplied by the number of solar modules. do not cast a shadow on the solar modules. The solar panels are mounted on a support structure.6 250 0.3 100 50 T = 0°C T = 25°C 0. AM 1.4.

Electrical connections GF 43. Note: To achieve good earth connection and thus to protect persons. make sure that the solar modules are covered with a nontransparent covering material to ensure that the modules are dead. • Measurements must be made when the solar modules are not connected. Note: The Grundfos GF solar modules must not be connected in series. GF 50 solar modules Note: Before making any electrical connections. IO 100 SQFlex IO 101 SQFlex IO 102 SQFlex CU 200 SQFlex Panel Array 4 8 9 16 17 3 7 10 15 18 2 6 11 14 19 1 5 12 13 20 Module Protective earth conductor A Row closure kit Fig. 5. The PE conductor is connected to the row closure by means of a screw terminal. Accessories needed to connect a PE conductor The solar panels must be connected to earth via the Protective Earth (PE) conductor supplied with the row closure kit. 15 / 66 . A) and earth terminals supplied with the row closure kit. it is of decisive importance to fit the earth clips (pos. • The current to be measured is the short-circuit current ISC. • The cover must be removed before measuring is made.

The solar modules must be mounted on a support structure. tilted at an angle ensuring optimum utilisation of the solar energy. buildings. CE and IEC 61215 approved. etc.50 50 3. • Make sure that trees. do not cast a shadow on the solar modules. • The current to be measured is the short-circuit current ISC. grass.75 0 0 0 500 1000 0 2 Irradiance [W/m ] 500 1000 Irradiance [W/m2 ] Visual inspection of solar modulesmodules • Check that the solar modules are intact. Peak power (PMax) 110 W Voltage (Vmp) 32. Electrical connection SX-110 solar modules Note: Before making any electrical connections. bushes.2 SX-110 solar modules The SX-110 solar modules consist of 72 multicrystalline silicon solar cells in series with bypass diodes installed. • The cover must be removed before measuring is made.75 40 3. make sure that the solar modules are covered with a nontransparent covering material to ensure that the modules are dead.4.34 A Open circut voltage (Voc) 41. 16 / 66 .50 T = 50°C T = 75°C 0.9 V Current (Imp) 3. Tüv. • Measurements must be made when the solar modules are not connected. This module is UL.00 30 2.2 V Short circut current (Isc) 3. The solar modules are equipped with plugs and sockets for easy connection of several modules in parallel or series.69 A Reference cell temperature (Tcref) 25 °C Solar irradiation at reference cell temperatue (Itref) W/m2 1000 Solar module current [A] Solar module voltage [VDC] 4.25 20 10 T = 0°C T = 25°C 1.1.

7 3-4 2 1 82 41 3.7 3.7 41 3.7 3.7 3-4 5-6 6 247 3.7 3.7 6-7 1 41 3.7 3.7 6-7 1 41 3.7 3-4 Voltage [v] Current [A] 3. 1 1 1 4 5 5 4 3 6 7 2 2 2 6 3 3 3 6 2 4 4 5 1 5 4 7 6 3 3 1 1 2 Plug Modules Voltage [v] Current [A] 1-2 8 165 3-4 5-6 4 6-7 1 2 Plug Modules Voltage [v] Current [A] 7.7 5-6 4 165 3.4 1-2 12 247 7.7 3.7 1 41 3.7 4.Electrical connection SX-110 solar modules (continued) 2. 5 4 4 7 1 2 3 6 3 1 2 Plug Modules 1-2 4 3 2 1 164 123 82 41 3. Plug Modules Voltage [v] Current [A] 1-2 7 6 5 288 247 206 3.7 The solar panels must be connected to earth via a Protective Earth (PE) conductor 17 / 66 TM02 6875 1903 4 .4 165 3. 1.

Peak power (PMax) 50 W Voltage (Vmp) 65 V Current (Imp) 0.3 FS-50-D solar modules The FS-50-D solar modules consist of thin-film of semiconductor material on glass. tilted at an angle ensuring optimum utilisation of the solar energy.2 0 0 0 250 500 750 0 1000 500 1000 Irradiance [W/m2 ] 2 Irradiance [W/m ] 18 / 66 .4. This module is UL and IEC 61646 approved.4 25 T = 50°C T = 75°C 0.0 100 0. The solar modules must be mounted on a support structure.1.2 125 1.6 50 T = 0°C T = 25°C 0. The solar modules are equipped with plugs and sockets for easy connection of several modules in parallel or series.8 75 0. series fuse rating 2 A Reference cell temperature (Tcref) 25 °C Solar irradiation at reference cell temperatue (Itref) W/m2 1000 Solar module current [A] Solar module voltage [VDC] 1.77 A Open circut voltage (Voc) 90 V Short circut current (Isc) 1 A Max.

7 8 3 5 4 6 1 2 Modules Voltage [v] Current [A] 1-2 20 18 16 14 12 10 180 180 180 180 180 180 10 9 8 7 6 5 3-4 8 6 180 180 4 3 5-6 4 2 180 180 2 1 7-8 1 90 1 The solar panels must be connected to earth via a Protective Earth (PE) conductor 19 / 66 TM02 6874 1903 Plug . bushes. • Measurements must be made when the solar modules are not connected. • The cover must be removed before measuring is made. etc. make sure that the solar modules are covered with a nontransparent covering material to ensure that the modules are dead. grass. • Make sure that trees. do not cast a shadow on the solar modules. • The current to be measured is the short-circuit current ISC. Note: Before making any electrical connections. Electrical connection of FS-50-D solar modules. buildings.Visual inspection of solar modules • Check that the solar modules are intact.

GF 55C GF 65C Peak power (PMax) 55 65 W Voltage (Vmp) 30.00 30 1. The solar modules must be mounted on a support structure.8 2.3 A Reference cell temperature (Tcref) 25 25 °C Solar irradiation at reference cell temperatue (Itref) 1000 W/m2 GF 55C Solar module voltage [VDC] 1000 Solar module current [A] 50 2. The solar modules are equipped with plugs and sockets for easy connection of several modules in parallel or series.1. Tüv.25 30 2. etc.4 V Current (Imp) 1. Electrical connection GF 55C and GF 65C solar modules Note: Before making any electrical connections.25 40 2.50 40 2.6 31.50 0 0 500 0 1000 0 Irradiance [W/m2 ] 500 1000 Irradiance [W/m2 ] Visual inspection of solar modulesmodules • Check that the solar modules are intact.0 39. CE and IEC 61215 approved. • The current to be measured is the short-circuit current ISC.4.00 20 T = 0°C T = 25°C 10 T = 50°C T = 75°C 1. do not cast a shadow on the solar modules. bushes. • Measurements must be made when the solar modules are not connected. tilted at an angle ensuring optimum utilisation of the solar energy.00 0.50 20 T = 0°C T = 25°C 10 T = 50°C T = 75°C 1. buildings.75 0 0 0 1000 500 0 500 Irradiance [W/m ] GF 65C Solar module voltage [VDC] 1000 Irradiance [W/m2 ] 2 Solar module current [A] 50 2. • The cover must be removed before measuring is made.7 V Short circut current (Isc) 2. • Make sure that trees.0 2.75 1.4 GF 55C and GF 65C solar modules The GF 55C and GF65C solar modules consist of 68 multicrystalline silicon cells in series.1 A Open circut voltage (Voc) 39. This module is UL. grass. 20 / 66 . make sure that the solar modules are covered with a nontransparent covering material to ensure that the modules are dead.

