Grundfos IO 113 Installation and Operating Instructions
Product Overview
The Grundfos IO 113 serves as an interface between Grundfos wastewater pumps equipped with sensors and pump controllers. It displays essential sensor status information on its front panel. Each IO 113 module can be connected to one pump and provides galvanic isolation between the pump's motor voltage and the connected controller(s).
Standard functions of the IO 113 include:
- Protection against overheating.
- Monitoring of motor winding temperature, leakage (WIO/WIA), and pump moisture.
- Measurement of stator insulation resistance.
- Stopping the pump in case of an alarm.
- Remote pump monitoring via RS-485 communication (Modbus or GENIbus).
- Pump control via a frequency converter.
When combined with an SM 113, the IO 113 can also monitor bearing temperature and pump vibration.
Note: WIO and WIA are abbreviations for water-in-oil and water-in-air respectively. Leakage sensor connections must be made via the SM 113 device if an SM 113 is installed.
The IO 113 is intended for handling internal and external signals from pumps, sensors, and controls, featuring potential-free alarm and operating relays to stop the pump when necessary. It is designed for use outside Ex zones but can monitor pumps within Ex zones.
Safety Information
DANGER: Electric shock
Death or serious personal injury may occur. Before installing the IO 113, ensure the power supply is switched off and cannot be accidentally switched on. Installation must be performed by authorized personnel in accordance with local regulations. All safety regulations must be observed.
CAUTION: Explosive environment
Minor or moderate personal injury may occur. Do not install the IO 113 in potentially explosive environments. Pumps with sensors may be installed in such environments if they have the necessary product certification.
CAUTION: Sharp element
Minor or moderate personal injury may occur. Wear protective gloves when handling the product.
WARNING: Electric shock
Minor or moderate personal injury may occur. Ensure the supply voltage corresponds to the values stated on the nameplate.
Hazard Symbols:
- DANGER: Indicates a hazardous situation which, if not avoided, will result in death or serious personal injury.
- WARNING: Indicates a hazardous situation which, if not avoided, could result in death or serious personal injury.
- CAUTION: Indicates a hazardous situation which, if not avoided, could result in minor or moderate personal injury.
- Blue/Grey Circle with White Symbol: Indicates an action that must be taken.
- Red Circle with Diagonal Bar: Indicates an action that must not be taken or must be stopped.
- Light Bulb Symbol: Tips and advice for easier work.
- Ex Symbol: Observe these instructions for explosion-proof products.
Installation
General Installation Data
- Supply voltage: 24 VAC ± 10% or 24 VDC ± 10%, 50 or 60 Hz.
- Supply current: Minimum 2.4 A, Maximum 8 A.
- Power consumption: Maximum 5 W.
- Ambient temperature: -25 to +65 °C.
- Enclosure class: IP20.
- Installation altitude: Maximum 2000 m above sea level.
- Relative humidity: Maximum 95%.
Dimensions and Mounting
The IO 113 is prepared for mounting on a 35 mm DIN rail (EN 50022). Recommended height: 7.5 mm. Ensure a minimum clearance of 30 mm above and below the unit.
DANGER: Electric shock
Always install the product in a suitable cabinet.
EMC-compliant Installation
For motor cables longer than 10 metres between the pump and frequency converter, an output filter is recommended. Ensure EMC-compliant installation, especially when using multiple IO 113 units in a cabinet. Connect cable screens to earth, avoid twisting screen ends, and ensure good electrical contact from the mounting plate to the metal cabinet.
Electrical Connection
Terminals are rated for a maximum of 8 A. Specific terminals are designated for different wire sizes and voltage ratings. Ensure proper insulation or earthing of the cabinet. External controllers connected via RS-485 must meet IEC 60950-1 or 61010-1 standards.
Wiring Diagrams: Various diagrams illustrate connections for different sensor configurations, including thermal switches, moisture switches, Pt100/Pt1000 sensors, WIO/WIA sensors, and the SM 113 sensor monitoring board.
Configuration
Potentiometer
The potentiometer is used to set the warning limit for stator insulation resistance, adjustable between 1 and 10 MΩ. The alarm limit is 1 MΩ.
DIP Switch Configuration
The IO 113 must be configured for the connected pump using DIP switches 1-12. Incorrect configuration can lead to configuration alarms.
Pump Variants (PA, PB, PC, PD): Specific DIP switch settings (1 and 2) are required for different pump variants and sensor connections (direct to IO 113 or via SM 113).
