Grundfos alpha2 l User manual

ALPHA2 L
Model C
Installation and operating instructions
GRUNDFOS INSTRUCTIONS

English (GB)
2
English (GB) Installation and operating instructions
Original installation and operating instructions
These installation and operating instructions describe ALPHA 2 L.
Sections 1-5 give the information necessary to be able to unpack,
install and start up the product in a safe way.
Sections 6-12 give important information about the product, as
well as information on service, fault finding and disposal of the
product.
CONTENTS
Page
1. General information
1.1 Target group
1.2 Hazard statements
The symbols and hazard statements below may appear in
Grundfos installation and operating instructions, safety
instructions and service instructions.
The hazard statements are structured in the following way:
1. General information 2
1.1 Target group 2
1.2 Hazard statements 2
1.3 Notes 3
2. Receiving the product 3
2.1 Inspecting the product 3
2.2 Scope of delivery 3
3. Installing the product 3
3.1 Mechanical installation 3
3.2 Positioning the pump 4
3.3 Control box positions 4
3.4 Insulating the pump housing 4
4. Electrical installation 5
4.1 Assembling the plug 5
4.2 Dismantling the plug 6
5. Starting up the product 6
5.1 Before startup 6
5.2 First startup 6
5.3 Venting the pump 7
6. Product introduction 7
6.1 Product description 7
6.2 Applications 8
6.3 Pumped liquids 8
6.4 Identification 8
7. Control functions 9
7.1 Elements on the operating panel 9
7.2 Display 9
7.3 Light fields indicating the pump setting 9
7.4 Control modes 10
7.5 Pump performance 12
8. Fault finding the product 13
9. Technical data 14
9.1 Data and operating conditions 14
9.2 Dimensions 15
10. Performance curves 16
10.1 Guide to performance curves 16
10.2 Curve conditions 16
10.3 Performance curves, ALPHA2 L, XX-40 17
10.4 Performance curves, ALPHA2 L, XX-60 18
11. Accessories 19
11.1 Unions 19
11.2 Insulating shells 20
11.3 ALPHA plugs 20
12. Disposing of the product 20
Read this document and the quick guide before
installing the product. Installation and operation must
comply with local regulations and accepted codes of
good practice.
This appliance can be used by children aged from 8
years and above and persons with reduced physical,
sensory or mental capabilities or lack of experience
and knowledge if they have been given supervision
or instruction concerning use of the appliance in a
safe way and understand the hazards involved.
Children shall not play with the appliance. Cleaning
and user maintenance shall not be made by children
without supervision.
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.
SIGNAL WORD
Description of hazard
Consequence of ignoring the warning.
- Action to avoid the hazard.

English (GB)
3
1.3 Notes
The symbols and notes below may appear in Grundfos
installation and operating instructions, safety instructions and
service instructions.
2. Receiving the product
2.1 Inspecting the product
Check that the product received is in accordance with the order.
Check that the voltage and frequency of the product match the
voltage and frequency of the installation site. See section
6.4.1 Nameplate.
2.2 Scope of delivery
The box contains the following items:
• ALPHA2 L pump
• ALPHA plug
• insulating shells
•two gaskets
• quick guide.
3. Installing the product
3.1 Mechanical installation
3.1.1 Mounting the product
Fig. 1 Mounting the product
The arrows on the pump housing indicate the flow direction
through the pump. See fig. 1 (A).
1. Fit the two gaskets when you mount the pump in the pipe. See
fig. 1 (B).
2. Install the pump with a horizontal motor shaft. See fig. 1 (C).
See also section 3.3 Control box positions.
3. Tighten the fittings.
Observe these instructions for explosion-proof
products.
A blue or grey circle with a white graphical symbol
indicates that an action must be taken.
A red or grey circle with a diagonal bar, possibly with
a black graphical symbol, indicates that an action
must not be taken or must be stopped.
If these instructions are not observed, it may result in
malfunction or damage to the equipment.
Tips and advice that make the work easier.
TM07 1193 1118