6 14 7 2 273 4 277.3 6 6 1 234 2 238.8 2.3 8 4 2 156 4 158.5 6.1 2.9 20 5 4 195 8 198.9 2.3 4 4 1 156 2 158.2 2.1 6.2 21 / 66 .9 10 5 2 195 4 198.9 16 4 4 156 8 158.3 3 1 117 2 119. it is of decisive importance to fit the earth clips and earth terminals Modules Seriel Parrallel 2 2 3 GF 55C GF 65C VOC [V] ISC [A] VOC [V] ISC [A] 1 78 2 79.6 9 3 3 117 6 119.3 5 5 1 195 2 198.Electrical connection GF 55C and GF 65C solar modules (continued) 1 1 1 2 2 3 3 7 7 2 2 TM02 8643 0604 1 The solar panels must be connected to earth via a Protective Earth (PE) conductor Note: To achieve good earth connection and thus to protect persons.8 9.9 4.5 9.4 2.5 4.2 6.3 7 7 1 273 2 277.2 4.5 2.2 18 6 3 234 6 238.6 15 5 3 195 6 198.8 4.6 12 6 2 234 4 238.

grass. bushes.0 100 0. 22 / 66 . Peak power (PMax) 55 W Voltage (Vmp) 63 V Current (Imp) 0. The solar modules are equipped with plugs and sockets for easy connection of several modules in parallel or series. do not cast a shadow on the solar modules. Low temperature coefficients provide more power at actual operating conditions.2 125 1.4. etc.5 GTF 55 GTF 55 solar modules consist of thin-film of semiconductor material on glass substrates.1. Weatherproof connectors and cordplate elimate the need for a junction box and module to module field wiring. The module is equipped with cost effective aluminium mounting frame. Proven durability eliminates the need for expensive frames to prevent delamination in the field. • Make sure that trees.8 75 50 T = 0°C T = 25°C 0. Architecturally aesthetic uniform black appearance.4 0 0 0 250 500 750 0 1000 500 1000 Irradiance [W/m2 ] 2 Irradiance [W/m ] • Check that the solar modules are intact. The solar modules must be mounted on a support structure. tilted at an angle ensuring optimum utilisation of the solar energy This module is UL and IEC 61646 approved.87 A Open circut voltage (Voc) 89 V Short circut current (Isc) 1.6 25 T = 50°C T = 75°C 0. buildings.1 A Reference cell temperature (Tcref) 25 °C Solar irradiation at reference cell temperatue (Itref) 1000 W/m2 Visual inspection of solar modules Solar module current [A] Solar module voltage [VDC] 1.

• The current to be measured is the short-circuit current ISC. • Measurements must be made when the solar modules are not connected.4 12 2 6 126 5. Product 1 Solar module GTF 55 Cable guards and connection wire kit Array-to-controller wire kit Array-to-array wire kit 2 3 4 The solar panels must be connected to earth via a Protective Earth (PE) conductor Note: To achieve good earth connection and thus to protect persons.6 8 2 4 126 3.5 10 2 5 126 4. • The cover must be removed before measuring is made.Electrical connection of GTF 55 solar modules.8 20 2 10 126 8. Note: Before making any electrical connections. it is of decisive importance to fit the earth clips and earth terminals Modules Seriel Parrallel 4 2 6 GTF 55 VOC [V] ISC [A] 2 126 1.2 14 2 7 126 6. 4 1 2 TM02 6874 1903 3 Pos.7 2 3 126 2. make sure that the solar modules are covered with a nontransparent covering material to ensure that the modules are dead.1 16 2 8 126 7.0 18 2 9 126 7.7 23 / 66 .

1.5 Wind turbine
VAC
160
Breaker Box IO 102
mV
mA
A
A

V
V
OFF

A mA A COM V

VDC
220
160

mV
V
V

mA
A
A

OFF
A mA A COM V

mV
V
V

mA
A
A

OFF
A mA A COM V

160

mV
V
V

mA
A
A

OFF
A mA A COM V

Measurement of VAC and VDC

Wind turbine
voltage [VAC]

IO 102
voltage [VDC]

350

250

300

200

250

150

200

100

150
100

50

50

0
0

5
11

10
22

m/s
mph

0

Values measured between the three phases must be identical.

24 / 66

0

5
11

10 m/s
22 mph

1.5.1 Trouble-shooting
1. Find out if the problem is mechanical or electrical.
• Propeller cannot turn = Mechanical problem, see Mechanical problems on page 26.
• Propeller turns slowly = Electrical problem, see Electrical problems on page 27.
Electrical problems may be in the wind turbine or the IO 102 breaker box. Determine which as follows:
2. Disconnect the three wires from the wind turbine one at a time at the IO 102 breaker box. If the propeller starts, the wire that allowed it to start leads to a defective rectifier in the IO 102 breaker box. Replace
the breaker box, see Overview of possible system combinations on page 33.
3. If the propeller still does not start, the problem is in the tower wiring or the wind turbine.
4. The propeller is running, but may have an electrical problem. Using a voltmeter, read the voltage across
the leads and see the list below as a guide to possible problems.
• The voltage increases and decreases slowly with wind speed and equally across all wires = Everything OK.
• No voltage across two wires = One wire from wind turbine is not carrying power. Check in order:
-the tower wiring to ensure it is properly wired.
-slip rings and brushes,
-stator connections and stator windings for obvious damage.
• The voltage is significantly higher across two wires than the others = Contact the distributor or the factory.
• Voltage is produced even after ON/OFF switch is activated = Possibly a faulty ON/OFF switch or a wire
has been short circuited to the other two wires or an internal fault has occurred in the IO 102 breaker
box.
• The voltage is significantly lower across two wires than the others = Bad connection at the wind turbine voltage connections or faulty stator winding.
5. Should these steps not solve the problem, proceed directly to Electrical problems on page 27.

25 / 66

Mechanical problems
Fault
1. Propeller is stationary, even in
high winds.

Cause
• Ice in wind turbine, or uneven
ice on propeller.

• Remove ice, or wait for warm
weather.

• Debris between rotor and stator.

• Turn propeller gently by hand
and blow or use piece of paper
to dislodge debris.

• Loose magnet.

• Contact distributor.

• Worn-out bearing.

• Contact distributor.

• Same as above.
2. a) Propeller will not turn at all
except in high wind
b) Scraping or rubbing sound at
low rpm
• Swelled wire keepers due to
c) Propeller always stops in the
high moisture.
same position.
3. a) Propeller is difficult to start
b) Output is low
c) more propeller noise than
usual.
d) Propeller seems out of balance.

Remedy

• Same as above.

• Contact distributor.

• Ice on blade.

• Remove ice, or wait for warm
weather.

• Dirty blade.

• Clean with soap or bug cleaner.

• Split, warped or damaged
blade.

• Replace broken or damaged
blade.

• One or more blades fitted
wrongly.

• Fit blade(s) correctly.

4. Propeller turns a little, but never • Blades fitted wrongly.
starts properly.

• Fit blades correctly. Leading
edge should move clockwise
when viewing propeller from
the front.

5. Tail, wind turbine and tower
vibrate.

• Blade out of balance.

• Contact distributor.

6. Rattling or clunking sound from
wind turbine.

• wind turbine loose in tower.

• Blade not tracking.
• Retighten mounting screws.
Use Loctite or equivalent
thread-locking compound.

• Repair as required.
• Loose rotor (magnet can) on
shaft, loose tail, missing rubber
bumper, wires slapping inside
of mast, governor pivot bolt
loose.
• Worn bearings.

• Contact distributor.

• Shaft broken.

• Contact distributor.

26 / 66

Electrical problems Note: Always be aware of the danger of high voltage. Reconnect the wires. • Set IO 102 ON/OFF switch to OFF. Replace the IO 102. Set IO 102 ON/OFF switch to ON. Replace the IO 102. Disconnect the three wires from the wind turbine one at the time at the IO 102. • Set IO 102 ON/OFF switch to ON. • IO 102 is defective. Possible cause Remedy • The wind speed is too slow. • Pump defective. Pump does not operate and propeller turns fast. Pump does not operate and propeller do not turn or turns slowly even in high winds. • Set IO 102 ON/OFF switch to OFF. • The IO 102 ON/OFF switch is set to OFF. • Wind turbine defective. Disconnect the pump from IO 102. Set ON/OFF switch to ON. Replace the pump. • Wait for the wind speed to increase. • Set IO 102 ON/OFF switch to OFF. Set IO 102 ON/OFF switch to ON. • Pump defective or pump cable short circuit. Set ON/OFF switch to ON. Replace the defective part and reconnect to IO 102. 27 / 66 . 3. Set IO 102 ON/OFF switch to ON. • Wires between IO 102 and pump may be disconnected. Propeller turns fast and are not alowing down when IO 102 ON/OFF switch is set to OFF. • Try to disconnect the three wires from the wind turbine in the IO 102 and short circute them. 2. Pump does not operate. If the propeller slows down or stops. Set IO 102 ON/OFF switch to ON. Replace wind turbine. Fault 1. • Set the IO 102 ON/OFF switch to ON. • One or more wires between wind turbine and IO 102 may be disconnected. If the propeller starts to turn. either the pump or the pump cable is defective. if the proppeler starts to turn the IO 102 is defective. • Set IO 102 ON/OFF switch to OFF. • Set IO 102 ON/OFF switch to OFF. • IO 102 defective. Reconnect the wires. Do not directly touch the wires. the IO 102 is defective. Set IO 102 ON/OFF switch to OFF.

