Grundfos CR series Installation And Operating Instructions Manual

GRUNDFOS INSTRUCTIONS

CR, CRI, CRN, CRT

Installation and operating instructions

Table of contents

2

CR, CRI, CRN, CRT

English (US)

Installation and operating instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Español (MX)

Instrucciones de instalación y operación . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Français (CA)

Notice d'installation et de fonctionnement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

3

English (US)

English (US) Installation and operating instructions

Original installation and operating instructions.

CONTENTS

Page

1. Limited warranty

4

2. Symbols used in this document

4

3. Introduction

4

4. Shipment inspection

5

4.1 Lifting instructions

5

4.2 Ensure you have the right pump

5

4.3 Checking the condition of the pump

5

4.4 Electrical requirements

5

5. Identification

6

5.1 Nameplate data

6

5.2 Type keys

6

6. Applications

9

7. Operating conditions

9

7.1 Ambient temperature and altitude

9

7.2 Liquid temperatures

9

7.3 Minimum inlet pressures

9

7.4 Maximum inlet pressures

10

7.5 Maximum operating pressures

11

8. Installation

12

8.1 Pump location

12

8.2 Foundation

12

8.3 Pump mounting

13

8.4 Suction pipe

13

8.5 Discharge pipe

13

8.6 Bypass

14

8.7 Flange forces and torques

14

8.8 Minimum continuous duty flow rates [gpm]

15

8.9 Check valves

16

8.10 Temperature rise

16

8.11 Electrical connection

16

8.12 Motors

16

8.13 Position of terminal box

16

8.14 Field wiring

16

8.15 Motor protection

17

9. Commissioning

17

9.1 Priming

17

9.2 Startup

18

10. Operation

18

10.1 Operating parameters

18

10.2 Pump cycling

18

10.3 Boiler feed installations

18

10.4 Frost protection

18

11. Maintaining the pump

18

12. Maintaining the motor

19

12.1 Motor inspection

19

12.2 Motor lubrication

19

12.3 Recommended lubricant

19

12.4 Lubricating chart (for motors with grease zerks)

19

12.5 Lubricating procedure

20

13. Replacing the motor

20

13.1 Disassembly

20

13.2 Assembly

20

14. Parts list

23

14.1 Spare parts

23

15. Preliminary electrical tests

23

15.1 Supply voltage

23

15.2 Current

24

15.3 Insulation resistance

24

16. Startup of pump with air-cooled top (Cool-Top

®

)

25

17. Diagnosing specific problems

26

18. Worksheet for three-phase motors

29

19. Disposal

29

Warning

Prior to installation, read these installation and

operating instructions. Installation and operation

must comply with local regulations and accepted

codes of good practice.

Warning

Electrical work: All electrical work should be

performed by a qualified electrician in

accordance with the latest edition of national,

state, and local codes and regulations.

Warning

Shock Hazard: A faulty motor or wiring can cause

electrical shock that could be fatal, whether

touched directly or conducted through standing

water. For this reason, proper grounding of the

pump to the power supply’s grounding terminal

is required for safe installation and operation.

In all installations, the above-ground metal

plumbing should be connected to the power

supply ground as described in Article 250-80 of

the National Electrical Code.

English (US)

4

1. Limited warranty

Products manufactured by GRUNDFOS PUMPS CORPORATION

(Grundfos) are warranted to the original user only to be free of

defects in material and workmanship for a period of 24 months

from date of installation, but not more than 30 months from date

of manufacture. Grundfos' liability under this warranty shall be

limited to repairing or replacing at Grundfos' option, without

charge, F.O.B. Grundfos' factory or authorized service station,

any product of Grundfos' manufacture. Grundfos will not be liable

for any costs of removal, installation, transportation, or any other

charges which may arise in connection with a warranty claim.

Products which are sold but not manufactured by Grundfos are

subject to the warranty provided by the manufacturer of said

products and not by Grundfos' warranty. Grundfos will not be

liable for damage or wear to products caused by abnormal

operating conditions, accident, abuse, misuse, unauthorized

alteration or repair, or if the product was not installed in

accordance with Grundfos' printed installation and operating

instructions.

To obtain service under this warranty, the defective product must

be returned to the distributor or dealer of Grundfos' products from

which it was purchased together with proof of purchase and

installation date, failure date, and supporting installation data.

Unless otherwise provided, the distributor or dealer will contact

Grundfos or an authorized service station for instructions.

Any defective product to be returned to Grundfos or a service

station must be sent freight prepaid; documentation supporting

the warranty claim and/or a Return Material Authorization must

be included if so instructed.

GRUNDFOS WILL NOT BE LIABLE FOR ANY INCIDENTAL OR

CONSEQUENTIAL DAMAGES, LOSSES, OR EXPENSES

ARISING FROM INSTALLATION, USE, OR ANY OTHER

CAUSES. THERE ARE NO EXPRESS OR IMPLIED

WARRANTIES, INCLUDING MERCHANTABILITY OR FITNESS

FOR A PARTICULAR PURPOSE, WHICH EXTEND BEYOND

THOSE WARRANTIES DESCRIBED OR REFERRED TO

ABOVE.

Some jurisdictions do not allow the exclusion or limitation of

incidental or consequential damages and some jurisdictions do

not allow limit actions on how long implied warranties may last.

Therefore, the above limitations or exclusions may not apply to

you. This warranty gives you specific legal rights and you may

also have other rights which vary from jurisdiction to jurisdiction.

2. Symbols used in this document

3. Introduction

The CR range is based on the inline multistage centrifugal pump

first pioneered by Grundfos. CR is available in four basic

materials and over one million configurations. CR is suitable for

pumping water and water-like liquids in industry, petrochemical

plants, water treatment plants, commercial buildings, and many

other applications. Some of the outstanding characteristics of CR

are:

• superior efficiency

• reliability

• easy maintenance

• compact size and small footprint

• quiet operation.

Warning

If these safety instructions are not observed,

it may result in personal injury.

Warning

If these instructions are not observed, it may lead

to electric shock with consequent risk of serious

personal injury or death.

Caution

If these safety instructions are not observed,

it may result in malfunction or damage to the

equipment.

Note

Notes or instructions that make the job easier

and ensure safe operation.