English (GB)
4
3.2 Positioning the pump
Fig. 2 Control box positions
Always install the pump with a horizontal motor shaft.
• Pump installed correctly in a vertical pipe. See fig. 2 (A).
• Pump installed correctly in a horizontal pipe. See fig. 2 (B).
• Do not install the pump with a vertical motor shaft. See fig. 2
(C and D).
3.3 Control box positions
3.3.1 Positioning of the control box
You can position the control box so that the plug is positioned at
3, 6 and 9 o'clock. See fig. 3.
Fig. 3 Control box positions, heating systems
3.3.2 Positioning the control box in air-conditioning and
cold-water systems
Position the control box so that the plug is pointing downwards in
applications where liquid temperature is below 2 °C. See fig. 4.
Fig. 4 Control box position, air-conditioning and cold-water
systems
3.3.3 Changing the control box position
Fig. 5 Changing the control box position
You can turn the control box in steps of 90 °.
1. Remove the four screws.
2. Turn the pump head to the desired position.
3. Insert and cross-tighten the screws.
3.4 Insulating the pump housing
Fig. 6 Insulating the pump housing
You can reduce the heat loss from the pump by insulating the
pump housing with the insulating shells supplied with the pump.
See fig. 6.
TM06 9089 4520TM07 7828 4520TM06 9091 4520
AB
CD
WARNING
Pressurised system
Minor or moderate personal injury
- Before dismantling the pump, drain the system or
close the isolating valves on either side of the
pump. The pumped liquid may be scalding hot and
under high pressure.
CAUTION
Hot surface
Minor or moderate personal injury
- Position the pump so that persons cannot
accidentally come into contact with hot surfaces.
If you change the position of the control box, fill the
system with the liquid to be pumped or open the
isolating valves.
TM06 9092 4520TM06 9093 4520
Do not insulate the control box or cover the operating
panel.

English (GB)
5
4. Electrical installation
Carry out the electrical connection and protection in accordance
with local regulations.
• The motor requires no external motor protection.
• Check that the supply voltage and frequency correspond to
the values stated on the nameplate. See section
6.4.1 Nameplate.
• Connect the pump to the power supply with the plug supplied
with the pump. See steps 1 to 7.
4.1 Assembling the plug
WARNING
Electric shock
Death or serious personal injury
- Switch off the power supply before starting any
work on the product. Make sure that the power
supply cannot be accidentally switched on.
WARNING
Electric shock
Death or serious personal injury
- Connect the pump to earth.
Connect the pump to an external main switch with
a minimum contact gap of 3 mm in all poles.
WARNING
Electric shock
Death or serious personal injury
- In case of an insulation fault, the fault current may
be a pulsating DC. Observe national legislation
about requirements for and selection of Residual
Current Device (RCD) when installing the pump.
Step Action Illustration
1
Fit the cable gland
and plug cover to
the cable. Strip the
cable conductors
as illustrated.
TM05 5538 3812
2
Connect the cable
conductors to the
power supply plug.
TM05 5539 3812
3
Bend the cable
with the cable
conductors
pointing upwards.
TM05 5540 3812
4
Pull out the
conductor guide
plate and throw it
away.
TM05 5541 3812
5
Click the plug
cover onto the
power supply plug.
TM05 5542 3812
6
Screw the cable
gland onto the
power supply plug.
TM05 5543 3812
7
Insert the power
supply plug into
the male plug in
the pump control
box.
TM07 1194 1118
12 mm
17 mm
7 mm
Ø 5.5 -10 mm
0.5 - 1.5 mm
2
L
N

English (GB)
6
4.2 Dismantling the plug
5. Starting up the product
5.1 Before startup
Do not start the pump until the system has been filled with liquid
and vented. Make sure that the required minimum inlet pressure
is available at the pump inlet. See section 9. Technical data. For
instructions on how to vent the system, see section 5.3 Venting
the pump.
5.2 First startup
After installing the product, see section 3. Installing the product,
turn on the power supply. The light in the operating panel shows
that the power supply has been switched on. See fig. 7.
The pump is factory set to intermediate proportional-pressure
curve, PP2.
Fig. 7 Starting the pump
Step Action Illustration
1
Loosen the cable
gland and remove it
from the plug.
TM05 5545 3812
2
Pull off the plug
cover while pressing
on both sides.
TM05 5546 3812
3
Add the conductor
guide plate to loosen
all three cable
conductors at the
same time.
If the guide plate is
missing, then loosen
the cable conductors
one by one by
pressing a
screwdriver gently
into the terminal clip.
TM05 5547 3812
4
The plug has now
been removed from
the power supply
plug.
TM05 5548 3812
TM07 7700 4520

English (GB)
7
5.3 Venting the pump
Fig. 8 Venting the pump
The pump is self-venting through the system. You do not have to
vent the pump before startup.
Air in the pump may cause noise. This noise ceases when the
pump has run for a few minutes.
You obtain quick venting of the pump by setting the pump to
speed III. How fast the pump is vented depends on the system
size and design.
When you have vented the pump, i.e. when the noise has
ceased, set the pump according to the recommendations. See
section 7. Control functions.
You cannot vent the system through the pump. See section
6. Product introduction.
6. Product introduction
6.1 Product description
Fig. 9 Pumped liquids, warnings and operating conditions
ALPHA1 pumps are a complete range of circulator pumps.
6.1.1 Model type
These installation and operating instructions cover ALPHA2 L.
The model type is stated on the packaging and nameplate. See
figs 10.
Fig. 10 Model type on the packaging
TM06 9104 4317
The pump must not run dry.
TM07 7701 4520TM07 7789 4520

English (GB)
8
6.2 Applications
The pump is designed for the circulation of water in heating
systems as well as air-conditioning and cold-water systems.
Cold-water systems are defined as systems where the ambient
temperature is higher than the temperature of the pumped liquid.
The pump is the best choice for the following systems:
• underfloor heating systems
• one-pipe systems
• two-pipe systems.
The pump is suitable for the following:
• Systems with constant or variable flow rates where you want
to optimise the setting of the pump duty point.
• Systems with variable flow-pipe temperature.
6.3 Pumped liquids
In heating systems, the water must meet the requirements of
accepted standards on water quality in heating systems, for
example the German standard VDI 2035.
The pump is suitable for the following liquids:
• Thin, clean, non-aggressive and non-explosive liquids, not
containing solid particles or fibres.
• Cooling liquids, not containing mineral oil.
• Domestic hot water
Maximum: 14 °dH
Maximum: 65 °C
Maximum peak: 70 °C.
For water with a higher degree of hardness, we recommend
that you use a direct-coupled TPE pump.
• Softened water.
The kinematic viscosity of water is 1 mm2/s (1 cSt) at 20 °C. If the
pump is used for a liquid with a higher viscosity, the hydraulic
performance of the pump will be reduced.
Example: 50 % glycol at 20 °C means a viscosity of approx. 10
mm2/s (10 cSt) and a reduction of the pump performance by
approx. 15 %.
Do not use additives that can or will disturb the functionality of the
pump.
When selecting a pump, take the viscosity of the pumped liquid
into consideration.
For more information about the pumped liquids, warnings and
operating conditions, see fig. 9.
6.4 Identification
6.4.1 Nameplate
Fig. 11 Nameplate
6.4.2 Type key
Example: ALPHA2 L 25 - 60 180
CAUTION
Flammable material
Minor or moderate personal injury
- Do not use the pump for flammable liquids, such
as diesel oil and petrol.
WARNING
Biological hazard
Death or serious personal injury
- In domestic hot-water systems, the temperature of
the pumped liquid must always be according to
local legislation.
CAUTION
Corrosive substance
Minor or moderate personal injury
- Do not use the pump for aggressive liquids, such
as acids and seawater.
TM05 3079 0912
Pos. Description
1 Minimum rated current [A]
2 Maximum rated current [A]
3 CE mark and approvals
4 EEI: Energy Efficiency Index
5 Voltage [V]
6 Product number
7 Serial number
8 Pump model
9 Country of origin
10 Data matrix code
11 Frequency [Hz]
12
Production code:
• 1st and 2nd figures: year
• 3rd and 4th figures: week
13 Temperature class
14 Enclosure class
15 Crossed-out wheeled bin according to EN 50419
16 Maximum system pressure [MPa]
17 Minimum input power P1 [W]
18 Maximum input power P1 [W]
Code Explanation
ALPHA2 L Pump type
25 Nominal diameter (DN) of inlet and outlet ports
[mm]
60 Maximum head [MPa]
-[ ]: Cast-iron pump housing
N: Stainless-steel pump housing
180 Port-to-port length [mm]
7
8
9
6
5
4
3
2
1
17
18
11
10
12
13
14
16
15
P1(W) MPa
I1/1 (A)
Min.
Max.
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English (GB)
9
7. Control functions
7.1 Elements on the operating panel
Fig. 12 Operating panel
7.2 Display
The display (1) is on when you have switched on the power
supply.
If the pump impeller is rotated, for example when filling the pump
with water, sufficient energy can be generated to light up the
display even if the power supply has been switched off.
7.3 Light fields indicating the pump setting
The pump has different performance settings which you can
select between with the button. See fig. 12 (2).
Every time you press the button , the pump setting is changed.
The pump setting is indicated by light fields in the display. See fig.
13.
Fig. 13 Nine light fields
For information about the function of the settings, see section
7.4 Control modes.
TM07 7703 4520
Pos. Description
1Light fields indicating the pump setting.
See section 7.3 Light fields indicating the pump setting.
2 Button for selection of pump setting.
1
2
TM077702 4520
Active light
fields Description
Factory setting
Lowest proportional-pressure curve, PP1
Highest proportional-pressure curve, PP2
Lowest constant-pressure curve, CP1
Highest constant-pressure curve, CP2
Constant curve/constant speed III
Constant curve/constant speed II
Constant curve/constant speed I