it may take up to one hour. current consumption will be constant. start. the pump rotor may be stuck due to dryness. Helical rotor pumps: • If sufficient energy is available the pump will normally be running within one minute. positioning of the rotor 3. At moderate energy supply and high head. Charging the capacitor 2. Consequently. during start-up the motor will make small rotations in order to bring the rotor into the correct starting position. it will take a while to fill the riser pipe. Dismantle the pump and loosen the rotor. How long depends on the energy available. • If sufficient energy is not available the starting sequence will be repeated. • If sufficient energy is available and the motor does not start within 15 minutes. Please note that after the pump has started running. the installation depth and the dimensions of the riser pipe. or add water to the pump rotor/stator assembly. Start-up The starting sequence has three steps: 1. 28 / 66 .2. During start-up current consumption will be uneven but when the motor has started. This situation can arise if the pump has been stocked for some time. These rotations also ensure that there is water in the pump and that the pump parts are lubricated.

3. Make sure there is no sand or other abrasive particles in the water. 29 / 66 . 3. • There is no need to clean the modules underneath. • Cut down grass or trees that cast a shadow on the solar modules.1 Solar modules Routine maintenance Cleaning • The solar modules must be cleaned when they are dirty. Use only clean water without soap and a soft brush or cloth. Maintenance This section describes how to maintain solar modules and wind turbines. Tighten • Tighten screws and nuts on the support structure if they have loosened. Clearing • Make sure that the sun can shine directly on the modules. Under normal operating conditions the pumps and the controls are maintenance-free.

if required. The propeller and tail must not wobble. Replace blades if they are cracked or damaged.2 Wind turbine Monthly maintenance Test brake (This checks electrical wiring. Lower or climb the tower for inspection. A noise during braking can indicate a disconnected wire.3. Check mechanical condition Watch and listen from the tower base. Use binoculars. There should be no mechanical noise.) Stop the wind turbine in a moderate wind (charging but not furling). Just perceptible play is acceptable. • Check tightness of all tower mounting nuts and screws and propeller mounting screws. Complete mechanical check • Lower the tower • Repair or replace any worn or loose parts. Check for broken wire strands and tighten guys. 30 / 66 . Check for cracks and bent or broken parts at the anchors and base structure. Tighten all nuts and screws. hub and blade mounting screws. tail. Tighten tower. Go to section Electrical problems on page 27. There should be no buzzing either heard or felt with your hand on the tower mast. especially wire clips. Inspect the tower Follow all inspection and maintenance requirements of the tower manufacturer. Annual maintenance Do not tighten pivot pin nut. No unusual difficulty or noise should be experienced in stopping the propeller. • Clean the propeller with mild detergent to remove all dirt and debris. if required. • Check all bearings. rattle or vibration.

31 / 66 .

POWER PUMP PE PE PE +5 V +10 V +24 V F1 = OVERVOLTAGE F2 = OVERTEMP F3 = NO CONTACT F4 = OVERLOAD CONTROL INDICATOR MAX SPEED Test by means of a service CU 200 GND IN LEVEL SWITCH If available. The dry running sensor must be under water. etc. Visual inspection of the wind turbine. do not cast a shadow on the solar modules. Connect the CU 200 and proceed according to the instructions in section 1. above the pump. bushes.3. buildings. grass. see Check mechanical condition on page 30 Visual inspection of cables • Check that the cables are intact. Trouble-shooting Visual/general inspection of main components Before starting specific Trouble-shooting. Visual inspection of the water level The water level must be at least 3 ft. go through these simple visual inspections first. 32 / 66 .4. Visual inspection of pipes and hoses • Check that hoses or pipes are intact. • Make sure that trees. Visual inspection of solar modules • Check that the solar modules are intact.1 CU 200 SQFlex control unit on page 6. a CU 200 can be used for testing systems without a CU 200.

5 Wind-powered system with CU 200 control unit and level switch on page 42 4. System components * * 4. CU 200 control unit Level switch Switch box Generator/ supply network Wind turbine with IO 102 Pump System Solar panel 3. In systems with wind turbine Trouble-shooting must be carried out at a wind speed of minimum 3. Follow the Trouble-shooting instructions for your system. 2. In systems with solar modules Trouble-shooting must be carried out in the middle of an unclouded day. In the table below find the system corresponding to your system.4 Wind-powered system on page 40 4. 33 / 66 .Overview of possible system combinations 1.5 m/s (8 mph).1 Solar-powered system on page 34 IO 100 4. Find the faulty component and repair/replace it or contact the Grundfos Service Centre stating the data from the component’s nameplate.3 Solar-powered system with generator back-up on page 38 IO 101 4.2 Solar-powered system with CU 200 control unit and level switch on page 36 4.7 Combined system with CU 200 control unit and level switch on page 46 4.6 Combined system on page 44 4.8 Options with generator as back-up source on page 49 * * IO 101 * May be a component in the system.

SQF pump 7 2.1 Solar-powered system Pos.1. Straining wire 5. Internal (and external) wiring of IO 100 SQFlex switch box. If the system does not work properly. Wire clamps 6. Support structure 12. 6. IO 100 SQFlex switch box 6 5 2 3 4 5 TM02 2304 4101 1 Fig.1 Trouble-shooting of a solarpowered system on page 35. Cable clips 4. Submersible drop cable 3. 7. follow the instructions in section 4. Component 12 1.4. 34 / 66 . Solar-powered system and its main components IO 100 Solar modules TM02 4372 4302 2T1 4T2 6T3 8T4 Fig. Solar modules 7.

If the pump starts. Disconnect the pump • Set the IO 100 switch to off. Check the pump • Set the IO 100 switch to Off. 8T4). 4.4. N.4. See electrical connection: 1. 2. If the pump does not start. • Wait five minutes.2 SX-110 solar modules on page 16 1.1 GF 43. 3.4. • Measure the DC current across the terminals (6T3. the IO 100 is defective.4 GF 55C and GF 65C solar modules on page 20 1. one or more of the solar modules is faulty.5 GTF 55 on page 22 If the DC voltage or DC current is outside the range. Check the IO 100 box • Set the IO 100 switch to on. GF 50 solar modules on page 14 1. • Reconnect the pump cable to the terminals (6T3.1 Trouble-shooting of a solar-powered system 1. • Measure the DC voltage across the terminals (6T3. N. 8T4) using a voltmeter. it was stopped due to dry running and has now been reset. 8T4). Check the solar modules • Measure the voltage and short-circuit current across the terminals (2T1. Replace the faulty solar module/s. it is defective. N.1. If the values differ from the values measured under step 2. 35 / 66 . N. 4T2).3 FS-50-D solar modules on page 18 1.4. Replace the IO 100 box. 8T4) using an ammeter. • Switch on the pump by setting the IO 100 switch to On. Note that the dry running sensor is covered with water.4. • Disconnect the pump cable from the terminals (6T3.4. Repair or replace the pump.

Cable clips 4. Submersible drop cable 3. Component 1.4.2. Support structure 11. Wire clamps 6. Water reservoir 15.1 Trouble-shooting of a solarpowered system with CU 200 control unit and level switch on page 37. Tank below level. CU 200 control unit 14.2 Solar-powered system with CU 200 control unit and level switch 14 15 Pos. Straining wire 5. Fig. Level switch (optional) 11 7 5 6 2 3 4 5 TM02 2305 4101 1 Fig. 8. 9. Internal (and external) wiring of CU 200 SQFlex control unit If the system does not work properly. 36 / 66 . Solar-powered system with CU 200 and level switch Solar modules CU 200 J1 J2 TM02 4371 0702 J5 Contact closed: Contact open: Tank full. follow the instructions in section 4. SQF pump 2. Solar modules 7.

