Grundfos UPZCP-3 User manual

GRUNDFOS INSTRUCTIONS
UPZCP-3, 4, 6
Multi-zone pump control
Installation and operating instructions

2
English (US)
English (US) Installation and operating instructions
Original installation and operating
instructions.
These installation and operating instructions
describe Grundfos UPZCP-3, 4, 6. Sections 1-4
give the information necessary to be able to
unpack, install and start up the product in a safe
way.
Sections 5-8 give important information about
the product, as well as information on service
and disposal of the product.
CONTENTS Page
1. General information
1.1 UPZCP-3, 4, 6
This is a multi-zone pump control relay for
domestic hydronic heating systems. It provides
control when zoning with pumps or low voltage
zone valves.
1.2 Limited warranty
Products manufactured by Grundfos are
warranted to the original user only to be free of
defects in material and workmanship for aperiod
of 24 months from date of installation, but not
more than 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.
1. General information 2
1.1 UPZCP-3, 4, 6 2
1.2 Limited warranty 2
1.3 Symbols used in this document 3
2. Receiving the product 3
2.1 Inspecting the product 3
3. Installing the product 3
3.1 Mechanical installation 3
3.2 Electrical connection 4
4. Starting up the product 7
4.1 LED diagnostics 7
4.2 DIP switch settings 7
5. Product introduction 8
5.1 Features and benefits 8
5.2 Identification 8
6. Servicing the product 9
6.1 Service parts 9
7. Technical data 9
8. Disposing of the product 9
WARNING
Prior to installation, read these
installation and operating instructions.
Installation and operation must
comply with local regulations and
accepted codes of good practice.
This booklet should be left with the
owner of the pump for future
reference and information regarding
its operation.
WARNING
The use of this product requires
experience with and knowledge of the
product.
Persons with reduced physical,
sensory or mental capabilities must
not use this product, unless they are
under supervision or have been
instructed in the use of the product by
a person responsible for their safety.
Children must not use or play with this
product.

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English (US)
MANUFACTURER 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. EXCEPT AS
EXPRESSLY HEREIN PROVIDED THE GOODS
ARE SOLD "AS IS", THE ENTIRE RISK AS TO
QUALITY AND FITNESS FOR A PARTICULAR
PURPOSE, AND PERFORMANCE OF THE
GOODS IS WITH THE BUYER, AND SHOULD
THE GOODS PROVE DEFECTIVE
FOLLOWING THEIR PURCHASE, THE BUYER
AND NOT THE MANUFACTURER,
DISTRIBUTOR, OR RETAILER ASSUMES THE
ENTIRE RISK OF ALL NECESSARY
SERVICING OR REPAIR.
Some jurisdictions do not allow the exclusion or
limitation of implied warranties of
merchantability and fitness for a particular
purpose, of incidental or consequential damages
and some jurisdictions do not allow limitations
on how long implied warranties may last or
require you to pay certain expenses as set forth
above. 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.
1.3 Symbols used in this document
2. Receiving the product
2.1 Inspecting the product
Examine the components carefully to make sure
no damage has occurred to the product during
shipment.
3. Installing the product
3.1 Mechanical installation
3.1.1 Installing the base
Attach the base firmly to the wall surface with
four screws and anchors using the key holes
provided.
Fig. 1 Attach the base plate to the wall
with screws and anchors
WARNING
If you do not observe these safety
instructions, it may result in personal
injury.
WARNING
If you do not observe these
instructions, it may lead to electric
shock with consequent risk of serious
personal injury or death.
Caution
CAUTION
If you do not observe these safety
instructions, it may result in
malfunction or damage to the
equipment.
WARNING
Electrical shock and potential circuit
damage. Disconnect the power
supply before beginning installation.
All wiring must comply with national
and local electrical codes, ordinances
and regulations. Failure to follow
electrical codes could result in
serious personal injury, death, and
property damages.
Caution
CAUTION
Disconnect the power supply before
changing any DIP switch settings.
TM06 5607 5015
Base plate

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English (US)
3.2 Electrical connection
3.2.1 Wiring connections
• All electrical connections must be made
using copper wire only.
• 12-16 AWG wire is recommended for 120
VAC connections.
• 12-22 AWG wire for thermostat connections.
• 12-22 AWG wire for 24 VAC connections.
• Use approved UL conduit fittings.
You find additional wiring schematics, specs,
and troubleshooting help online at
www.grundfos.us/controls.
Caution
CAUTION
Class 2 wiring must be segregated
from the wiring of Class 1 circuits.
When Class 2 wiring is routed with
Class 1 wiring, the Class 2 wiring
insulation must be rated for the
minimum voltage of the Class 1
wiring. Segregation is not required if
all circuits are wired as Class 1,
electric light or power circuits.