English (GB)
10
7.4 Control modes
7.4.1 Pump setting for two-pipe heating systems
Fig. 14 Selection of pump setting for system type
Recommended and alternative pump settings according to fig.
14:
* See section 10.1 Guide to performance curves.
Proportional-pressure curve, PP1 or PP2
Proportional-pressure control adjusts the pump performance to
the actual heat demand in the system. The pump performance
follows the selected performance curve, PP1 or PP2. See fig. 15
where PP1 has been selected. For further information, see
section 10.1 Guide to performance curves.
Fig. 15 The proportional-pressure curves and settings
The selection of the proportional-pressure setting depends on the
characteristics of the heating system and the actual heat
demand.
7.4.2 Pump setting for one-pipe heating systems
Fig. 16 Selection of pump setting for system type
Recommended and alternative pump settings according to fig.
16:
* See section 10.1 Guide to performance curves.
Constant-pressure curve, CP1 or CP2
The constant-pressure control adjusts the flow rate to the actual
heat demand in the system keeping a constant pressure at the
same time. The pump performance follows the selected
performance curve, CP1 or CP2. See fig. 17 where CP1 has been
selected. For further information, see section 10.1 Guide to
performance curves.
Fig. 17 The constant-pressure curves and settings
The selection of the constant-pressure setting depends on the
characteristics of the heating system and the actual heat
demand.
TM07 7705
Heating
system
Pump setting
Recommended Alternative
Two-pipe
system
Proportional-pressure
curve, PP1 or PP2 *
Constant-pressure
curve, CP1 or CP2 *
TM07 7706 4520
Q
H
PP2
PP1
Q
H
TM07 7704 4520
Heating
system
Pump setting
Recommended Alternative
One-pipe
system
Constant-pressure
curve, CP1 or CP2 *
Constant curve/constant
speed, I, II or III*
TM07 7707 4520
Q
H
Q
H
CP2
CP1