Grundfos MixiMizer UP15-42 Manual

Grundfos MixiMizer ™
Installation & Operating Instructions
Pumps Incorporating the
(MR) Mixing Reset Control
1 .Shipment
Inspection
Page 3
2 .General Page 3
3
.Operational
Limits
Page 4
4 .Pump
Installation
Page 6
5
.Installation
Requirements
Page 7
6
.Mounting
Control System
Page 7
7 .Rough-in
Wiring
Page 10
8
.Settings
Page 13
9
.Error Messages
& Control Response
Page 18
10 .Quick
Reference
Page 19

Page 1
CONGRATULATIONS!
You are now the fortunate owner of a MixiMizerTM
PUMP. It has been carefully inspected and tested
before shipment. It should give you long, efficient,
trouble-free service. For maximum performance and
reliability, please follow the simple instructions in this
manual.
Since mixing by a variable speed injection pump is a
relatively new concept, there are a few simple piping
details that should be considered.
Variable speed injection systems require complete
isolation between the boiler loop and system loop. For
example, when the injection pump is turned off, there
must be no heat transfer from the boiler loop to the
system loop. In order to avoid this unwanted heat
transfer, standard primary-secondary piping tech-
niques are used.
This piping arrangement requires that the injection
piping be at least one pipe diameter smaller than the
piping of the boiler and system loops.
Note 1:
There must be a maximum of 4 pipe diameters
between the tees in the boiler and system loops in
order to prevent ghosts flow when the variable speed
injection pump is off and either the boiler pump or
system pump is on.
Note 2:
There must be at least 6 pipe diameters of straight
pipe on either side of the tees in order to prevent
momentum of water in the boiler and system loops
from pushing flow through the injection loop.
System
Loop
Balancing
Valve
Grundfos
MixiMizer Pump
Note 1
Note 2
Boiler
Loop
}
}
Note 2
}
Figure A - Injection loop without thermal trap.
Balancing
Valve
Note 2
Note 1
Note 2
Grundfos
MixiMizer Pump

Wheninstallingandusingthiselectricalequipment,basic
safety precautions should always be followed, including
the following:
The installer must ensure that this control and its wiring
are isolated and/or shielded from strong sources of
electromagnetic noise. Conversely, this Class B digital
apparatus complies with Part 15 of the FCC Rules and
meets all requirements of the Canadian Interference-
Causing Equipment Regulations. However, if this
control does cause harmful interference to radio or
television reception, which can be determined by
turning the control off and on, the user is encouraged
to try to correct the interference by reorienting or
relocating the receiving antenna, relocating the receiver
with respect to this control, and/or connecting the
control to a different circuit from that to which the
receiver is connected.
CAUTION: The non-metallic enclosure does not
provide grounding between conduit connections. Use
grounding type bushings and jumper wires.
CAUTION: Improper installation and operation of this
control could result in damage to the equipment and
possibly even personal injury. It is your responsibility
to ensure that this control is safely installed according
to all applicable codes and standards. This electronic
control is not intended for use as a primary limit control.
Other controls that are intended and certified as safety
limits must be placed into the control circuit.
WARNING!
All field wiring to be low voltage. Power
for control is provided through the power
cord supplying power to the pump. Use
copper conductors only. Disconnect all
power sources prior to servicing.
Risk of electric 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.
Page 2

Page 3
1.Shipment Inspection
Check the contents of this package. Care should be
taken to ensure the pump is NOT dropped or mis-
handled; dropping will damage the pump.
Grundfos MixiMizer Injection Pump Package Includes:
• One Grundfos UP15-42 MixiMizer pump with
integral control or one Grundfos UP43-64
MixiMizer pump with integral control.
• Two Water Temperature Sensors 071 – Pre-wired
into control unit with 6’ of wire.
• One 6’ line cord with 115 V plug, pre-wired into
control unit.
• One Outdoor Air Temperature Sensor 070
• Two flange gaskets
• Installation and Operating Instructions.
• Two cable ties.
2.General
• All minimum and maximum settings are operating,
not safety limits. Necessary auxiliary equipment
and safety devices must be added.
• The boiler return minimum temperature is fixed at
135°F. This function can be disabled by DIP
switch.
• The system supply maximum temperature is fixed
at 140°F. This function can be disabled by DIP
switch.
• External “Call For Heat”/Demand Input: The unit
can accept external “Call For Heat” input signal.
This must be a powered signal (20 to 30V AC .1
VA). This function can be enabled by DIP switch.
• Warm Weather Shut Down (WWSD): When the
outdoor air temperature is warmer than 70°F (with
±1°F hysteresis), the unit shuts down until the
temperature drops below 70°F.
• Heating curve parallel shift:The heating curve is
shifted up 5°F parallel to the existing curve.This
function can be enabled by the dip switch.

3. Operational Limits
Outdoor Sensor 070
Approvals: CSA, UL
Operating range: -60 to 140°F (-50 to 60°C)
Sensor: NTC thermistor, 10 kW
@ 77°F (25°C ± 0.2°C), B=3892
Enclosure: White U.V. resistantPVC
Universal Sensor 071
Approvals: CSA, UL
Operating range: -60 to 255°F (-50 to 125°C)
Sensor: NTC thermistor, 10 kW
@ 77°F (25°C ± 0.2°C), B=3892
Wire: 6’ 20 AWG XPE Wire
Grundfos MixiMizer pumps with "FC" designation are
designed to pump liquids compatible with their cast
iron pump housing construction. They are recom-
mended for use in closed hydronic systems. Grundfos
MixiMizer pumps with "BUC" and "BF" designations
are designed to pump liquids compatible with their
bronze pump housing construction and can be used in
both open and closed systems. Grundfos MixiMizer
pumps are for Indoor Use Only.
Grundfos MixiMizer Pumps are intended for use with
water, or a 50/50 mixture by weight of propylene
glycol.
Page 4
• Pump Exercising: After every three days of no
operation, the control will exercise the pump for 10
seconds. The % of Pump Performance LED will be
on during exercising.
• Post Purge: A 20 second post purge is available
once the heat demand is removed or control
enters WWSD. The purging holds the last speed
used.
• As variable speed output modulates, the control
flashes the % of Pump Performance LED on for ¼
second and off for ¼ to 2 1/2 seconds.
• A 2 second delay from demand to actually starting
the pump is used to prevent issues with a noisy
demand relay signal.

Page 5
UP15-42FC/MR 115V 60 Hz MixiMizer Pump
UP15-42BUC5/MR 115V 60 Hz MixiMizer Pump
UP15-42BUC7/MR 115V 60 Hz MixiMizer Pump
Maximum fluid temperature: 200°F (95°C)
Maximum ambient:
• 115°F (46°C) with control module vertical
(Fig. 4a).
• 115°F (46°C) with control module under
pump and horizontal (Fig. 4B).
• 105°F (40°C) with control module on top of
pump and horizontal (Fig 4B).
Maximum Working Pressure: 145 PSI
Minimum Inlet Pressure: 5 PSI
UP43-64FC/MR 115V 60 Hz MixiMizer Pump
UP43-64BFC/MR 115V 60 Hz MixiMizer Pump
Maximum fluid temperature: 195°F (90°C)
Maximum ambient:
• 105°F (40°C) with control module vertical
(Fig. 4A).
• 105°F (40°C) with control module under
pump and horizontal (Fig. 4B).
• 92°F (33°C) with control module on top of
pump and horizontal (Fig. 4B).
Maximum Working Pressure: 145 PSI
Maximum Inlet Pressure: 5 PSI
Design Injection Nominal Injection MixiMizer
Flow Rate (GPM) Pipe Diameter Pump Model
UP15-42FC/MR*
0-8 3/4" UP15-42BUC5/MR
UP15-42BUC7/MR*
UP43-64FC/MR*
0-32 11/4, 11/2or 2" UP43-64BFC/MR
UP43-64FC/MR
*Can produce flow velocity greater than 8 ft/sec in this size.
0-5 1/2" UP15-42BUC5/MR*
UP15-42FC/MR
0-16 1" UP15-42BUC7/MR

4. Pump Installation
Remove the control from the pump and install pump in
injection loop
Position of terminal box:
Prefered installation of the pump will have the terminal
box located to one side of the pump or the other, with
the conduit entry down.
Page 6
If the terminal box position needs to be changed, it is
best to do so before installation. However, if the pump
is already installed, ensure that the electrical supply is
turned off and close the isolation valves before
removing the Allen screws.
To Change terminal box position:
• Remove the four (4) Allen screws (4 or 5mm
wrench) while supporting the stator (motor).
• Carefully separate the stator from the pump
chamber and rotate it to the correct terminal box
orientation.
• Replace the Allen screws and tighten diagonally
and evenly (7 ft. –lb. torque).
• Check that the motor shaft turns freely. Remove
the large screw in the middle of the nameplate,
insert a small flat blade screwdriver into the end
of the shaft, and turn gently.
• If the shaft does not turn easily, repeat the
disassembly/reassembly process.
Pump Mounting: For Indoor Use Only
Arrows on the side or bottom of the pump chamber
indicate direction of flow through the pump. Grundfos
Miximizer pumps can be installed in both vertical and
horizontal lines. Flow direction should be from the
boiler/supply loop into the system loop.
Figure 4A - Prefered Terminal
Box Orientation Figure 4B - Optional Terminal Box Orientation (see Operational
Limits)

Page 7
The pump must be installed with the motor shaft
positioned horizontally. Under no circumstances should
the pump be installed with the shaft vertical or where
the shaft falls below the horizontal plane (Fig.4C).
5.Installation Requirements
• Thoroughly clean and flush the system prior to
pump installation
• Ensure that water does not enter the terminal box
during the installation process.
•DO NOT STARTTHE PUMP UNTIL THE
SYSTEM HAS BEEN FILLED AND CHECKED
FOR LEAKS.
• Do not use the pump to vent the system.
• Never operate the pump dry. The bearings
require water lubrication and will be damaged
otherwise.
• