Grundfos ALPHA User manual

Grundfos ALPHA

GRUNDFOS INSTRUCTIONS

Installation and operating instructions

Grundfos.bk Page 1 Wednesday, March 11, 2009 2:27 PM

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 36 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.

Grundfos.bk Page 2 Wednesday, March 11, 2009 2:27 PM

Grundfos ALPHA

Installation and operating instructions 4

Notice d’installation et d’entretien 11

Instrucciones de instalación y funcionamiento 19

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CONTENTS Page

1. General 4

2. Shipment inspection 4

3. Pumped Liquids 4

4. Pump installation 4

5. Changing the control box position 5

6. Electrical installation 5

7. Name Plate 6

8. Control Display 6

9. Performance & operation modes 7

10. Fault finding 8

11. Disposal 8

12. Technical data 9

1. General

Grundfos Alpha is suitable for systems with constant

or variable flows where it is desirable to optimize the

setting of the pump duty point.

2. Shipment inspection

Examine the components carefully to make sure no

damage has occurred to the pump during shipment.

Care should be taken to ensure the pump is NOT

dropped or mishandled.

• One Grundfos Alpha pump

• One line cord

• Two gaskets

• One installation and operating instructions

• One check valve

• One "Check Valve Installed" sticker

3. Pumped liquids

Clean, thin, non-aggressive and non-explosive

liquids, not containing solid particles, fibers or

mineral oil.

For glycol usage see Section 10. Review Section 10

for additional liquid information.

4. Pump installation

When making piping connections, be sure to

follow piping manufactures recommendations

and all code requirements for piping material.

• System should be properly flushed of debris

before pump installation.

• Insert check valve only if required; see fig. 1.

• Arrows on the pump housing indicate the liquid

flow direction through the pump.

• Install the pump with the motor shaft horizontal;

See fig. 2.

• Fit the two gaskets supplied to pump ends.

Fig. 1 Check valve installation

Fig. 2 Installation positions

Warning

Prior to installation, read these

installation and operating instructions.

Installation and operation must comply

with national, state, and local

regulations and accepted codes of

good practice.

Warning

The pump must not be used for the

transfer of flammable liquids such as

diesel oil, gasoline, and similar liquids.

Pump not for pool or marine use.

Warning

Do not energize pump until properly

installed.

Risk of electric shock — This pump has

not been investigated for use in

swimming pool or marine areas.

TM 3422 4408TM04 3417 4408

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5. Changing the control box position

The control box orientation change should be made

before filling the system with fluid.

Pump liquid may be scalding hot and under high

pressure.

The control box can be rotated in steps of 90°.

Review fig. 3 for possible/permissible positions.

Only use orientations C and D for CSA Enclosure

Type 2.

Fig. 3 Changing the control box position

Procedure:

1. If fluid is present, drain system fluid from pump or

isolate system fluid from pump.

2. Loosen 4mm screws and turn the pump head to

desired position; see fig. 3.

3. Insert and cross-tighten the screws to 7 ft-lbs

torque.

6. Electrical installation

All electrical work should be performed by a qualified

electrician in accordance with the latest edition of the

National Electric Code and state, local codes and

regulations.

• The motor of Grundfos Alpha is protected by the

electronics in the control box and requires no

external motor protection.

• Check that the supply voltage and frequency

correspond to the values stated on the pump.

• Only connect the pump to the mains with the cord

set supplied; see fig. 4.

• Lights on the control panel indicate that the

electrical supply has been switched on.

• Do not modify and only use cord set supplied.

Fig. 4 Connecting and removing power plug

Warning

Before starting any work on this

circulator, make sure electrical supply

has been switched off and that it cannot

be accidentally switched on.

TM04 3418 4408

Warning

Risk of electrical shock - This pump is

supplied with a grounding conductor

and grounding-type attachment plug.

To reduce the risk of electric shock, be

certain that it is connected only to a

properly grounded, grounding-type

receptacle in accordance with the

National Electric Code and any state,

local governing codes and regulations.