• Reconnect lewel switch to J5. Replace the level switch. 5. the level switch is defective.1 GF 43. • Turn the level switch upwards => the contact in the level switch is closed. Disconnect the pump • Switch off the pump by pressing the ON/OFF button at the CU 200. The measured value must be ∞ Ω.2 SX-110 solar modules on page 16 1.5 GTF 55 on page 22 If the DC voltage or DC current is outside the range. The measured value must be approx. • Wait five minutes. If one of the two values is not correct. Check the system by means of the CU 200 If the CU 200 indicates fault. The on light must be on.4. it is defective. it was stopped due to dry running and has now been reset. Replace the CU 200. If the pump does not start. the CU 200 is defective. the lewel switch must point downwards to send a starting signal to the CU 200. 37 / 66 . • Switch on the pump by pressing the ON/OFF button. 4T2). one or more of the solar modules is faulty.4. If the values measured differ from the values measured under step 3. • Turn the level switch downwards => the contact in the level switch is open. 1.4. Replace the faulty solar module/s. See electrical connection: 1. 0 Ω.1 Trouble-shooting of a solar-powered system with CU 200 control unit and level switch All measuring points/terminal designations in the following refer to the CU 200 control unit.4. If the pump starts. 3. Check the solar modules • Measure the voltage and short-circuit current across the terminals (2T1. The OFF light must be on. Repair or replace the pump.4. • Measure the voltage and current across the terminals for the pump (J2). 2. proceed according to section Trouble-shooting by means of CU 200 on page 8.2. GF 50 solar modules on page 14 1. The OFF light must be on. Check the level switch in the water reservoir • Disconnect the level switch cable from the terminal J5.4 GF 55C and GF 65C solar modules on page 20 1. 6. • Reconnect the pump cable to the terminal J2.3 FS-50-D solar modules on page 18 1. • Measure the disconnected level switch cable with an ohmmeter. 4. Check the pump • Make sure that CU 200 is set to off by pressing ON/OFF button. Check the CU 200 control unit • Let the level switch remain disconnected. • Disconnect the pump cable from the terminal J2. Note that the dry running sensor is covered with water.4.

3 X1.1 Trouble-shooting of a solarpowered system with generator back-up.4.3 Solar-powered system with generator back-up Pos. Internal (and external) wiring of IO 101 SQFlex switch box If the system does not work properly.4 Generator TM02 4373 0702 IO 101 Fig. 11.3. follow the instructions in section 4. 38 / 66 . Solar-powered system with IO 101 and generator 4T2 L Solar modules N 2T1 X1. Component 13 10 7 6 1 SQF pump 2 Submersible drop cable 3 Cable clips 4 Straining wire 5 Wire clamps 6 Solar modules 7 Support structure 10 Diesel or petrol powered generator 13 IO 101 switch box 5 2 3 4 5 TM02 2309 4101 1 Fig. 10.

If the value is not correct.2 SX-110 solar modules on page 16 1.1 Trouble-shooting of a solar-powered system with generator back-up All measuring points/terminal designations in the following refer to the IO 101 switch box 1. X1. Check the solar modules • Measure the DC voltage and short-circuit DC current across the terminals (2T1. GF 50 solar modules on page 14 1. • Set the IO 101 switch to on. Set the IO 101 switch to on. • Set the IO 101 switch to Off.4.5 GTF 55 on page 22 If the DC voltage or DC current is outside the range. The voltage (U) = rated generator voltage (see generator nameplate). 5. See electrical connection: 1. If the value is not correct. 2.4. • Measure the DC voltage and DC current across the terminals (X1. • Measure the AC voltage across the terminals (L. X1. Repair or replace the generator. Replace the IO 101. X1.3. • Turn on the generator. 4T2). • Measure the AC voltage across the terminals (X1.3. it is defective.4). it was stopped due to dry running and has now been reset. 6. the IO 101 is defective. the IO 101 is faulty. X1.4). Replace the solar module.4. Check the IO 101 box • Set the IO 101 switch to on.4.4. one of the solar modules is faulty.4). • Disconnect the pump cable from the terminals (X1.4. 4. Repair or replace the pump. Check the pump • Set the IO 101 switch to off. If the values differ from the values measured under step 2. If the pump does not start.1 GF 43. If the pump starts. N).3. • Reconnect the pump cable to the terminals (X1. • Wait five minutes.3. the generator is faulty.3 FS-50-D solar modules on page 18 1.4 GF 55C and GF 65C solar modules on page 20 1. Check the generator • Set the IO 101 switch to off. The voltage (U) = rated generator voltage (see generator nameplate).4). Note that the dry running sensor is covered with water. 3. Replace the IO 101. Check the IO 101 box during generator operation • The generator must be running. 39 / 66 . Disconnect the pump • Make sure that the generator has been turned off.3.

Cable clips 4. Submersible drop cable 3. Internal (and external) wiring of IO 102 SQFlex breaker box If the system does not work properly. TM02 4374 0702 IO 102 Fig.1 Trouble-shooting of a windpowered system on page 41. 40 / 66 . SQF pump 2.4. IO 102 breaker box 8 9 5 2 3 4 5 TM02 2306 4101 1 Fig. follow the instructions in section 4.4. 12. Component 1. Wire clamps 8. 13. Straining wire 5. Wind turbine 9.4 Wind-powered system Pos. The wind-powered system main components.

see Wind turbine on page 24.e. 2. • Release the wind turbine and turn on the pump. • Disconnect the pump cable from the terminals in the IO 102 breaker box. The voltage (U) = 0-250 VAC.4. the wind turbine is faulty. by turning the ON/OFF switch to off. The voltage depends on the wind speed. it was stopped due to dry running and has now been reset. • Release the wind turbine by turning the ON/OFF switch to on. If they differ.1 Trouble-shooting of a wind-powered system All measuring points/terminal designations in the following refer to the IO 102 breaker box. • Reconnect the pump cable to the terminals. one measurement between each of the three phases. the breaker box is faulty. Repair or replace the pump. it is defective. Check the wind turbine • Measure the AC voltage across the terminals for the wind turbine. Replace the breaker box. Note that the dry running sensor is covered with water. The three values measured must be identical. If no voltage is measured and the Propeller is turning. The voltage depends on the wind speed. Check the IO 102 breaker box • Measure the DC voltage across the terminals for the pump. by turning the ON/OFF switch to on. 1. Disconnect the pump • Stop the wind turbine and turn off the pump. or if no voltage is measured and the propeller is turning. 3. Repair or replace the wind turbine. • Wait five minutes. 4. The voltage (U) = 0-300 VDC. i. Check the pump • Stop the wind turbine by turning the ON/OFF switch to off. 41 / 66 . see Wind turbine on page 24.4. If the pump starts. If the pump does not start.

TM02 4377 0702 J1 J2 Fig. Level switch 8 14 15 11 9 5 2 3 4 5 TM02 2308 4101 1 Fig.1 Trouble-shooting of a windpowered system with CU 200 control unit and level switch on page 43.5. IO 102 breaker box 11. Submersible drop cable 3. Cable clips 4. Wire clamps 8. SQF pump 2. Internal (and external) wiring of IO 102 breaker box and CU 200 SQFlex control unit If the system does not work properly. Straining wire 5.5 Wind-powered system with CU 200 control unit and level switch Pos. Contact open: Tank below level. 15. Wind-powered system with CU 200 and level switch CU 200 IO 102 J5 Contact closed: Tank full. Component 1. Wind turbine 9. Water reservoir 15.4. 42 / 66 . follow the instructions in section 4. CU 200 control unit 14. 14.