5
English (US)
Fig. 2 UPZCP-6 multi-zone pump board layout
DIP switches
The DIP switch settings are also listed in section 4.2 DIP switch settings. See fig. 2.
Master/Slave: Allows expansion to additional UPZC units.
Priority ON: Zone 1 operates as priority and the other zones are switched off for a selectable 30- or
60-minute timeout.
Post purge ON: The boiler pump will continue to run for two minutes after priority ends to remove
residual heat from the boiler.
Pump Exercise ON: The pumps will operate for 30 seconds every 72 hours or every 14 days.
Primary pump ON: During the PRIORITY demand, select whether the PRIMARY PUMP is ON or
OFF.
TM06 5605 5015
L
N
L
N
ZC
ZR
L
N
C
B
A
X
X
X
X
R
W
C
R
W
C
R
W
C
R
W
C
R
W
C
R
W
C
LN
L
N
L
N
L
N
L
N
L
N
L
N
L
N
OFF
OFF
Master
SW1
Post Purge ON
Priority 30 min.
Slave
Priority ON
Pump Exercise ON
60 minutes
OFF
Exercise 30 sec./72 hrs. 30 sec./14 days
OFF
Primary ON
DIP switches
RRhWC
Jumper
24 VAC
40 VA
Transformer
5 A fuses
250 mA fuse
Mod/con boiler
Aquastat
2-wire
thermostat
3-wire
thermostat
4-wire
thermostat
Ground
screws on
base

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English (US)
Multi-zone pump board expansion
Fig. 3 UPZCP multi-zone pump board expansion
See fig. 3.
• You can only use the MASTER controller
with PRIORITY.
• When priority calls, the MASTER board will
produce 5 VDC between terminals B and C.
This tells the SLAVE board to turn off any
zones that are calling for heat. This also will
close the contacts XX PRIORITY.
• When there is a demand for heat, the SLAVE
board will produce 5 VDC between terminals
A and C. This tells the MASTER board to
activate any boiler or secondary pumps and
close the contacts XX MAIN.
• You can connect the pump and valve boards.
• When the SLAVE board calls for heat, the
secondary pump will be powered. If a boiler
pump and secondary pump are to be used,
connect them to the same terminals.
• You can use the low voltage wire to connect
ABC terminals.
• Connect the 120 VAC power supply to each
board.
TM06 5606 5015
C
B
A
C
B
A
Master
Slave
Master
Slave
E
X
P
A
N
S
I
O
N
E
X
P
A
N
S
I
O
N
Master board
Slave board
Caution
CAUTION
Connect the L and N terminals the
same way on each board. If switched,
a differential of 240 VAC can occur
resulting in damage to the equipment.

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English (US)
4. Starting up the product
4.1 LED diagnostics
Fig. 4 The indicator lights located on the control plate
4.2 DIP switch settings
TM06 5584 4915
UPZCP-6 6 Pump Zone Relay
Part Number: 98863566
Input: 120VAC 50/60Hz 20A MAX
CAUTION, RISK OF ELECTRICAL SHOCK -
DISCONNECT POWER PRIOR TO SERVICING
ATTENTION, RISQUE DE CHOC ÉLÉCTRIQUE -
DÉCONNECTEZ LA PUISSANCE AVANT D’ENTRETENIR
ZONE 1
ZONE 2
ZONE 3
ZONE 4
ZONE 5
ZONE 6
Certified to CSA C22.2 No 24
Conforms to UL Standard 873
Listed
The power indicator light "Grundfos" is lit
when you power the unit on.
The red LED is lit
when there is a call
for heat.
Caution
CAUTION
Disconnect the power supply before
changing any DIP switch settings.
TM06 5585 0516
Master/Slave
Allows expansion to additional Grundfos UPZC
units.
Priority ON
Zone 1 operates as priority and the other
zones are switched off for a selectable 30- or
60-minute timeout.
Post purge ON
The boiler pump will continue to run for two
minutes after priority ends to remove residual
heat from the boiler.
Pump Exercise ON
Pumps will operate for 30 seconds every 72
hours or every 14 days.
Primary pump ON
During the PRIORITY demand, select whether
the PRIMARY PUMP is ON or OFF.
OFF
Post Purge ON
OFF
Primary ON
OFF
Priority 30 min.
Priority ON
60 minutes
Pump Exercise ON OFF
Exercise 30 sec./72 hrs. 30 sec./14 days
Master
Slave