5

English (US)

4. Shipment inspection

Examine the components carefully to make sure no damage has

occurred to the pump during shipment. Ensure that the pump is

NOT dropped or mishandled.

4.1 Lifting instructions

Lift pump assembly with lifting straps that pass through the motor

stool. Ensure that the load is not applied to the pump shaft.

Fig. 1 Correct lifting of a CR pump

4.2 Ensure you have the right pump

Check the pump nameplate to make sure that it is the one you

ordered.

• CR: Centrifugal pump; all parts in contact with the pumped

liquid are made of standard cast iron and AISI 304 stainless

steel

• CRI: Centrifugal pump; all parts in contact with the pumped

liquid are made of AISI 304 stainless steel

• CRN: Centrifugal pump; all parts in contact with the pumped

liquid are made of AISI 316 stainless steel

• CRT: Centrifugal pump; all parts in contact with the pumped

liquid are made of titanium

• CRE: Centrifugal pump with a Grundfos MLE variable

frequency drive motor.

4.3 Checking the condition of the pump

The packing in which your pump arrived is specially designed for

your pump to prevent damage during shipment. As a precaution,

leave the pump in the packing until you are ready to install it.

Examine the pump for any damage that may have occurred

during shipping. Examine any other parts of the shipment as well

for any visible damage.

Pump without motor (CR, CRI, CRN 1s, 1, 3, 5, 10, 15, and 20

only):

If you purchased a pump end without motor, the shaft seal has

been set from factory. Do not loosen the three set screws on the

shaft seal when attaching the motor.

Pump without motor (CR, CRN 32, 45, 64, 90, 120, and 150

only):

If you purchased a pump end without motor, you must install the

shaft seal. The shaft seal is protected in its own box inside the

pump packing crate. To protect the shaft and bearings during

shipment, a transport protector is used. Remove the transport

protector prior to installation of the shaft seal. Read the seal

installation instructions which are included in the pump packing.

4.4 Electrical requirements

Verify the power supply to make sure that the voltage, phases

and frequency match those of the pump. The proper operating

voltage and other electrical information appear on the motor

nameplate. These motors are designed to run on - 10 %/+ 10 %

of the rated nameplate voltage. For dual-voltage motors, the

motor should be internally connected to operate on the voltage

closest to the 10 % rating, i.e., a 208 V motor should be wired

according to the 208 V wiring diagram. The wiring diagram can be

found on either a plate attached to the motor or on a label inside

the terminal box cover.

Caution

Do not use the lifting eyes of the motor for lifting

the entire pump and motor assembly.

TM04 0339 0608

Note

If the shipment consists of a complete unit

(motor attached to pump end), the position of the

coupling connecting the pump shaft to the motor

shaft is set to factory specifications.

No adjustment is required. If the shipment is a

pump end without motor, follow the adjustment

procedures in section 13. Replacing the motor.

Warning

Electrical work: All electrical work should be

performed by a qualified electrician in

accordance with the current national, state, and

local codes and regulations.

Warning

Shock hazard: A faulty motor or faulty wiring can

cause electric shock that could be fatal, whether

the motor is touched directly or the current is

conducted through standing water. For this

reason, safe installation and operation require

proper grounding of the pump to the power

supply ground (earth) terminal.

In all installations, connect the above-ground

metal plumbing to the power supply ground

terminal as described in Article 250-80 of the

National Electrical Code.

Caution

Do not operate the pump if voltage variations are

greater than - 10 % /+ 10 %.

English (US)

6

5. Identification

5.1 Nameplate data

Fig. 1 Example of nameplate CR, CRI, CRN, CRT

Specification of the model line in nameplates:

Fig. 2 Key to model line in nameplates

5.2 Type keys

5.2.1 CR, CRI, CRN 1s, 1, 3, 5, 10, 15, and 20

5.2.2 CR, CRN 32, 45, 64, 90, 120, and 150

5.2.3 CRT 2, 4, 8, and 16

1. Type designation

TM04 3895 2609

2. Model, material

number, production

number

3. Head in feet at

rated flow

4. Rated motor hp

5. Head at zero flow

6. Rated rpm

7. Rated flow

8. Rated frequency

9. Maximum pressure

and maximum

liquid temperature

10. Direction of rotation

11. Production country

TM04 3904 3913

1

2

43

6

87

910

5

11

A

12345678 0123

P1

13

41

Model e.g.

ABCD

Material number

Production company

Last two digits of production year

Production week number (01-52)

Sequence of pump within production week

Example CR 3- 10 A FG A E HQQE

Type range: CR, CRI, CRN

Rated flow rate in [m

3

/h] (x 5 gpm)

Number of impellers

Code for pump version

Code for pipe connection

Code for materials

Code for rubber parts

Code for shaft seal

Example CR 32- 2- 1 A G A E KUBE

Pump range: CR, CRN

Rated flow rate in [m

3

/h] (x 5 gpm)

Number of impellers

Number of reduced-diameter impellers

Code for pump version

Code for pipe connection

Code for materials

Code for rubber parts

Code for shaft seal

Example CRT 16- 30 /2 A G A AUUE

Pump range: CRT

Rated flow rate in [m

3

/h] (x 5gpm)

Number of stages x 10

Code for impellers (used only if the pump has

fewer impellers than stages)

Code for pump version

Code for pipe connection

Code for materials

Code for shaft seal and rubber parts

7

English (US)

5.2.4 Codes

Example A-G-A-E-H QQ E

Pump version

ABasic version

1)

BOversize motor

E Certificate/approval

F CR pump for high temperatures (air-cooled top assembly)

H Horizontal version

HS High-pressure pump with high-speed MLE motor

I Different pressure rating

J Pump with different max. speed

K Pump with low NPSH

M Magnetic drive

N Fitted with sensor

P Undersize motor

R Horizontal version with bearing bracket

SF High-pressure pump

T Oversize motor (two flange sizes bigger)

U NEMA version

1)

X Special version

2)

Pipe connection

A Oval flange, Rp thread

B Oval flange, NPT thread

CA FlexiClamp (CRI(E), CRN(E) 1, 3, 5, 10, 15, 20)

CX Triclamp (CRI(E), CRN(E) 1, 3, 5, 10, 15, 20)

F DIN flange

G ANSI flange

J JIS flange

N Changed diameter of ports

P PJE coupling

X Special version

Materials

ABasic version

D Carbon-graphite filled PTFE (bearings)

G Wetted parts, AISI 316

GI All parts stainless steel, wetted parts, AISI 316

I Wetted parts, AISI 304

II All parts stainless steel, wetted parts, AISI 304

K Bronze (bearings)

S SiC bearings + PTFE neck rings

X Special version

Code for rubber parts

EEPDM

FFXM

K FFKM

VFKM

English (US)

8

1)

In August 2003 the NEMA version pump code was discontinued for all material numbers created by Grundfos manufacturing

companies in North America. The NEMA version pump code will still remain in effect for existing material numbers. NEMA version

pumps built in North America after this change will have either an A or a U as the pump version code depending on the date the

material number was created.

2)

If a pump incorporates more than two pump versions, the code for the pump version is X. X also indicates special pump versions not

listed above.

Shaft seal

A O-ring seal with fixed driver

B Rubber bellows seal

E Cartridge seal with O-ring

H Balanced cartridge seal with O-ring

K Metal bellows cartridge seal

O Double seal, back-to-back

P Double seal, tandem

X Special version

B Carbon, synthetic resin-impregnated

H Cemented tungsten carbide, embedded (hybrid)

Q Silicon carbide

U Cemented tungsten carbide

X Other ceramics

EEPDM

FFXM

K FFKM

VFKM

Example A-G-A-E-H QQ E

9

English (US)

6. Applications

Compare the pump’s nameplate data or its performance curve

with the application in which you plan to install it. Make sure the

application falls within the following limits.

7. Operating conditions

7.1 Ambient temperature and altitude

If the ambient temperature exceeds the maximum temperature

limits of the pump or the pump is installed at an altitude

exceeding the altitude values in the chart below, the motor must

not be fully loaded due to the risk of overheating.

Overheating may result from excessive ambient temperatures or

the low density and consequently low cooling effect of the air at

high altitudes. In such cases, it may be necessary to use a motor

with a higher rated output (P

2

).

Fig. 3 Relationship between motor output (P

2

) and ambient

temperature/altitude

Legend

Example: From fig. 3 it appears that P

2

must be reduced to 88 %

when a pump with a NEMA premium-efficiency ML motor is

installed 15,584 feet above sea level. At an ambient temperature

of 167 °F, P

2

of a standard-efficiency motor must be reduced to

74 % of rated output.

In cases where both the maximum temperature and the maximum

altitude are exceeded, the derating factors must be multiplied.

Example: 0.89 x 0.89 = 0.79.

7.2 Liquid temperatures

All motors are designed for continuous duty in 104 °F (40 °C)

ambient air conditions. For higher ambient temperature

conditions, consult Grundfos.

* We recommend xUBE shaft seals for temperatures above

200 °F. Pumps with KUHE hybrid shaft seals can only operate

up to 200 °F (90 °C). Pumps with xUUE shaft seals can be

operated down to -40 °F (-40 °C). ("x" is the seal type).

7.3 Minimum inlet pressures

Type Application/liquid

CR

Hot and chilled water, boiler feed, condensate

return, glycols and solar thermal liquids.

CRI/CRN

Deionized, demineralized and distilled water.

Brackish water and other liquids unsuitable for

contact with iron or copper alloys. (Consult

manufacturer for specific liquid compatibilities.)

CRN-SF

High-pressure washdown, reverse osmosis or other

high-pressure applications.

CRT

Salt water, chloride based liquids and liquids

approved for titanium.

TM03 4272 2006

Pos. Description

1 NEMA standard-efficiency motors

2 NEMA premium-efficiency motors

Pump Liquid temperature

CR, CRI, CRN 1s, 3, 5, 10, 15, and 20

-4 - +248 °F

(-20 - +120 °C)

CR, CRN 32, 45, 64, and 90*

-22 - +248 °F

(-30 - +120 °C)

CR, CRN 120 and 150* (up to 60 hp)

-22 - +248 °F

(-30 - +120 °C)

CR, CRN 120 and 150 (75 and 100 hp)

32-248 °F

(0-120 °C)

CRT 2, 4, 8, 16

-4 - +248 °F

(-20 - +120 °C)

CRN-SF

-4 - +221 °F

(-15 - +105 °C)

Pumps with Cool-Top™

up to 356 °F

(180 °C)

All CR, CRI, CRN NPSHR + 2 feet

CRN-SF 29 psi (2 bar)

English (US)

10

7.4 Maximum inlet pressures

* While pump is off or during start-up.

** During operation.

Pump type

Stages

Max.

[psi (bar)]

60 Hz 50 Hz

CR, CRI, CRN 1s 2-27 2-36 145 (10)

CR, CRI, CRN 1 2-25 2-36 145 (10)

27 217 (15)

CR, CRI, CRN 3 2-17 2-29 145 (10)

19-25 31-36 217 (15)

CR, CRI, CRN 5 2-9 3-16 145 (10)

10-24 18-36 217 (15)

CR, CRI, CRN 10 1-5 1-6 116 (8)

6-17 7-22 145 (10)

CR, CRI, CRN 15 1-2 1-3 116 (8)

3-12 4-17 145 (10)

CR, CRI, CRN 20 1 1-3 116 (8)

2-10 4-17 145 (10)

CR, CRN 32 1-1 - 2 1-1 - 4 58 (4)

3-2 - 6 5-2 - 10 145 (10)

7-2 - 11-2 11-14 217 (15)

CR, CRN 45 1-1 - 1 1-1 - 2 58 (4)

2-2 - 3 3-2 - 5 145 (10)

4-2 - 8-1 6-2 - 13-2 217 (15)

CR, CRN 64 1-1 1-1 - 2-2 58 (4)

1 - 2-1 2-1 - 4-2 145 (10)

2 - 5-2 4-1 - 8-1 217 (15)

CR, CRN 90 1-1 - 1 58 (4)

1-1 - 1 2-2 - 3-2 145 (10)

2-2 - 4-1 3-6 217 (15)

CR, CRN 120 1-1 - 1 1 - 2-1 145 (10)

2-2 - 3 2 - 5-1 217 (15)

4-1 - 5-1 6-1 - 7 290 (20)

CR, CRN 150 1-1 1-1 - 1 145 (10)

1-2 2-1 - 4-1 217 (15)

3-2 - 4-2 5-2 - 6 290 (20)

CRT 2 2-6 2-11 145 (10)

7-18 13-26 217 (15)

CRT 4 1-7 1-12 145 (10)

8-16 14-22 217 (15)

CRT 8 1-16 1-20 145 (10)

CRT 16 2-10 2-16 145 (10)

CRN-SF all all 72 (5)*

362 (25)**

11

English (US)

7.5 Maximum operating pressures

250 °F (194 °F for CRN-SF)

Consult Grundfos in case of other operating conditions.

