Grundfos ALPHA2 Series User manual

ALPHA2
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 ALPHA2.
Sections 1-4 give the information necessary to be able to unpack,
install and start up the product in a safe way.
Sections 5-12 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 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 Hazard statements 2
1.2 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 4
3.2 Pump positions 4
3.3 Control box positions 4
3.4 Insulating the pump housing 5
3.5 Electrical installation 6
3.6 Assembling the plug 6
4. Starting up the product 7
4.1 Before startup 7
4.2 First startup 7
4.3 Venting the pump 7
5. Product introduction 8
5.1 Product description 8
5.2 Intended use 8
5.3 Pumped liquids 8
5.4 Identification 9
5.5 Accessories 10
5.6 Insulating shells, ALPHA2 11
5.7 ALPHA plugs 11
5.8 ALPHA Reader 11
6. Control modes 12
6.1 AUTOADAPT 12
6.2 Proportional-pressure mode 12
6.3 Constant-pressure mode 12
6.4 Constant curve/constant speed 12
6.5 Automatic night setback 12
6.6 Guide to control mode selection 12
6.7 Pump performance 13
7. Setting the product 14
7.1 Elements on the operating panel 14
7.2 Display 14
7.3 Light fields indicating the pump setting 14
7.4 Button for enabling or disabling of automatic night
setback 15
7.5 Button for selection of pump setting 15
7.6 Setting automatic night setback 15
7.7 Setting manual summer mode 15
7.8 Dry-running protection 15
7.9 Using ALPHA Reader 16
8. Servicing the product 17
8.1 Dismantling the product 17
8.2 Dismantling the plug 17
9. Fault finding the product 18
9.1 High-torque start 18
9.2 Fault finding table 18
10. Technical data 19
10.1 Dimensions, ALPHA2 XX-40, XX-50, XX-60, XX-80 20
11. Performance curves 21
11.1 Guide to performance curves 21
11.2 Curve conditions 21
11.3 Performance curves, ALPHA2 XX-40 (N) 22
11.4 Performance curves, ALPHA2 XX-50 (N) 23
11.5 Performance curves, ALPHA2 XX-60 (N) 24
11.6 Performance curves, ALPHA2 XX-80 (N) 25
12. Disposing of the product 25
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
1.2 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
voltage and frequency of the installation site. See section
5.4.2 Nameplate.
2.2 Scope of delivery
The box contains the following items:
• ALPHA2 pump
• ALPHA plug
• insulating shells
•two gaskets
• quick guide.
3. Installing the product
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.
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.
CAUTION
Crushing of feet
Minor or moderate personal injury
- Wear safety shoes when opening the box and
handling the product.
The pump must always be installed with a horizontal
motor shaft within ± 5 °.

English (GB)
4
3.1 Mechanical installation
3.1.1 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 supplied with the pump when you mount
the pump in the pipe. See fig. 1 (B).
2. Install the pump with a horizontal motor shaft within ± 5 °. See
fig. 1 (C). See also section 3.2 Pump positions.
3. Tighten the fittings.
Fig. 1 Mounting ALPHA2
3.2 Pump positions
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 in heating and domestic
hot-water systems
You can position the control box in position 3, 6 and 9 o'clock.
See fig. 3.
Fig. 3 Control box positions, heating and domestic hot-water
systems
TM07 1193 2119
TM07 4605 2119TM07 4606 2119
AB
CD
B

English (GB)
5
3.3.2 Positioning the control box in air-conditioning and
cold-water systems
Position the control box with the plug pointing downwards. See
fig. 4.
Fig. 4 Control box position, air-conditioning and cold-water
systems
3.3.3 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.
Fig. 5 Changing the control box position
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.
TM07 4607 2119
WARNING
Pressurised system
Death or serious personal injury
- Tighten the bolts before opening the isolating
valves. The pumped liquid may be scalding hot
and under high pressure.
If you change the position of the control box, fill the
system with the liquid to be pumped or open the
isolating valves.
TM07 4608 2119
2
3
TM07 4604 2119
Do not insulate the control box or cover the operating
panel.