TM04 3420 4408

Insert line cord plug onto pump

To remove cord plug from pump:

(Side view)

(Bottom view)

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7. Name Plate

Fig. 5 Nameplate

8. Control Display

Fig. 6 Control display

TM04 3419 4408

Pos. Description

1 Product Number

2 Production Code:

• 1st and 2nd figures = year

• 3rd and 4th figures = week

3 Voltage (V):

4 Rated current (A):

• Min.: Minimum Current (A)

• Max.: Maximum Current (A)

5 Input power (W):

• Min.: Minimum Power (W)

• Max.: Maximum Power (W)

6 Max. fluid temperature (F)

TM04 3421 4408

Pos. Description

1 LED showing Watt or flow indicator

2 LED indicating fixed speed

3 LED indicating constant pressure

4 LED AutoADAPT

5 Push-button for selection of pump setting

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9. Performance* and operation mode selection

*Hydraulic performance without check valve

Pos. Description

• Push-button for selection of pump setting

• Every time the push-button is pressed, the circulator setting is changed

III

High Fixed Speed

• Runs at a constant speed and consequently on a constant curve. In Speed III, the pump is set

on the maximum curve under all operating conditions. Quick Vent of the pump can be obtained

by setting the pump to Speed III for a short period.

II Medium Fixed Speed

• Runs at a constant speed and consequently on a constant curve. In Speed II, the pump is set on

the medium curve under all operating conditions.

ILow Fixed Speed

• Runs at a constant speed and consequently on a constant curve. In Speed I, the pump is set on

the minimum curve under all operating conditions.

Constant Pressure I

• The duty point of the pump will move left and right along the lowest constant-pressure curve

depending on water demand in the system. The pump head (pressure) is kept constant,

irrespective of the water demand.

Constant Pressure II

• The duty point of the pump will move left and right along the middle constant-pressure curve

depending on water demand in the system. The pump head (pressure) is kept constant,

irrespective of the water demand.

Constant Pressure III

• The duty point of the pump will move left and right along the highest constant-pressure curve

depending on water demand in the system. The pump head (pressure) is kept constant,

irrespective of the water demand.

AutoADAPT (Factory Setting)

• This function controls the pump performance automatically within the defined performance

range (shaded area). AutoADAPT will adjust the pump performance to system demands over

time.

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10. Fault finding

11. Disposal

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

environmentally sound way; please use the public or

private waste collection service.

Warning

Before starting any work on this circulator, make sure electrical supply has been

switched off and that it cannot be accidentally switched on.

Pump liquid may be scalding hot and under high pressure.

Fault Control panel Remedy

1. The pump does not run LED off Check power supply (voltage) and

circuit breaker.

Check zone control; voltage, control

options, and thermostat.

Check all power connections.

Damaged circulator / replace.

LED on Check that the electricity supply falls

within the specified range.

Impeller blocked by impurities.

"___ ___"Requires turning power OFF and back

On to pump.

2. Noise in the system LED on Install air eliminator.

Reduce the pump speed.

Fluid velocities to high; reduce pump

speed.

Emitter or piping expanding.

3. Noise in the pump LED on Let the circulator run, will vent over time.

Increase the inlet pressure or check the

air volume in the expansion tank, if

installed.

No fluid (dry running).

Damaged circulator / replace.

4. Insufficient heat LED on Increase circulator speed or constant

pressure.

Circulator in proper operating mode.

Check for air; piping, zone(s) and

emitter(s).

Check thermostat(s).

Check all valving.

Heat emitter large enough.

Check direction of flow.

Check water temperature from boiler

and boiler functions.

Check proper sizing of circulator.

Check ΔT calculation.

Grundfos.bk Page 8 Wednesday, March 11, 2009 2:27 PM

12. Technical data

Supply voltage:

1x115V +/-10 %, 60Hz.

Motor protection:

The pump requires no external motor protection.

Enclosure class:

Indoor use only, IP42.

CSA Enclosure Type 2.

Insulation class:

Relative air humidity:

Maximum 95 %.

Maximum discharge pressure:

150 psi (10.34 bar).