Pump type/

connection

Stages

Max.

[psi (bar)]

60 Hz 50 Hz

CR, CRI, CRN 1s

Oval flange 1-17 1-23 232 (16)

FGJ, PJE 1-27 1-36 362 (25)

CR, CRI, CRN 1

Oval flange 1-17 1-23 232 (16)

FGJ, PJE 1-27 1-36 362 (25)

CR, CRI, CRN 3

Oval flange 1-17 1-23 232 (16)

FGJ, PJE 1-27 1-36 362 (25)

CR, CRI, CRN 5

Oval flange 1-16 1-22 232 (16)

FGJ, PJE 1-24 1-36 362 (25)

CR, CRI 10

Oval flange CR 1-6 145 (10)

Oval flange, CRI 1-10 1-16 232 (16)

FGJ, GJ, PJE 1-10 1-16 232 (16)

FGJ, GJ, PJE 12-17 17-22 362 (25)

CRN 10

All 1-17 1-22 362 (25)

CR, CRI 15

Oval flange 1-5 1-7 145 (10)

FGJ, GJ, PJE 1-8 1-10 232 (16)

FGJ, GJ, PJE 9-12 12-17 362 (25)

CRN 15

All 1-12 1-17 362 (25)

CR, CRI 20

Oval flange 1-5 1-7 145 (10)

FGJ, GJ, PJE 1-7 1-10 232 (16)

FGJ, GJ, PJE 8-10 12-17 362 (25)

CRN 20

All 1-10 1-17 362 (25)

CR, CRN 32

1-1 - 5 1-1 - 7 232 (16)

6-2 - 11-2 8-2 - 14 435 (30)

CR, CRN 45

1-1 - 4-2 1-1 - 5 232 (16)

4-2 - 8-1 6-2 - 13-2 435 (30)

CR, CRN 64

1-1 - 3 1-1 - 5 232 (16)

4-2 - 5-2 6-2 - 8-1 435 (30)

CR, CRN 90

1-1 - 3 1-1 - 4 232 (16)

4-2 - 4-1 5-2 - 6 435 (30)

CR, CRN 120

1-1 - 3 232 (16)

4-2 - 5-2 1-1 - 5-2 435 (30)

CR, CRN 150

1-1 - 3 232 (16)

4-1 - 4-2 1-1 - 4-2 435 (30)

CRT 2 2-18 2-26 305 (21)

CRT 4 1-16 1-22 305 (21)

CRT 8 1-8 1-12 232 (16)

10-16 14-20 362 (25)

CRT 16 1-8 1-8 232 (16)

10-12 10-16 362 (25)

Pump type/

connection

Stages

Max.

[psi (bar)]

60 Hz 50 Hz

English (US)

12

8. Installation

8.1 Pump location

Locate the pump in a dry, well-ventilated, frost-free area which is

not subject to extreme variation in temperature.

Make sure the pump is mounted at least 6 inches (150 mm) clear

of any obstruction or hot surfaces.

The motor requires an adequate air supply to prevent overheating

and adequate vertical space to remove the motor for repair.

In open systems requiring suction lift, locate the pump as close to

the liquid source as possible to reduce friction loss in pipes.

8.2 Foundation

Use concrete or similar foundation material to provide a secure,

stable mounting base for the pump.

See table below for bolt hole center line dimensions for the

various pump types.

Secure the pump to the foundation using all four bolts and shim

pump base to assure the pump is vertical and all four pads on the

base are properly supported (uneven surfaces can result in pump

base breakage when mounting bolts are tightened).

Fig. 4 Pump position

The pump can be installed vertically or horizontally. See fig. 4.

Ensure that an adequate supply of cool air reaches the motor

cooling fan. The motor must never fall below the horizontal plane.

Arrows on the pump base show the direction of flow of liquid

through the pump.

To minimize possible noise from the pump, it is advisable to fit

expansion joints on either side of the pump and anti-vibration

mountings between the foundation and the pump.

Fit isolating valves on either side of the pump to avoid draining

the system if the pump needs to be cleaned, repaired or replaced.

Warning

Do not turn on the power supply until the pump is

properly installed.

TM04 3906 0409

Note

Make sure the vent plug is located in the

uppermost position.

Base and bolt hole center line dimensions

TM00 2256 3393

Pump type

L1 L2 B1 B2 ∅

[inches] [mm] [inches] [mm] [inches] [mm] [inches] [mm] [inches] [mm]

CR 1s, 1, 3, 5 3 15/16 100 5 11/16 145 7 1/16 180 8 11/16 220 1/2 13

CRI, CRN 1s 1, 3, 5

CRT 2, 4

3 15/16 100 5 7/8 150 7 1/16 180 8 11/16 220 1/2 13

CR 10, 15, 20 5 1/8 130 6 15/16 176 8 7/16 215 10 1/16 256 9/16 13.5

CRN 10, 15, 20

CRT 8, 16

5 1/8 130 7 7/8 200 8 7/16 215 9 3/4 248 1/2 13

CR 32 6 11/16 170 8 3/4 223 9 7/16 240 11 3/4 298 9/16 14

CRN 32 6 11/16 170 8 7/8 226 9 7/16 240 11 3/4 298 9/16 14

CR 45, 64 7 1/2 190 9 3/4 248 10 1/2 266 13 1/16 331 9/16 14

CRN 45, 64 7 1/2 190 9 7/8 251 10 1/2 266 13 1/16 331 9/16 14

CR, CRN 90 7 13/16 199 10 1/4 261 11 280 13 11/16 348 9/16 14

CR, CRN 120, 150 10 13/16 275 13 9/16 344 14 15/16 380 18 9/16 472 11/16 18

2

1

2

1

L

B

4 x ø

B

13

English (US)

8.3 Pump mounting

8.3.1 Recommended installation torques

8.4 Suction pipe

The suction pipe should be adequately sized and run as straight

and short as possible to keep friction losses to a minimum

(minimum of four pipe diameters straight run prior to the suction

flange). Avoid using unnecessary fittings, valves or accessory

items. Use butterfly valves in the suction line only when it is

necessary to isolate a pump because of a flooded suction

condition. This would occur if the water source is above the

pump. See fig. 5 and fig. 6. Flush piping prior to pump installation

to remove loose debris.