the level switch is defective. The measured value must be ∞ Ω. it is defective. • Connect the level switch cable to the terminal J5. it was stopped due to dry running and has now been reset. 7. Check the IO 102 breaker box • Measure the DC voltage across the terminals for the CU 200 in the breaker box. see Wind turbine on page 24. If the value differs. 5. or if no AC voltage is measured and the Propeller is turning. The measured value must be approx. The value must correspond to the value measured under step 4.e. Check the system by means of the CU 200 If the CU 200 indicates fault. If no DC voltage is measured and the Propeller is turning. see Wind turbine on page 24. 43 / 66 . 2. proceed according to section Trouble-shooting by means of CU 200 on page 8. Check the CU 200 control unit • Let the level switch remain disconnected. The voltage depends on the wind speed. 0 Ω. The on light must be on. the wind turbine is faulty. The OFF light must be on. the breaker box is faulty. • Measure the disconnected level switch cable with an ohmmeter. The three values measured must be identical. If the pump starts. one measurement between each of the three phases. The voltage depends on the wind speed. Replace the CU 200. U = 0-250 VAC. If they differ. Replace the breaker box. The level switch must point downwards to send a starting signal to the CU 200. • Turn the level switch downwards => the contact in the level switch is open. • Switch on the pump by pressing the ON/OFF button. • Measure the DC voltage across the terminal for the pump (J2) in CU 200. Replace the level switch. 3. U = 0-300 VDC. 4. If one of the two values is not correct. • Wait five minutes. Disconnect the pump • Switch off the pump by pressing the ON/OFF button at the CU 200. Check the wind turbine • Measure the AC voltage across the terminals for the wind turbine. 6.1 Trouble-shooting of a wind-powered system with CU 200 control unit and level switch 1. Repair or replace the wind turbine. • Reconnect the pump cable to the terminal J2. • Turn the level switch upwards => the contact in the level switch is closed. i. If the pump does not start.5. Note that the dry running sensor is covered with water. the CU 200 is defective. • Disconnect the pump cable from the terminal J2. Repair or replace the pump. Check the level switch in the water reservoir • Disconnect the level switch cable from the terminal J5 in CU 200. Check the pump • Make sure that CU 200 is set to off by pressing ON/OFF button.4. The OFF light must be on.

IO 102 breaker box 8 7 5 2 3 4 5 TM02 2307 4101 1 Fig. Cable clips 4. Combined system main components Solar modules TM02 4375 0702 IO 102 Fig. Support structure 8.1 Trouble-shooting of a wind-powered system with CU 200 control unit and level switch on page 43. SQF pump 2. follow the instructions in section 4. Component 1.4. Submersible drop cable 3. 16. Straining wire 5. 17. Wind turbine 9. Solar modules 7.5. 44 / 66 .6 Combined system 9 6 Pos. Internal (and external) wiring of IO 102 SQFlex breaker box If the SQFlex system does not work properly. Wire clamps 6.

The three values measured must be identical. The voltage depends on the wind speed. Check the IO 102 breaker box with wind turbine connected • Measure the DC voltage across the terminals for the CU 200 in the breaker box. U = 0-250 VAC.4.3 FS-50-D solar modules on page 18 1. 1.4. • Set the IO 102 switch to on.6. 4. or if no voltage is measured and the wind turbine is turning. If they differ (more than 10 V).4. 2. • Disconnect the pump cable from the terminals. • Measure the DC voltage and short-circuit DC current across the terminals (2T1.4. If the pump does not start. Replace the faulty solar module/s. • Wait five minutes. If no DC voltage is measured and the wind turbine is turning. • Reconnect the pump cable to the terminals. WARNING: Do not touch the wire due to high voltage.1 Trouble-shooting of a combined system All measuring points/terminal designations in the following refer to the IO 102 breaker box. Check the solar modules • Disconnect the three wires from the wind turbine one by one and short-circuit all three wires to each other in order to stop the turbine. Repair or replace the pump. Disconnect the pump • Set the IO 102 switch to off.4 GF 55C and GF 65C solar modules on page 20 1. 4T2). GF 50 solar modules on page 14 1. Repair or replace the wind turbine. one measurement between each of the three phases.e. • Measure the DC voltage and short circuit DC current. Replace the breaker box. 3. the breaker box is defective. the breaker box is faulty. Release the wind turbine by setting the IO 102 switch to on. the wind turbine is faulty. Note that the dry running sensor is covered with water. Reset of dry-running alarm • Set the IO 102 switch to off.1 GF 43. see Wind turbine on page 24. Check the wind turbine • Measure the AC voltage across the terminals for the wind turbine. U = 0-300 VDC. 5. it was stopped due to dry running and has now been reset.4.2 SX-110 solar modules on page 16 1. across the terminals for the pump. one ore more of the solar modules is faulty. The voltage depends on the wind speed. 45 / 66 . • Reconnect the wire from the solar panel which was disconnected under step 1. WARNING: Do not touch the wire due to high voltage. If the pump starts. If the values differ. See electrical connection: 1. 6. i. The values must correspond to the values measured under step 4. • Disconnect plus or minus from the solar modules.4. see Wind turbine on page 24. Check the IO 102 breaker box with solar modules connected • Connect the solar modules by setting the IO 102 switch to on. Replace the breaker box.5 GTF 55 on page 22 If the DC voltage or DC current is outside the range. it is defective.

4. CU 200 control unit 14. Wind turbine 9. Level switch 7 9 11 5 2 3 4 5 TM02 2310 4101 1 Fig.7. Water reservoir 15. IO 102 breaker box 11. Submersible drop cable 3. 19. 46 / 66 . Internal (and external) wiring for IO 102 SQFlex breaker box and CU 200 SQFlex control unit If the system does not work properly. Straining wire 5.1 Trouble-shooting of a combined system with CU 200 control unit and level switch on page 47. Wire clamps 6. SQF pump 2. TM02 4376 0702 J1 J2 Fig. follow the instructions in section 4.7 Combined system with CU 200 control unit and level switch 8 14 15 6 Pos. Contact open: Tank below level. Cable clips 4. Solar modules 7. Support structure 8. Component 1. Combined system with CU 200 and level switch CU 200 IO 102 J5 Contact closed: Tank full. 18.

Check the IO 102 breaker box with solar modules • Connect the solar modules by setting the IO 102 switch to on. The three values measured must be identical.4. The measured value must be ∞ Ω. Check the IO 102 breaker box with wind turbine connected • Measure the DC voltage across the terminals for the CU 200 in the breaker box.5 GTF 55 on page 22 If the DC voltage or DC current is outside the range.2 SX-110 solar modules on page 16 1. • Disconnect the pump cable from the terminal J2. • Turn the level switch downwards => the contact in the level switch is open. See electrical connection: 1. one or more of the solar modules is faulty. the level switch is defective. Replace the breaker box. the breaker box is faulty.1 GF 43. 4. WARNING: Do not touch the wire due to high voltage. U = 0-250 VAC. • Disconnect the level switch cable from the terminal J5. The value must correspond to the value measured under step 3 or 5. Replace the CU 200. one measurement between each of the three phases. If they differ. • Release the wind turbine by setting the IO 102 switch to on. • Disconnect plus or minus from the solar modules. • Measure the DC voltage across the terminals for the pump (J2). 7. Check level switch in the water reservoir • Release the wind turbine by setting the IO 102 switch to on. across the terminals for the pump. GF 50 solar modules on page 14 1.3 FS-50-D solar modules on page 18 1.4.4. The values must correspond to the values measured under step 4. Check the wind turbine • Measure the AC voltage across the terminals for the wind turbine.4. or if no voltage is measured and the wind turbine is turning. The voltage depends on the wind speed. 3. • Reconnect the wire from the solar panel which was disconnected under step 1.1 Trouble-shooting of a combined system with CU 200 control unit and level switch Measuring points/terminal designations in the following refer to the IO 102 breaker box or the CU 200. If no voltage is measured and the wind turbine is turning. WARNING: Do not touch the wire due to high voltage. the wind turbine is faulty. The measured value must be approx. Note: The sun and wind conditions may have changed since the measurements in point 3 or 5 were made If the value differs. 0 Ω. • Turn the level switch upwards => the contact in the level switch is closed. i. • Measure the DC voltage and short circuit DC current. Disconnect the pump • Set the IO 102 switch to off. Check the CU 200 control unit • Let the level switch remain disconnected. 1. Replace the faulty solar module/s. If the values differ. Repair or replace the wind turbine. If one of the two values is not correct.4. Replace the level switch. 5. U = 0-300 VDC.4. Replace the breaker box. 4T2). • Measure the DC voltage and short-circuit DC current across the terminals (2T1. the breaker box is defective.e. 2. 6.7. 47 / 66 . see Wind turbine on page 24.4 GF 55C and GF 65C solar modules on page 20 1. see Wind turbine on page 24. The voltage depends on the wind speed. • Measure the disconnected level switch cable with an ohmmeter. the CU 200 is defective. Check the solar modules • Disconnect the three wires from the wind turbine one by one and short-circuit all three wires to each other in order to stop the turbine.