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English (US)
5. Product introduction
5.1 Features and benefits
• Compatible with 2-, 3-, and 4-wire low
voltage controllers or thermostats.
• Wiring ease with 120 VAC, ground and low
voltage screw terminal inputs.
• Low voltage end-switch output terminals for
the zone valves.
• Zone priority with selectable time-out feature
• Pump exercise feature, selectable 72-hours
or 14-days.
– The pumps will be turned on for 30
seconds every 72 hours or 14 days in
order to prevent pumps from seizing up.
This feature will only work if there is a
jumper wire connecting the ZR ZC
terminals on the pump controller.
• Post purge feature for pump controllers (3, 4,
and 6 zones).
– After the priority zone calls for heat, the
priority pump will be allowed to run for an
additional 2 minutes after the thermostat
contacts open. This allows some of the
residual heat in the boiler to be transferred
to the water.
• Boiler demand terminals.
– The two terminals, labeled MAIN XX, are
wired to the boiler. When the contacts
close, the boiler starts and will come up to
a preset temperature for hydronic heating.
• DHW terminal.
– The two terminals, labeled PRIORITY XX,
are wired to the boiler. When the contacts
close, the boiler starts and will come up to
a preset temperature for domestic hot
water heating.
• ZR and ZC terminals.
– Available on the pump controllers only.
These terminals are connected by a
jumper wire at the factory. The ZR terminal
is always powered with 120 VAC. When
you remove the jumper wire, all 120 V
power is removed from the pumps.
• Front facing LED indicator lights on the
cover.
• Side-mounted terminal connections for ease
of wiring and installation.
5.2 Identification
5.2.1 Part numbers
5.2.2 Production code
The production code represents the date of
manufacture. You find the production code on
the circuit board and the carton label.
Example:
PC 1542 = year 2015, week 42.
Fig. 5 Locating production code
Model Description Part number
UPZCP-3 Three-pump zone
control 98863563
UPZCP-4 Four-pump zone
control 98863565
UPZCP-6 Six-pump zone
control 98863566
Production code
YYWW
PC1542
1542
Circuit board
Carton label

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English (US)
6. Servicing the product
6.1 Service parts
7. Technical data
8. Disposing of the product
This product or parts of it must be disposed of in
an environmentally sound way:
1. Use the public or private waste collection
service.
2. If this is not possible, contact the nearest
Grundfos company or service workshop.
Subject to alterations.
Part Description Part number
5 A fuse Kit, UPZC pump fuse, 5-pack 98996468
250 mA fuse Kit, UPZC transformer fuse, pump board 250 mA, 5-pack 98996472
500 mA fuse Kit, UPZC transformer fuse, pump board 500 mA, 5-pack 98996473
Three-zone pump Four-zone pump Six-zone pump
Model number UPZCP-3 UPZCP-4 UPZCP-6
Part number 98863563 98863565 98863566
Input power 60 Hz 120 VAC
Transformer voltage 24 VAC, 40 VA, Class 2
Thermostat output [A] 0.375 0.5 0.75
Maximum single phase motor rating,
per zone [A] 5
Maximum combined load rating:
output @ 120 VAC [A] 20
Temperature range (storage) [°F (°C)] 50-100 (10-38)
Temperature range
(maximum operation) [°F (°C)] 0-100 (-18 - +38)
Maximum operating humidity range
[%] RH 90
Number of knockouts 12
Size of knockouts [in. (mm)] 0.875 (22)
Dimensions, W x H x D [in. (mm)] 8.15 x 10.67 x 2.72 (208 x 272 x 70)
Approvals CSA 22.2 No. 24/UL Standard 873
Relay type Sealed
Cover panel ABS - fire rated
Base material Galvanized steel
Terminal block (side mounted) PA66
Front display lights LED

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Grundfos companies
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17100 West 118th Terrace
Olathe, Kansas 66061
Phone: [phone]
Fax: [phone]
www.grundfos.us
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2941 Brighton Road
Oakville, Ontario L6H 6C9 Canada
Phone: [phone]
Fax: [phone]
www.grundfos.ca
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Boulevard TLC No. 15
Parque Industrial Stiva Aeropuerto
C.P. 66600 Apodaca, N.L. Mexico
Phone: [phone]
Fax: [phone]
www.grundfos.mx

99028491 0216
ECM: 1173387
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