Fig. 5 Flooded suction

Fig. 6 Suction lift*

* The suction pipe should have a fitting on it for priming. CRN-

SF pumps cannot be used for suction lift.

8.4.1 Suction pipe sizes

The following recommended suction pipe sizes are the smallest

sizes which should be used with any specific CR pump type.

Verify the suction pipe size in each installation to ensure that

good pipe practices are being observed and excess friction

losses are not encountered.

High temperatures may require larger diameter pipes to reduce

friction and improve NPHSA.

8.5 Discharge pipe

We suggest to install a check valve and a isolating valve in the

discharge pipe.

Pipe, valves and fittings should be at least the same diameter as

the discharge pipe or sized in accordance with good piping

practices to reduce excessive flow velocities and friction losses in

pipes.

Before installing the pump, pressure check the discharge piping

to at least the maximum pressure the pump is capable of

generating or as required by codes or local regulations.

Whenever possible, avoid high pressure-loss fittings, such as

elbows or branch tees directly on either side of the pump.

The piping should be adequately supported to reduce thermal

and mechanical stresses on the pump.

According to good installation practices, clean the system

thoroughly and flush it of all foreign materials and sediment prior

to pump installation. Furthermore, never install the pump at the

lowest point of the system due to the natural accumulation of dirt

and sediment. If there is excessive sediment or suspended

particles, we recommend that a strainer or filter is used.

Grundfos recommends that pressure gauges are installed on

suction and discharge flanges or in pipes to monitor pump and

system performance.

Warning

CR, CRI, CRN pumps are shipped with covered

suction and discharge ports. Remove the covers

before the pipes are connected to the pump.

Pump type

Recommended

foundation torque

[ft-lbs]

Recommended

flange torque

[ft-lbs]

CR, CRI, CRN 1s/1/3/

5 and CRT 2/4

30 37-44

CR, CRI, CRN 10/15/

20 and CRT 8/16

37 44-52

CR, CRN 32/45/64/90/

120/150

52 52-59

TM05 9273 3613

TM05 9274 3613

Strainer

Reservoir

Butterfly

valve

Check

valve

Expansion joints

Butterfly

valve

Eccentric

reducer

Butterfly

valve

Suction

pipe

Foot valve

Reservoir

Check

valve

Pump type Min. suction pipe size

CR, CRI, CRN 1s, 1, 3;

CRT 2

1"

Nominal diameter acc. to

ANSI schedule 40

CR, CRI, CRN 5; CRT 4 1 - 1/4"

Nominal diameter acc. to

ANSI schedule 40

CR, CRI, CRN 10, 15, 20;

CRT 8, 16

2"

Nominal diameter acc. to

ANSI schedule 40

CR, CRN 32 2 - 1/2"

Nominal diameter acc. to

ANSI schedule 40

CR, CRN 45 3"

Nominal diameter acc. to

ANSI schedule 40

CR, CRN64, 90 4"

Nominal diameter acc. to

ANSI schedule 40

CR, CRN 120, 150 5"

Nominal diameter acc. to

ANSI schedule 40

Caution

The pressure rating of pipes, valves and fittings

must be equal to or greater than the maximum

system pressure.

Warning

To avoid problems with water hammer, do not

use quick-closing valves in CRN-SF applications.

English (US)

14

8.6 Bypass

Install a bypass in the discharge pipe if there is any risk that the

pump may operate against a closed valve in the discharge line.

Flow through the pump is required to ensure that adequate

cooling and lubrication of the pump is maintained.

See 7.3 Minimum inlet pressures for minimum flow rates.

Elbows should be at least 12" from the bypass opening to prevent

erosion.

Fig. 7 Recommended bypass arrangement

Fig. 8 Optional bypass arrangement

Fig. 9 Optional bypass arrangement for CR, CRN 32, 45, 64

and CR 90, 120 and 150 only

8.7 Flange forces and torques

If not all loads reach the maximum permissible value stated in the

tables after fig. 10, one of these values may exceed the normal

limit. Contact Grundfos for further information.

Fig. 10 Flange forces and torques

TM04 3926 3613TM04 3909 3613TM04 3924 0409

Discharge

Suction

Bypass line

B

y

p

a

s

o

p

e

n

i

n

g

Discharge

Bypass line

Bypass

opening

Suction

Bypass line

Bypass

opening

Suction

Discharge

TM04 0346 1613

Flange

CR, CRI,

CRN

Force [F]

Y-direction

[lb]

Z-direction

[lb]

X-direction

[lb]

1 1/4" 1s to 5 171 263 175

2"

10, 15 and

20

303 371 337

2 1/2" 32 382 466 422

3" 45 461 562 506

4" 64 and 90 607 753 674

5", 6"

120 and

150

607 753 674

Flange

CR, CRI,

CRN

Torque [M]

Y-direction

[ft-lb]

Z-direction

[ft-lb]

X-direction

[ft-lb]

1 1/4" 1s to 5 605 715 900

2"

10, 15 and

20

738 848 1,033

2 1/2" 32 793 904 1,106

3" 45 848 959 1,180

4" 64 and 90 922 1,069 1,291

5", 6"

120 and

150

922 1,069 1,291

Y-direction: Direction of chamber stack

Z-direction: 90 ° from inlet/outlet

X-direction: Inlet/outlet

15

English (US)

8.8 Minimum continuous duty flow rates [gpm]

* Grundfos Cool-Top

®

is only available in the following pump types:

Pump type

min. °F to 176 °F

(min. °C to 80 °C)

at 210 °F

(at 99 °C)

at 248 °F

(at 120 °C)

at 356 °F

(at 180 °C)