Address for Bus Communication
IO 113 modules require unique addresses for bus communication (slave units). Addresses can be set between 32 and 231. By default, the address is 231. DIP switches 3, 4, and 5 are used for address configuration. If SM 113 is used, it also acts as a slave, and unique addresses are required for each pair.
SM 113 Sensor Detection and Address Setting
Upon initial power-up, SM 113 detects connected sensors. If errors occur, DIP switch 6 on the IO 113 can be used to reset SM 113 for re-detection. When using multiple IO 113 and SM 113 pairs, ensure only one pair is active during the setting process.
Analog Outputs
Analog outputs can be configured for various signals:
- Analog Output 2 (G2, A2): Can be set for motor temperature (4-20 mA, 0-180 °C) or Pt1000 emulator (1000-1685 Ω, 0-180 °C).
- Analog Output 1 (G1, A1): Configurable for Water in Oil (4-20 mA, 0-20%), Water in Air (4-20 mA, 0-20%), or Pulse Output (0-20% for water in oil, or for insulation resistance).
Bus Protocol
The bus protocol can be set using DIP switches. Options include GENIbus (Grundfos standard) and Modbus (for communication with other suppliers' control units).
ATEX/IEC Ex Protection
ATEX/IEC Ex protection can be enabled or disabled using DIP switch 10. Enabling this feature activates additional alarms for main bearing temperature, support bearing temperature, missing bearing sensor signal, missing WIO/WIA sensor signal, and communication faults.
Product Type
DIP switches 11 and 12 are used to configure the product type, such as 'Pump with WIO sensor', 'Pump with WIA sensor', or 'Pump without WIO/WIA sensor'.
Commissioning
Before installation, verify that the IO 113 is the correct variant, suitable for the available supply voltage and frequency, and has not been damaged in transit.
Startup Procedure:
- Switch on the power supply to the IO 113.
- The IO 113 performs a self-test. Indicator lights will illuminate briefly. If no fault is detected, only the water-in-oil and stator insulation resistance indicators remain on. Faults are indicated by specific indicator lights.
- Check for any warnings or alarms before switching on the pump.
User Interface and Indicator Lights
User Interface
The IO 113 module features terminals for alarm relay, analog and digital inputs/outputs, supply voltage, RS-485 communication, sensors, and digital outputs. It also includes a potentiometer for setting the warning limit, DIP switches for configuration, and a reset button.
Indicator Lights and Their Function
Seven indicator lights on the front panel provide status information:
- Moisture (Pos. 6): Red flashing indicates an alarm for moisture in the motor.
- Insulation Resistance (Pos. 7): Green indicates correct resistance (above warning level). Yellow indicates the warning limit has been reached. Red flashing indicates the alarm limit has been reached (below 1 MΩ). Active only if contactor status is connected (K1, K2) and the motor is stopped.
- Leakage (Pos. 8): Indicates water-in-oil or water-in-air status. Green steady for <5% leakage, green flashing for 5-10%, yellow steady for 10-15%, yellow flashing for out-of-range signal, red flashing for 15-20% leakage, and red steady for >20% leakage or empty oil chamber. For SE/SL 9-30 kW, the light is off if the WIO/WIA sensor is disabled. Green steady indicates correct operation, red flashing indicates alarm.
- Vibrations (Pos. 9): Yellow steady indicates vibrations are within the warning range (exceeds alarm range).
- Temperature (Pos. 13): Red flashing indicates an alarm for high temperature. With ATEX/IEC Ex protection, it can also indicate high bearing temperatures or missing bearing sensor signals.
- Motor Running (Pos. 15): Green steady indicates the motor is running. Active only if contactor status is connected (K1, K2).
- Service (Pos. 16): Yellow steady indicates a communication problem with SM 113. Yellow flashing indicates a warning, requiring immediate service.
Identification
Type Key
The type key identifies the input/output unit, controller series, and model number.
Nameplate
The nameplate provides details such as type designation, product number, rated voltage, version number, serial number, EAC approval logo, production code, enclosure class, and power consumption.
Approval
The IO 113 is UL listed to US and Canadian safety standards.
Variants
The IO 113 is available in two variants: standard (without communication module) and with a communication module. The product number on the nameplate indicates the variant (98097391 for standard, 98711370 for communication module).