English (GB)
6
3.5 Electrical installation
• The pump requires no external motor protection.
• Check that the supply voltage and frequency correspond to
the values stated on the nameplate. See section
5.4.2 Nameplate.
• Connect the pump to the power supply with the plug supplied
with the pump. See steps 1 to 7.
3.6 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.
WARNING
Electric shock
Death or serious personal injury
- If national legislation requires a Residual Current
Device (RCD) or equivalent in the electrical
installation, or if the pump is connected to an
electric installation where an RCD is used as an
additional protection, this must be type A or better,
due to the nature of the pulsating DC leakage
current. The RCD must be marked with the symbol
shown below;
WARNING
Electric shock
Death or serious personal injury
- All electrical connections must be carried out by a
qualified electrician in accordance with local
regulations.
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
12 mm
17 mm
7 mm
Ø 5.5 -10 mm
0.5 - 1.5 mm
2
L
N
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
Step Action Illustration

English (GB)
7
4. Starting up the product
4.1 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 10. Technical data. For
instructions on how to vent the system, see section 4.3 Venting
the pump.
4.2 First startup
After 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 AUTOADAPT.
Fig. 7 Starting up the pump
4.3 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, that is when the noise has
ceased, set the pump according to the recommendations. See
section 6. Control modes.
You cannot vent the system through the pump. See section
5. Product introduction.
WARNING
Pressurised system
Death or serious personal injury
- Tighten the bolts before opening the isolating
valves. The pumped liquid may be scalding hot
and under high pressure.
TM07 4603 2119
1 x 230 V± 10 %
~ 50/60 Hz
0/O
1/On
TM07 462 21191
The pump must not run dry.
30 min

English (GB)
8
5. Product introduction
5.1 Product description
The pump is designed for circulating liquids in systems with
variable flow rates where it is desirable to optimise the setting of
the pump duty point to reduce energy costs.
The table below shows the ALPHA2 models with built-in functions
and features.
Comparison of ALPHA2 models according to built-in functions and features
* Production code (Year-Week).
5.2 Intended use
The pump is designed for circulating liquids in heating and
air-conditioning systems with temperatures equal to or higher
than 2 °C. You can also use pumps with stainless-steel pump
housing in domestic hot-water systems.
5.3 Pumped liquids
The pump is suitable for the following liquids:
• clean, thin, non-aggressive and non-explosive liquids, not
containing solid particles or fibres
• cooling liquids, not containing mineral oil
• 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 section Comparison of ALPHA2
models according to built-in functions and features.
Functions/features ALPHA2 model B ALPHA2 model C ALPHA2 model D ALPHA2 model E
Starts from PC 12xx* PC 14xx* PC 15xx* PC 17xx*
AUTOADAPT ●●● ●
Proportional pressure ● ● ● ●
Constant pressure ● ● ● ●
Constant curve ● ● ● ●
Automatic night setback ● ● ● ●
Manual summer mode ● ● ●
Dry-running protection ●●
ALPHA Reader compatible ●
High-torque start ●●
ALPHA2XX-40 ● ● ● ●
ALPHA2XX-50 ● ● ● ●
ALPHA2XX-60 ● ● ● ●
ALPHA2XX-80 ● ● ●

English (GB)
9
5.4 Identification
5.4.1 Model type
These installation and operating instructions cover ALPHA2
model B, C, D and E. The model type is stated on the packaging
and nameplate. See figs 9 and 10.
Fig. 9 Model type on the packaging
Fig. 10 Model type on the nameplate
5.4.2 Nameplate
Fig. 11 Nameplate
5.4.3 Type key
TM06 45820 2515TM06 1716 2614
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]
Example ALPHA2 25 -40 N 180
Pump type
[ ]: Standard version
Nominal diameter (DN) of inlet and outlet
ports [mm]
Maximum head [dm]
[ ]: Cast-iron pump housing
A: Pump housing with air separator
N: Stainless-steel pump housing
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)
10
5.5 Accessories
5.5.1 Unions and valve kits
Note: The product numbers are always for one complete set, including gaskets.
G-threads have a cylindrical form in accordance with the EN ISO
228-1 standard and are not sealing the thread. It requires a flat
gasket. You can only screw male G-threads (cylindrical) into
female G-threads. The G-threads are standard thread on the
pump housing.
R-threads are tapered external threads in accordance with the EN
10226-1 standard.
Rc- or Rp-threads are internal threads with either tapered or
cylindrical (parallel) threads. You can screw male R-threads
(conical) into female Rc- or Rp-threads. See fig. 12.
Fig. 12 G-threads and R-threads
Product numbers, unions
Union nut with internal
threads
Union nut with
external threads
Ball valve with internal
threads
Ball valve with
compression fitting Union nut with soldering fitting
ALPHA2 Connection
3/4 1 1 1/4 1 1 1/4 3/4 1 1 1/4 ∅22 ∅28 ∅18 ∅22 ∅28 ∅42
15-xx* G 1
15-xx N*
25-xx G 1 1/2 529921 529922 529821 529925 529924
25-xx N 529971 529972 519805 519806 519807 519808 519809 529977 529978 529979
32-xx G 2 509921 509922
32-xx N 509971 529995
Rp
R
Rp
mm
mm
TM06 9235 2017
R
RRp Rc
G
Rc Rp R
Rp