CR, CRI, CRN 1s 0.5 0.7 1.2 1.2*

CR, CRI, CRN 1 0.9 1.3 2.3 2.3*

CR, CRI, CRN 3 1.6 2.4 4.0 4.0*

CR, CRI, CRN 5 3.0 4.5 7.5 7.5*

CR, CRI, CRN 10 5.5 8.3 14 14*

CR, CRI, CRN 15 9.5 14 24 24*

CR, CRI, CRN 20 11 17 28 28*

CR, CRN 32 14 21 35 35*

CR, CRN 45 22 33 55 55*

CR, CRN 64 34 51 85 85*

CR, CRN 90 44 66 110 110*

CR, CRN 120 60 90 N/A N/A

CR, CRN 150 75 115 N/A N/A

CRT 2 1.3 2.0 3.3 N/A

CRT 4 3.0 4.5 7.5 N/A

CRT 8 4.0 6.0 10 N/A

CRT 16 8.0 12 20 N/A

Pump type CR 1s CR 1 CR 3 CR 5 CR 10 CR 15 CR 20 CR 32 CR 45 CR 64 CR 90

Standard (CR) ●●●●

I version (CRI) ●●●●●●●

N version (CRN) ●●●●●●●●●●●

English (US)

16

8.9 Check valves

A check valve may be required on the discharge side of the pump

to prevent the pump inlet pressure from being exceeded.

When a pump with no check valve is stopped because there is no

demand on the system (all valves are closed), the high system

pressure on the discharge side of the pump will "find" its way

back to the inlet of the pump.

This is especially critical for CRN-SF applications because of the

very high discharge pressures involved. As a result, most CRN-

SF installations require a check valve on the discharge piping.

8.10 Temperature rise

It may sometimes be necessary to stop the flow through a pump

during operation.

When the flow is stopped, the power to the pump is transferred to

the pumped liquid as heat, causing a temperature rise in the

liquid.

The result is risk of overheating and consequent damage to the

pump. The risk depends on the temperature of the pumped liquid

and for how long the pump is operating without flow. See the

following temperature rise table.

Conditions/reservations

The listed times are subject to the following conditions/

reservations:

• No exchange of heat with the surroundings.

• The pumped liquid is water with a specific heat capacity of

1.0

Btu

/

lb.

°F (4.18

kJ

/

kg

°C).

• Pump parts (chambers, impellers and shaft) have the same

heat capacity as water.

• The water in the base and the pump head is not included.

These reservations should give sufficient safety margin against

excessive temperature rise.

The maximum temperature must not exceed the pump maximum

temperature rating.

8.11 Electrical connection

8.12 Motors

Grundfos CR pumps are supplied with heavy-duty, 2-pole

(3600 rpm), ODP (open drip-proof) or TEFC (totally enclosed fan

cooled), NEMA C frame motors selected to our rigid

specifications.

Motors with other enclosure types and for other voltages and

frequencies are available on a special-order basis.

CRN-SF pumps are supplied with an IEC (metric) type motor with

a reverse thrust bearing.

If you replace the pump, but keep a motor previously used on

another CR pump, be sure to read 12. Maintaining the motor for

proper adjustment of the coupling height.

8.13 Position of terminal box

The motor terminal box can be turned to any of four positions in

steps of 90 °.

To rotate the terminal box, remove the four bolts securing the

motor to the pump but do not remove the coupling. Turn the motor

to the desired position; replace and securely tighten the four

bolts. See fig. 11.

Fig. 11 Motor terminal box positions (top view)

8.14 Field wiring

Lead sizes should be based on the current carrying properties of

conductors required by the latest edition of the National Electrical

Code or local regulations. Direct-on-line (DOL) starting is

approved due to the extremely short run-up time of the motor and

the low moment of inertia of the pump and motor. If DOL starting

is not acceptable and reduced starting current is required, use an

auto transformer, resistance starter or soft starter. We suggest to

use a fused disconnect for each pump in case standby pumps are

installed.

Pump type

Time for temperature rise of 18 °F (10 °C)

Seconds Minutes

CR 1s, 1, 3 210 3.5

CR 5 240 4.0

CR 10 210 3.5

CR 15 150 2.5

CR 20 120 2.0

CR 32, 45, 64,

90, 120, 150

60 1.0

Warning

The safe operation of this pump requires that it is

grounded in accordance with the National

Electrical Code and local codes and regulations.

Connect the ground conductor to the grounding

screw in the terminal box and then to the

ACCEPTABLE grounding point. All electrical

work must be performed by a qualified electrician

in accordance with the latest edition of the

National Electrical Code and local codes and

regulations.

TM04 3923 0409

Discharge

Position 9:00

Position 12:00

Suction

Position 3:00

Standard terminal

box position (6:00)

17

English (US)

8.15 Motor protection

8.15.1 Single-phase motors

All CR pumps with single phase motors, except 10 hp, are

equipped with multi-voltage, squirrel cage induction motors which

include built-in thermal protection.

8.15.2 Three-phase motors

CR pumps with three-phase motors must be used with the proper

size and type of motor-protective circuit breaker to ensure the

motor is protected against damage from low voltage, phase

failure, current unbalance and overloads.

Use a properly sized circuit breaker with manual reset and

ambient-temperature compensated extra-quick trip in all three

phases. The overload protection should be set and adjusted to

the full-load current rating of the motor. Under no circumstances

should the overload protection be set to a higher value than the

full-load current shown on the motor nameplate. This will void the

warranty.

Set overload protection for auto transformers and resistance

starters in accordance with the recommendations of the

manufacturer.

Three-phase MLE motors (CRE-pumps) require only fuses as

circuit breaker. They do not require a motor-protective circuit

breaker. Check for phase unbalance (worksheet is provided.

See section 18. Worksheet for three-phase motors).

8.15.3 CRN-SF

The CRN-SF is typically operated in series with a feed pump.

Because the maximum allowable inlet pressure of the CRN-SF

increases from 73 psi (when pump is off and during start-up) to

365 psi (during operation), use a control device to start the CRN-

SF pump one second before the feed pump starts. Similarly, the

CRN-SF must stop one second after the feed pump stops.

See CRN-SF start-up timeline below.

Fig. 12 CRN-SF start-up

9. Commissioning

9.1 Priming

To prime the pump in a closed system or an open system where

the water source is above the pump, close the pump isolating

valve(s) and open the priming plug on the pump head.

See fig. 13, fig. 14, and fig. 15.