The OFF light must be on. If the pump starts.8. • Press the ON/OFF button the on light must be on. The level switch must point downwards to send a starting signal to the CU 200. If the pump does not start. • Wait five minutes. Note that the dry running sensor is covered with water. • Connect the level switch cable to the terminal J5. it is defective. • Reconnect the pump cable to the terminal J2. 48 / 66 . Check the pump • Make sure that CU 200 is set to off by pressing ON/OFF button. it was stopped due to dry running and has now been reset. Repair or replace the pump.

4 J2 J5 Wind-powered system IO 101 IO 102 4T2 X1.1 to 3.7.3 X1. For application overview see section Overview of possible system combinations on page 33.4 2T1 L N Wind-powered system with CU 200 control unit and level switch IO 101 IO 102 CU 200 4T2 X1.4 J1 J2 J5 .3 L N 2T1 J1 X1.4. Solar-powered system with CU 200 control unit and level switch IO 101 CU 200 4T2 X1.8 Options with generator as back-up source Below are wiring diagrams for options with generator as a power supply back-up source.3 L N 2T1 49 / 66 X1. For Trouble-shooting of the individual components see sections 3.

3 X1.3 X1.4 2T1 L N Combined system with CU 200 control unit and level switch IO 101 IO 102 L N 4T2 2T1 50 / 66 CU 200 X1.Combined system IO 101 IO 102 4T2 X1.4 J1 J2 J5 .

Refit the filling plug and make sure that it is tight. 2. 10 4. 5. 51 / 66 . tool letters refer to section 5.3 Torques and lubricants on page 54. When fixing the motor in a vice. 5.4.1. 5.1. see section 5.4 After assembly • Test the head and flow according to the test specifications. Filling of motor liquid 1. • Before connecting the pump to the motor. • Replace defective parts by new parts. Fig. TM01 1434 4597 5. Filling of motor 5.2 Before assembly • Clean all parts and check them for fractures and wear. sectional drawings and parts lists.1. Position numbers refer to exploded views. move the motor from side to side. • Order the necessary service kits and/or parts.2 Fitting pump to motor on page 56 (centrifugal pump) or section 5. 20.1. see section 5. Fit the pump to the motor.5. • Moisten rubber parts with soapy water before fitting them. Service of pump and motor 5. fill the motor with GRUNDFOS motor liquid SML 2.4 Helical pump type on page 55. 21. Inject motor liquid SML 2. tighten only on the 30 mm wide area starting 37 mm from the upper edge of the motor sleeve. Remove the filling plug using a screwdriver or a similar tool.1 Before dismantling • Disconnect the electricity supply to the motor. To allow possible air to escape.3 During assembly • Lubricate and/or tighten screws and rubber parts according to section 5.2 Assembly on page 55 (helical pumps) Fig. the pump must be dismantled.2 Service tools on page 52. 10°. 3.5. see section 5.1 General information 30 TM02 5769 3902 37 Helical rotor pumps cannot be separated from the motor as a unit. If the motor or the pump has to be replaced. Place the motor in vertical position with an inclination of approx. into the motor with a filling syringe or the like.9 Testing the pump by means of CU 200 SQFlex control unit on page 60.

5.5 SV0006a ∅ 13 / ∅ 8. Only for 25 SQF N 52 / 66 .5 x 39.2 Service tools A B C D E F G H I J K L M N O P Q R S T Special tools Designation A Mounting plate B Spline pin with screw C Spacing pipe To be used for Supplementary information Helical pump 25 SQF 40 SQF 75 SQF SV0049 SV0226 ∅ 13 / ∅ 8.0 SV0008 D Hexagon socket head screw with washer K E Key for split cone nut 11-12 F Key for discharge chamber 1a G Open-end spanner 1a H Measuring template 24 96079961 I Depth gauge 14-16 Standard M8 x 65 SV0008 SV0074 22 mm SV0182 SV0187 27 mm SV0217 SV0064 62 mm SV2080 a.5 x 39.

Standard tools Pos.16) 19-19a 13 mm 250 7 mm 13 1" 14a 4" 18a T10 250-S Helical pump SV0083 SV0055 SV0065 standard standard SV0066 7 mm 1/4" SV0457 Torque tools Pos. Designation P Torque wrench Q To be used for S-U Supplementary information 4-20 Nm 9x12 G 40-200 Nm14x18 Torque screwdriver S 1-6 Nm R Adapter for torque screwdriver O-P S Ring insert tool T Open-end spanner Q-19-19a 13 mm Helical pump 25 SQF 40 SQF SV0292 SV0400 1/4" SV0438 1/4" SV0437 9x12 F-Q-1112 22 mm 9x12 Q-16 10 mm 9x12 53 / 66 75 SQF SV0294 SV0622 SV0610 . Designation J Hexagon key K Ring/open-end spanner L Nut driver with socket M Pipe wrench N Screwdriver (torx) O Socket for hexagon head screws To be used for E Supplementary information 25 SQF 6 mm 40 SQF 75 SQF SV1204 16-24 10 mm (two pcs. needed for pos.

5 Rocol Sapphire Aqua-Sil.5 l). It is not necessary to lubricate screws and nuts treated with "Delta Seal". * The thread of the discharge chamber must be lubricated. part no. splined shaft 11 Gardolube Centrifugal 18 Nut Centrifugal.5. Pos. part no. cylindrical shaft 19a Nut 19b Nut 24 Shaft end (nut) End cover with cable All Nut All Rocol 1. as this coat is anti-corrosive and lubricating. Gardolube L 6034. 54 / 66 . splined shaft 19 18 Gardolube Centrifugal 18 Gardolube Centrifugal. RM2924 (0.3 Torques and lubricants This section shows the screws and nuts that must be tightened to a certain torque and the lubricants to be used. 1a 13/16 Description Pump type Torque [Nm] Pump / motor Helical 55 Discharge chamber* Helical 100 Pump rotor / torsion shaft Helical 18 14a Connecting piece 16 Torsion shaft / motor shaft Lubricant Rocol Centrifugal Helical Screw 18 Centrifugal. SV9995 (1 l).

Hold the pump using the pipe wrench N or fix it in a vice.3. 6 with the even surface against the stator pos. 7. Assemble the valve and discharge chamber if it has been dismantled. Loosen the outer sleeve pos. See section 5. Prise the retaining ring pos.9 Testing the pump by means of CU 200 SQFlex control unit on page 60 12. 9. 6 downwards. 16 with a bump.4 Helical pump type Helical pumps cannot be separated from the motor as a unit. 1a with valve casing complete and tighten to the correct torque by means of the key for discharge chamber G. 11SQF-2: Turn the flange pos. see 5. 6. Remove the pump rotor pos. Moisten the pump rotor pos. Start-up on page 28. the cable need not to be removed. Fill the motor with liquid. 5. 10. fixing the stator in the centre of the outer sleeve. 9 from the motor using the pipe wrench N on the weld just above the upper strainer. 7. 1d with grease and fit it in the outside recess of the valve casing. Remove the discharge chamber pos. The jaws must be placed on the weld just above the upper strainer. remove the nuts for end cover with socket at the bottom of the motor and pull the end cover with cable and socket out of the motor. 5. 11.5.1 Dismantling 1. Fit the discharge chamber pos. 18a and 18b and remove them together with the cable guard pos. Hold the pump rotor using the pipe wrench N on the cylindrical part below the pump rotor. 9. 7a in the recess of the discharge chamber. Fit the pump rotor pos. 13 from the torsion shaft pos. Remove the pump stator pos. 9. Fit the flange pos. Fix the motor in a vice. See section 2. Turn the discharge chamber and fit the retaining ring pos. Hold the torsion shaft with the ring/open-end spanner L. 1a with valve casing complete using the key for discharge chamber G. 2. If the motor or the pump must be replaced. 16 from the motor shaft using two ring/open-end spanners L. Test the pump performance using a CU 200 control unit. Tighten to the correct torque. Install the pump. see 5. if available. 8. Pull the outer sleeve pos. 9 and flange pos. Unscrew the screws pos. Push the end cover with socket and cable into the motor if it has been removed. Fit the cable guard pos. 16 using the pipe wrench N. 1a and press the parts down and out of the discharge chamber. 1a over the valve casing. 13 to the torsion shaft pos. If the motor is defective. 9 with the conical stator inlet against the strainer into the outer sleeve pos. Note: Tighten only on the area shown in fig. 8. 16 and tighten to correct torque. Press the two upper flaps under the outer sleeve and fit the screws pos. see 5. 55 / 66 . 18. If the motor is intact. the pump must be dismantled. 13 and torsion shaft pos. replace these parts. 55 . Fit the torsion shaft to the motor shaft and tighten to the correct torque. • Grease the thread of the discharge chamber with valve casing complete and screw it into the top of the sleeve. Fit and tighten the nuts using the socket for hexagon head screws P. 9 free of the pump rotor pos. 20. If the accessible holes in the outer sleeve at the lower strainer are not threaded. 4.3 by means of the key for discharge chamber G. 6 into the outer sleeve and press it on the upper part of the stator. see Filling of motor liquid on page 51 2. 5. Hold the pump by means of the pipe wrench N on the weld just above the upper strainer. Fit the pump stator pos. 18. 55 with pump stator pos. If the parts of the valve casing complete are defective. Remove the torsion shaft pos.2 Assembly 1. 18a and 18b.3. Hold the motor with the open-end spanner H.4. 3. they must be tapped using the tapping screw included in the cable guard service kit and the assembly kit or by means of an M3 set screw. • Press the discharge chamber pos. 55 with pump stator pos. 7a out of the recess of the discharge chamber pos. 5. 10. 4. • Place the valve casing complete on a plane surface with the bearing pos. 6 by knocking the discharge end of the outer sleeve hard against a solid wooden surface such as a workbench or table. the adapter for torque screwdriver S and the torque screwdriver R. 6. 13 with clean water and fit the pump on the motor. 3.4. • Lubricate the O-ring pos.

Fix the motor in a vice. 18. Note: Tighten only on the area shown in fig. 8.5. 5. 7.1 Detaching pump from motor 1. Fit the supporting ring pos. 18a. If the motor is defective. Adjust the height to 88. TM02 5770 3902 2. the adapter for torque screwdriver S and the torque screwdriver R. 3. 5. 24a and the spline protector pos.2 mm. Remove the connecting piece pos. Fig. Install the pump. Tighten the nut to the correct torque. see fig.9 Testing the pump by means of CU 200 SQFlex control unit on page 60.2 mm by means of the measuring template I.15 mm ±0. 20. 4. Fit and tighten the nuts. 18a and remove them together with the cable guard pos. Unscrew the screws pos. 14a must be next to each other. 24a from the pump shaft. Fit the cable guard pos. see 5.5 Centrifugal pump and motor 5. the cable need not be removed. 9. see 5.15 mm ±0. Test the pump performance using a CU 200 control unit.3 using the socket for hexagon head screws P. 22. If the motor is intact. Unscrew the screws pos. 18c and secure it with screws pos. Push the end cover with cable into the motor if it has been removed. 24 on to the motor shaft and push it home. 3. 24b and supporting ring pos. 18 and secure with screws pos. 10. 56 / 66 .5. 18b and remove them (if any) together with the cable guard pos.5. Fit the connecting piece pos. 19a and lift the pump off the motor 6. see section 2. Fit the pump to the motor. Remove the shaft end pos. 7. 5. 22. 8. Fit the four nuts pos. 6. 4.2 Fitting pump to motor 1. Remove the spline protector pos. 19a and tighten diagonally to the correct torque. 18c. 14a and tighten using the pipe wrench N. 11. See section 5. see 5. Screw the shaft end pos. The cable recesses in the suction interconnector pos. 18b ( 25 SQF). Hold the motor using the open-end spanner H.3. 14 and the connecting piece pos. Fit the cable guard pos. 2. Fill the motor with liquid.3. if available. see Filling of motor liquid on page 51. Start-up on page 28. Check that the height is still 88. 24b. 24 from the motor shaft. remove the nuts for the end cover with socket and pull the end cover with cable and socket out of the motor. Remove the nuts pos. 14a from the motor by means of the pipe wrench N.

Fit the valve casing complete pos. 19b • washer pos.5. Pull the pump shaft pos. 1 • nut pos.6 Centrifugal pump type with splined shaft 5. 6. Replace worn wear parts. Note: Check that the impellers can be raised and lowered. 3. 9 and the impeller pos. Slide the priming disc pos. 14 and the bottom chamber pos. 11. 8. 14. 57 / 66 .1 Dismantling 1. Note: Make sure that the mounting plate is positioned correctly so that the recess of the mounting plate and the suction interconnector pos. 4. as it is important that the nut is tightened against the impellers. see 5. see section 5. 64 over the pump shaft pos. 17. 9. Lubricate the threads of the screws pos. 1 and the discharge piece pos. and fit the straps pos.2 Fitting pump to motor on page 56. 5. 7. 14. 76 • impeller pos. 5. Note: The dogs of the priming disc must point upwards. 71 and screws pos. 16 with priming disc pos. 1b. 3.5. Fit the pump shaft to the spline pin with screw B.8 Checking and replacing wear parts of centrifugal pumps on page 59 5. Remove the strap pos. 10 into the suction interconnector pos. Make sure that the top impeller engages with the splined shaft and tighten the nut pos. 13 and press it until it engages with the neck ring pos. Tighten diagonally to the correct torque. see section 5.2 Assembly 1. 17.6. 7 in the bottom chamber pos. 76 (with the three grooves upwards) and the nut pos. Fit the first impeller pos. 2. 10. Fit the washer pos. 19. Fit the chamber pos. 19b.6. see 5.3. 7. Unscrew and remove the screws pos. 19 together with the washers pos.3. Place the pump on the mounting plate A. Dismantle the pump in the following order until the last chamber has been removed: • discharge piece pos. Note: Turn the discharge piece so that the slots for the cable guard are located above the screw holes for the screws pos. 2. Fit the suction interconnector pos. 14 to the mounting plate A. 19. 9. 6. Remove the pump from the mounting plate A and fit the pump to the motor. Press the bottom chamber pos. 14 and the bottom chamber pos. 1b • valve casing complete pos. 64 up and out of the suction interconnector pos. Lift the suction interconnector pos. 10. 18b in the suction interconnector pos. washers pos. 4. 14 fit into each other. Fit the and tighten the spline pin with screw B on the mounting plate A. 13 until the last impeller has been fitted. 10 free of the mounting plate A. if any. 10. 16 and push until it touches the coupling. 19b to the correct torque. 13 • chamber pos. 71.