Expansion using SM 113
The SM 113 module collects and transfers additional sensor data, working with the IO 113. It can collect data from current sensors (4-20 mA), Pt100/Pt1000 thermal sensors, and vibration, water-in-oil, or water-in-air sensors (WIO/WIA).
WIO/WIA Sensor in Ex Applications: In Ex and IEC Ex applications, the maximum current supplied to the sensor must not exceed 350 mA according to EN/IEC 60079-18. The IO 113's current limitation requires no further protection.
Control Functions
The IO 113 module has various terminals for control functions:
- T1, T2: Alarm relay terminals. The relay closes during normal operation and opens in case of alarm or if the IO 113 is not connected to the power supply.
- G1, A1 (Analog Output 1): Configurable for 4-20 mA or pulse output for water in oil and stator insulation resistance.
- G2, A2 (Analog Output 2): Configurable for 4-20 mA for stator winding temperature or Pt1000 emulator.
- K1, K2: Feedback from motor contactor for status indication (running or not running).
- R1, R2: Terminals for resetting alarms.
Fault Finding
WARNING: Electric shock
Before fault finding, ensure fuses are removed or the main switch is off. Ensure the power supply cannot be accidentally switched on.
Troubleshooting Table:
| Fault | Cause | Remedy |
|---|---|---|
| Green indicator light is off when the pump is running. | Conductor for contactor status has not been connected to terminals K1 and K2. | Connect the conductor. |
| Yellow indicator light is flashing at startup. | Configuration setting conflicts or incorrect DIP switch settings. | Reset the DIP switches. |
| Yellow indicator light is permanently on. | Connection between IO 113 and SM 113 is interrupted, or DIP switches 1 and 2 settings are incorrect. | Re-establish connection or reconfigure DIP switches 1 and 2. |
| Red indicator light is flashing. | Motor winding or bearing temperature is too high, or missing signal from bearing sensor. | Check connection to SM 113. |
| Yellow indicator light is permanently on. | Warning limit for stator insulation resistance is too low. | Set a higher limit using the potentiometer (see section 4.1). |
| New oil does not show 4 mA on analog output 1. | Oil in the oil chamber has not been changed completely, or it was changed to another type. | Calibrate IO 113 for the new oil (see section 10). |
| Water-in-oil sensor previously indicated water, but now indicates less than 5% water. | The power supply to IO 113 has been interrupted. | Let the pump run for some time and check again. |
| Yellow indicator light is flashing. | WIO sensor is disconnected, defective, short-circuited, or incorrectly configured (with SM 113). | Reconnect or replace the sensor. For SM 113, select the correct DIP switch settings. |
| SM 113 cannot detect the sensor (non-Ex applications with DIP switch 10 OFF). | Fault in signal from sensor. | Re-establish signal by changing DIP switch 9 or securing wire connection to SM 113. |
Alarms and Warnings
The IO 113 categorizes faults into two types:
- Alarm: The pump stops. Related to primary functionality (e.g., high motor temperature). The relay opens between T1 and T2 if an alarm occurs or if IO 113 loses power. Alarms are indicated by front panel lights and digital outputs.
- Warning: The pump does not stop. Related to secondary functionality (e.g., excessive water in oil). Warnings are indicated by front panel lights and can be read via digital outputs D7 and D8.
A table details various faults, their standard and ATEX/IEC Ex warning/alarm status.
Alarm Resetting
Alarms can be reset manually by short-circuiting terminals R1 and R2 (or using the reset button). Automatic resetting occurs when the cause of the alarm disappears if a permanent short circuit is made between R1 and R2.
Calibration
After an oil change, calibrate the water-in-oil measurement for the new oil:
- Run the pump for at least one minute.
- Press the reset button for more than five seconds.
- Verify that 4 mA can be read between terminals A1 and G1 of analog output 1 (4 mA = 0% water).
Note: Using used oil for calibration may lead to incorrect water measurement.
Maintenance and Service
The IO 113 module cannot be serviced and requires no maintenance. If faulty, it must be replaced.
Disposing of the Product
Dispose of the product or its parts in an environmentally sound manner. Use public or private waste collection services. If unavailable, contact the nearest Grundfos company or service workshop. The crossed-out wheelie bin symbol indicates separate disposal from household waste. Follow local regulations for collection and recycling to protect the environment and human health.
Further information can be found at: www.grundfos.com/products/product-sustainability/product-recycling.html