Fig. 13 Position of plugs and bypass valve

Fig. 14 Position of plugs CR, CRN 32, 45, 64, 90, 120, 150

Fig. 15 Vent plug

In open systems where the water level is below the pump inlet,

the suction pipe and pump must be filled with liquid and vented

before starting the pump.

1. Close the discharge isolating valve and remove the priming

plug.

2. Pour water through the priming hole until the suction pipe and

pump are completely filled with liquid. If the suction pipe does

not slope downwards away from the pump, the air must be

purged while priming the pump.

3. Replace the priming plug and tighten securely.

Caution

Standard allowable phase unbalance is 5 %.

TM04 3921 0409

TIME

CRN-SF

starts

CRN-SF

stops

Feed pump

starts

Feed pump

stops

1 or more

seconds

1 or more

seconds

Both pumps operating

TIME

CRN-SF

starts

Feed pump

starts

1 or more

seconds

Feed pump

stops

CRN-SF

stops

1 or more

seconds

Both pumps operating

TM04 3922 3613TM04 4036 3613TM04 3920 3613

Drain plug

Bypass

valve

Priming vent plug

CR(I)(N) 1s, 1, 3, 5,

10, 15, 20

CRT 2, 4, 8, 16

Suction

Drain plug

Discharge

Vent plug

Discharge

Priming plug

(Opposite side)

Suction

Drain plugs (G 1 1/2 A) with 1/4"

NPI gauge/sensor taps

Loosen

center plug

to vent

pump

Vent plug

English (US)

18

9.2 Startup

1. Gradually open the isolating valve in the suction line until a

steady stream of airless water runs out of the priming hole.

2. Close the plug and tighten securely.

3. Completely open the isolating valves.

For pumps with Cool-Top

®

, see section 16. Startup of pump with

air-cooled top (Cool-Top

®

).

Follow these steps:

1. Switch off the power supply.

2. Check to make sure the pump has been filled and vented.

3. Remove the coupling guard and rotate the pump shaft by

hand to make sure it turns freely.

4. Verify that the electrical connections are in accordance with

the wiring diagram on the motor.

5. Switch on the power and observe the direction of rotation.

When viewed from above, the pump should rotate counter-

clockwise (clockwise for CRN-SF).

6. To reverse the direction of rotation, first switch off the power

supply.

7. On three-phase motors, interchange any two phases of the

power supply.

On single-phase motors, see wiring diagram on the

nameplate. Change wiring as required.

8. Switch on the power again and check for proper direction of

rotation. Once direction of rotation has been verified, switch

off the power again. Do not attempt to reinstall the coupling

guards while the motor is on. Replace the coupling guard if

the direction of rotation is correct. When the guards are in

place, the power can be switched on again.

10. Operation

10.1 Operating parameters

CR multi-stage centrifugal pumps installed in accordance with

these instructions and sized for correct performance will operate

efficiently and provide years of service. The pumps are water-

lubricated and do not require any external lubrication or

inspection. The motors may require periodic lubrication as

described in section 12. Maintaining the motor.

Under no circumstances should the pump be operated for any

prolonged periods of time without flow through the pump.

This can result in motor and pump damage due to overheating.

A properly sized relief valve should be installed to allow sufficient

liquid to circulate through the pump to provide adequate cooling

and lubrication of the pump bearings and seals.

10.2 Pump cycling

Pump cycling should be checked to ensure the pump is not

starting more often than the following max. starts per hour:

Grundfos ML motors:

• 200 times per hour on 1/3 to 5 hp models

• 100 times per hour on 7 1/2 to 15 hp models

• 40 times per hour on 20 to 30 hp models.

Baldor motors:

• 20 times per hour on 1/3 to 5 hp models

• 15 times per hour on 7 1/2 to 15 hp models

• 10 times per hour on 20 to 100 hp models.

Rapid cycling is a major cause of premature motor failure due to

overheating of the motor. If necessary, adjust controller to reduce

the frequency of starts and stops.

10.3 Boiler feed installations

If the pump is used as a boiler feed pump, make sure the pump is

capable of supplying sufficient water throughout its entire

evaporation and pressure ranges. Where modulating control

valves are used, a bypass around the pump must be installed to

ensure pump lubrication. See section 7.3 Minimum inlet

pressures.

10.4 Frost protection

If the pump is installed in an area where frost could occur, the

pump and system should be drained during freezing

temperatures to avoid damage. To drain the pump, close the

isolating valves, remove the priming plug and drain plug at the

base of the pump. Do not refit the plugs until the pump is to be

used again. Always replace the drain plug with the original or an

exact replacement. Do not replace with a standard plug.

Internal recirculation will occur, reducing the output pressure and

flow.

11. Maintaining the pump

Depending on the conditions and operating time, make the

following checks at regular intervals:

• Check that the pump meets the required performance and is

operating smoothly and quietly.

• Check that there are no leaks, particularly at the shaft seal.

• Check that the motor is not overheating.

• Remove and clean all strainers or filters in the system.

• Check that the tripping function of the motor overload

protection works.

• Check the operation of all controls.

• If the pump is not operated for unusually long periods,

maintain the pump in accordance with these instructions.

In addition, if the pump is not drained, the pump shaft should

be manually rotated or run for short periods of time at monthly

intervals.

• In severe-duty applications, pump life may be extended by

performing one of the following actions:

– Drain the pump after each use.

– Flush the pump with water or other liquid that is compatible

with the pump materials and process liquid.

– Disassemble the pump and thoroughly rinse or wash

components in contact with the pumped liquid with water or

other liquid that is compatible with the pump materials and

process liquid.

If the pump fails to operate or there is a loss of performance, see

to section 17. Diagnosing specific problems.

Note

For CR, CRI, CRN 1s to 5 it is advisable to open

the bypass valve during start-up. See fig. 13.

The bypass valve connects the suction and

discharge sides of the pump, thus making the

filling procedure easier. Close the bypass valve

when operation is stable.

Caution

Motors should not be run unloaded or uncoupled

from the pump at any time; damage to the motor

bearings will occur.

Do not start the pump before priming or venting

the pump. See fig. 15. Never let the pump run dry.

19

English (US)

12. Maintaining the motor

12.1 Motor inspection

Inspect the motor approximately every 500 hours of operation or

every three months, whichever occurs first. Keep the motor clean

and the ventilation openings clear.

Go through the following steps during each inspection:

1. Check that the motor is clean. Check that the interior and

exterior of the motor are free of dirt, oil, grease, water, etc.

