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

3
Grundfos ALPHA
Installation and operating instructions 4
Notice d’installation et d’entretien 11
Instrucciones de instalación y funcionamiento 19
Grundfos.bk Page 3 Wednesday, March 11, 2009 2:27 PM

4
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
Grundfos.bk Page 4 Wednesday, March 11, 2009 2:27 PM

5
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:
1
2
3
(Side view)
(Bottom view)
Grundfos.bk Page 5 Wednesday, March 11, 2009 2:27 PM

6
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
Grundfos.bk Page 6 Wednesday, March 11, 2009 2:27 PM

7
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.
Grundfos.bk Page 7 Wednesday, March 11, 2009 2:27 PM

8
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

9
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:
F.
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

10
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