Inlet pressure:

Sound pressure level:

43 dB (A).

Ambient temperature:

+32 °F (0 °C) to +104 °F (+40 °C).

Liquid temperature:

+36 °F (+2 °C) to +230 °F (+110 °C).

To avoid condensation in the control box and stator,

the liquid temperature must always be higher than

the ambient temperature.

Maximum glycol concentrations:

50 % glycol @ 36 °F (2 °C).

Hydraulic performance change can be expected.

Watt readings:

Accuracy +/-1 Watt.

Flow indicator:

Provides a relative indication of flow — should not

be used in lieu of a flow meter.

Check valve:

Use of check valve may reduce pump hydraulic

performance (up to -10%).

Use check valve in parallel pumping applications.

Curve conditions:

Test liquid: Airless water.

Curves apply to a density of 983.2 kg/m3and a

liquid temperature of +140 °F (+60 °C).

All curves show average values and should not be

used as guarantee curves. If a specific minimum

performance is required, individual measurements

must be made.

Curves apply to a kinematic viscosity of 0.474 cSt.

Approximate power usage:

Liquid temperature Min. inlet pressure

167 °F (75 °C) 0.75 psi (0.05 bar)

194 °F (90 °C) 4.06 psi (0.28 bar)

230 °F (110 °C) 15.7 psi (1.08 bar)

Ambient

temperature

[°F (°C)]

Liquid temperature

Min. [°F (°C)] Max. [°F (°C)]

+32 °F

(0 °C) +36 °F

(+2 °C) +230 °F

(+110 °C)

+50 °F

(+10 °C) +50 °F

(+10 °C) +230 °F

(+110 °C)

+68 °F

(+20 °C) +68 °F

(+20 °C) +230 °F

(+110 °C)

+86 °F

(+30 °C) +86 °F

(+30 °C) +230 °F

(+110 °C)

+95 °F

(+35 °C) +95 °F

(+35 °C) +194 °F

(+90 °C)

+104 °F

(+40 °C) +104 °F

(+40 °C) +158 °F

(+70 °C)

Caution

In domestic hot-water system, it is

recommended to keep the liquid

temperature below +149 °F (+65 °C) to

eliminate the risk of lime precipitation.

Speed setting Min. Max.

High fixed speed III 39W 45W

Medium fixed speed II 15W 30W

Low fixed speed I 5W 8W

Constant pressure 8W 45W

Constant pressure 14W 45W

Constant pressure 22W 45W

AutoADAPT 5W 45W

Grundfos.bk Page 9 Wednesday, March 11, 2009 2:27 PM

12.1 Approvals:

FCC Sections:

Section 15.19 (a) 3:

This device complies with Part 15 of the FCC Rules.

Operation is subject to the following two conditions:

(1) this device may not cause harmful interference,

and (2) this device must accept any interference

received, including interference that may cause

undesired operation.

Section 15.21:

Any changes or modifications to this equipment not

expressly approved by the party responsible for

compliance could void the user's authority to operate

this equipment.

Section 15.105 (b):

NOTE: This equipment has been tested and found

to comply with the limits for a Class B digital device,

pursuant to Part 15 of the FCC Rules. These limits

are designed to provide reasonable protection

against harmful interference in a residential

installation. This equipment generates, uses, and

can radiate radio frequency energy and, if not

installed and used in accordance with the

instructions, may cause harmful interference to radio

communications. However, there is no guarantee

that interference will not occur in a particular

installation. If this equipment does cause harmful

interference to radio or television reception, which

can be determined by turning the equipment off and

on, the user is encouraged to try to correct the

interference by one or more of the following

measures;

• Reorient or relocated the receiving antenna.

• Increase the separation between the equipment

and receiver.

• Connect the equipment into an outlet on a circuit

different from that to which the receiver is

connected.

• Consult the dealer or an experienced radio/TV

technician for help.

Canadian EMC Standard:

ICES-003

This Class B digital apparatus complies with

Canadian ICES-003.

Subject to alterations.

Grundfos.bk Page 10 Wednesday, March 11, 2009 2:27 PM

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