Oily residue, paper, pulp, textile lint, etc. can accumulate and

block motor ventilation. If the motor is not properly ventilated,

overheating can occur and cause early motor failure.

2. Use an ohmmeter periodically to ensure that the winding

insulation is OK. Record the ohmmeter readings, and

immediately investigate any significant drop in insulation

resistance.

3. Check all electrical connections to be sure that they are

tightened securely.

12.2 Motor lubrication

Electric motors are pre-lubricated from factory and do not require

additional lubrication at start-up. Motors without external grease

zerks have sealed bearings that cannot be re-lubricated.

Motors with grease zerks should only be lubricated with approved

types of grease. Do not over-grease the bearings. Over-greasing

will cause increased bearing heat and can result in bearing or

motor failure. Do not mix oil-based grease and silicon grease in

motor bearings.

Bearing grease will lose its lubricating ability over time.

The lubricating ability of a grease depends primarily on the type

of grease, the size of the bearings, the speed at which the

bearings operate and the severity of the operating conditions.

Good results can be obtained if the following recommendations

are used in your maintenance program. It should also be noted

that multistage pumps, pumps running to the left of the

performance curve, and certain pump ranges may have higher

thrust loads. Pumps with high thrust loads should be greased

according to the next service interval level.

12.3 Recommended lubricant

12.4 Lubricating chart (for motors with grease zerks)

New motors that have been stored for a year or more should be regreased according to the following table:

Warning

Before starting work on the motor, make sure that

all power supplies to the motor have been

switched off and that they cannot be accidentally

switched on. Electric shock can cause serious or

fatal injury. Only qualified personnel should

attempt installation, operation, and maintenance

of this equipment.

Warning

The grease outlet plug MUST be removed before

adding new grease.

Severity of duty Ambient temperature (max.) Environment Approved types of grease

Standard 104 °F (40 °C) Clean, little corrosion Grundfos ML motors are greased

for life, or the grease type will be

stated on the nameplate.

Baldor motors are greased with

Polyrex EM (Exxon Mobile).

Severe 122 °F (50 °C) Moderate dirt, corrosion

Extreme

> 122 °F (50 °C) or class H

insulation

Severe dirt, abrasive dust,

corrosion

NEMA (IEC) frame size

Service intervals [hours]

Weight of grease

[oz (grams)]

Volume of grease

[in

3

(teaspoons)]

Standard duty Severe duty Extreme duty

Up to and incl. 210 (132) 5500 2750 550 0.30 (8.4) 0.6 (2)

Over 210 up to and incl.

280 (180)

3600 1800 360 0.61 (17.4) 1.2 (3.9)

Over 280 up to and incl.

360 (225)

2200 1100 220 0.81 (23.1) 1.5 (5.2)

Over 360 (225) 2200 1100 220 2.12 (60.0) 4.1 (13.4)

English (US)

20

12.5 Lubricating procedure

1. Clean all grease zerks. If the motor does not have grease

zerks, the bearing is sealed and cannot be greased externally.

2. If the motor is equipped with a grease outlet plug, remove it.

This will allow the old grease to be displaced by the new

grease. If the motor is stopped, add the recommended

amount of grease. If the motor is to be lubricated while

running, add a slightly greater quantity of grease.

3. Add grease SLOWLY taking approximately one minute until

new grease appears at the shaft hole in the flange or grease

outlet plug. Never add more than 1 1/2 times the amount of

grease shown in the lubricating chart.

4. Let motors equipped with a grease outlet plug run for

20 minutes before replacing the plug.

13. Replacing the motor

If the motor is damaged due to bearing failure, burning or

electrical failure, observe the following instructions as to how to

remove the motor and how to mount the replacement motor.

13.1 Disassembly

Proceed as follows:

1. Disconnect the power supply leads from the motor.

Remove the coupling guards.

2. Use the proper metric hexagon key to loosen the four cap

screws in the coupling. Remove coupling halves completely.

On CR 1s-CR 20, the shaft pin can be left in the pump shaft.

CR, CRN 32, 45, 64, 90, 120, and 150 do not have a shaft pin.

3. Use the correct size spanner to loosen and remove the four

mounting bolts joining motor and pump.

4. Lift the motor straight up until the shaft has cleared the motor

stool.

13.2 Assembly

Proceed as follows:

1. Remove key from motor shaft, if present, and discard.

2. Thoroughly clean the surfaces of the motor and pump

mounting flanges. The motor and shaft must be clean of all oil

or grease and other contaminants where the coupling

attaches. Place the motor on top of the pump.

3. Turn the terminal box to the desired position by rotating the

motor.

4. Insert the four mounting bolts, then tighten diagonally and

evenly:

– for 3/8" bolts (1/2 - 2 hp), torque = 17 ft-lb

– for 1/2" bolts (3 - 40 hp), torque = 30 ft-lb

– for 5/8" bolts (50 - 100 hp), torque = 59 ft-lb

– follow instructions for particular pump model in sections

13.2.2 CR 1s, 1, 3, and 5 to 13.2.5 CR, CRN 32, 45, 64, 90,

120, and 150.

13.2.1 Torque specifications

Caution

Keep grease free from dirt to avoid damage to

motor bearings. If the environment is extremely

dirty, contact Grundfos, the motor manufacturer,

or an authorized service center for additional

information.

Do not mix dissimilar types of grease.

Note

If new grease does not appear at the shaft hole or

grease outlet, the outlet passage may be blocked.

Contact Grundfos service center or certified

motor shop.

Caution

Motors used on CR pumps are specifically

selected to our rigid specifications.

Replacement motors must be of the same frame

size, should be equipped with the same or better

bearings and have the same service factor.

Failure to follow these recommendations may

result in premature motor failure.

Warning

Before starting work on the motor, make sure that

the mains switch has been switched off. It must

be ensured that the power supply cannot be

accidentally switched on.

Note

For CR 1s, 1, 3, 5, 10, 15, and 20: Do not loosen

the three hexagon socket head cap screws

securing the shaft seal.

Torque specifications for CR, CRI, CRN 1s, 1, 3, 5, 10, 15,

and 20 CRT 2, 4, 8, and 16

Coupling screw size Minimum torque

M6 10 ft-lb

M8 23 ft-lb

M10 46 ft-lb

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