14 fit into each other. 14 over the shaft so that the projection of the suction interconnector engages with the recess of the mounting plate. Slide the suction interconnector pos. split cone pos. 9. 5. Note: Fit the stop ring pos. until all impellers and chambers have been fitted. 25 from the recess of the suction interconnector pos. see 5. 17. 10 / guide pos. 9. see section 5.5. 85 of 25 SQF N. 3. 14 fit into each other. Measure with the shaft in its top and bottom position.1 Dismantling 1. Fix the mounting plate in a vice. 4. 25 home in the suction interconnector.3.2 Fitting pump to motor on page 56. Check the axial clearance of the pump shaft by measuring the distance between the contact surface of the suction interconnector and the shaft end using a slide gauge or depth gauge. 19. Slacken and remove the nuts pos. make sure that the chamber and the impeller are fitted correctly before the split cone nut is tightened. 16 to the mounting plate A by means of the spacing pipe D and hexagon socket head screw with washer E. Remove the stop ring pos. see section 5.15 39. Repeat steps 3. 10 / guide pos. Remove the hexagon socket head screw with washer E. 11 using the key for split cone nut F. Knock the split cone pos. Give the split cone nut a few turns. Fit the valve housing pos. Remove the impeller pos. Note: Make sure that the mounting plate is positioned correctly so that the recess of the mounting plate and the projection of the suction interconnector pos. 8.) Remove the stop ring pos. until all impellers and chambers have been removed. Note: The top chamber of 40 SQF and 75 SQF is pos. 2. Press the bottom chamber pos. 12. Tighten diagonally to the correct torque. 3. Fit the split cone pos. 5. spacing pipe D and pump shaft pos. Top position Hmin 25 SQF 37. and 4. Lift the suction interconnector off the mounting plate A. 85 after the middle impeller of 25 SQF and 75 SQF. split cone nut pos. Remove the strap pos. 13 (the impeller collar must point downwards) and split cone nut pos. 14 (only 75 SQF). see below. . Fix the mounting plate in a vice. Repeat steps 4. 25 using the key for split cone nut F and tighten to the correct torque.15 H Bottom position Hmax 58 / 66 TM01 6247 1999 9. 13.15 40 SQF 37. Note: Make sure that the mounting plate is positioned correctly so that the recess of the mounting plate and the projection of the suction interconnector pos. impeller pos. 14 by means of the spacing pipe D and the hexagon socket head screw with washer E. 7.7. 1 and the top chamber pos. 9. Loosen the split cone nut pos.2 Assembly 1. 4 (25 SQF N chamber pos.3. 12. Remove the pump from the mounting plate A and fit it on the motor. 19. Remove the valve housing complete pos. 85 of 75 SQF. Fit the strap pos. 11 and chamber pos. Note: For each section. 5. Check and replace wear parts. Fit the shaft pos.5 38.4 75 SQF 37. 12 down through and out of the impeller pos. Fit the mounting plate A to the suction interconnector pos.7. 2. 17 and nuts pos. Loosen the guide pos. 6. 4. see 5.7 Centrifugal pump type with cylindrical shaft 5. 11. 1 so that the holes for the straining wire are opposite the motor cable (cable opening in the suction interconnector) and that the slots for the straps are aligned to the points where the straps are attached to the suction interconnector. 6.8 Checking and replacing wear parts of centrifugal pumps on page 59. Press the impeller home against the chamber pos. In 75 SQF the small recess of the stop ring must be downwards.15 40. 4.5. 13 using the key for split cone nut F. Fit the chamber pos. 7. 9. 8. and 5. 16.

8 by pressing it out of sand or dry running. pos. • Push the valve seat pos. 3 out of the valve housing by inserting a screwdriver between the valve seat and the valve housing. 70 where it is posiso that the valve cup pos. 7 free of the chamber may reduce the head or flow rate. 9/ 10 or guide pos. 6 out of the valve housing (cylindrical shaft). 25 SQF (splined shaft): Press the bearing out using a screwdriver. the chamber pos. if necessary. 2 out of the valve housing. 25. Top bearing pos. 8 Check Replace • Check whether the bearings are defective due to • Remove the bearing pos. 6 Check Replace • Check whether the bearing is defective.8 Checking and replacing wear parts of centrifugal pumps Bearing pos. 2 touches the metal. 7 Check Replace • Check whether the rubber is hard or worn as this • Prize the neck ring pos. 3 (only in 25 SQF) Check Replace • Check whether the rubber is hard or compressed • Free the valve guide pos. 9/10 or guide pos. 9. Pull the guide and the valve cup pos. • Press a new bearing into the chamber from the bottom side with the largest bearing diameter against the bottom side of the chamber. Neck ring pos. The following side of the neck ring must be up: • 25 SQF smooth surface • 40 SQF "This side up" • 75 SQF lip 59 / 66 . Valve seat pos. 25 by inserting a screwdriver between the neck ring and the chamber/ guide. • Press the new bearing into the valve housing from the bottom side. • Press the bearing pos.5. • Press the valve seat home in the valve housing with the flat side downwards. • Press the neck ring home in the chamber pos. tioned under the recess of the valve casing.

The curve values are minimum values. The CU 200 is no longer in test mode. and set the test jumper to service position. 5. Press the ON/OFF button for at least four seconds.9 Testing the pump by means of CU 200 SQFlex control unit The pump must deliver a flow rate (m³/h) at a given power consumption and head. and the pump should be checked and defective parts replaced. 12. 13. 6. Connect the power supply. 4. Refit the front cover. find the intersection point of the values read for flow (Q) and power consumption P1 [W]. In the relevant curve chart. Remove the front cover of the CU 200. Make sure that the system is off. The pump now adjusts its speed. Press the ON/OFF button twice (the upper flow indicator is permanently on). (The bottom flow indicator is permanently on. and disconnect the pump and the CU 200. the flow rate is sufficient. The “Test value curves ‘ on page 61 apply to the head stated for each pump. Read the flow rate Q [m³/h] using a flowmeter or a similar device and the power consumption P1 [W] using a wattmeter.If the intersection is above the minimum curve. Disconnect the power supply to the pump. press the ON/OFF button once. 8.1 Test value curves on page 61. . If the system is not off. Adjust the counter-pressure to the value stated for each pump in the curves in section 5. and the pump is running slowly. Open the discharge valve completely to reduce the counter-pressure to a minimum.If the intersection is below the minimum curve.9. The red indicator light of the ON/OFF button must be on. the flow rate is insufficient. see illustration. Release the button. Move the test jumper from service to normal position. 60 / 66 . 11. 9. SERVICE SERVICE Test jumper NORMAL NORMAL AC MAIN SWITCH W H Q Head Flow TM02 5908 4002 90-240 VAC +6%/-10% 50/60 Hz 1. The CU 200 is now in test mode. Disconnect the power supply. 3.) 7. 10. .5. Press the ON/OFF button once. 2.

00 2 0.9. 10 18 9 5 0 0 0 100 200 300 400 500 600 700 800 900 1000 800 900 1000 0 100 Service test. Service test.50 3 1. 25 SQF-3 H = 30 ft.5.2 Drawings 61 / 66 200 300 400 500 P1 [W] P1 [W] US gal/m 500 400 P1 [W] 66 600 700 800 900 1000 .1 Test value curves The curve shown in the curve charts below is the minimum performance curve for the pump. 40 SQF-3 H = 30 ft. 28 11 24 US gal/m 9 20 US gal/m 7 5 16 12 8 3 4 0 0 200 100 400 300 500 600 0 700 0 300 200 100 P1 [W] 600 Service test. 3 SQF-2 H = 200 ft. 25 45 20 36 15 27 US gal/m US gal/m Service test.00 4 US gal/m US gal/m H Service test. 6 SQF-2 H = 200 ft.00 6 2. 11 SQF-2 H = 130 ft. 3. 200 ft. 45 40 35 30 25 20 15 10 5 0 0 100 200 300 400 500 600 700 P1 [W] 5. 75 SQF-3 H = 50 ft. 1.50 5 2. 25 SQF-6 H = 100 ft.50 1 0 0 0 50 100 0 300 250 200 150 100 300 200 500 400 P1 [W] P1 [W] Service test.9. Service test.

25 SQF-3 7 19 71 9 8 1b 13 70 64 18 2 16 17 1 18b 3 24b 24a 24 6 19b 76 7 10 13 7 19a 9 14 18c 8 13 78 18a TM02 2247 3901 14a 62 / 66 66 .

40 SQF-3 1 6 4 18 16 11 13 12 24b 24a 7 24 8 9 15 11 17 14 13 12 19a 18c 7 19 10 78 18a TM02 2247 3901 14a 63 / 66 66 .

75 SQF-3 11 13 1 12 7 25 4 6 11 16 13 18 12 7 24b 24a 9 24 8 85 15 11 13 17 14 12 7 19a 18c 19 9 78 18a 14a TM02 2438 4301 8 64 / 66 66 .

Helical 3 SQF-2. 6 SQF-2. 11 SQF-2 1b 1a 70 18 39 2 3 1 1d 55 7a 6 18b 13 9 16 TM02 2216 3901 18a 65 / 66 66 .

Windturbine 10 14 13 15 6 5 11 12 7 19 1 17 17 4 3 2 16 16 18 8 TM02 4386 0802 9 66 / 66 66 .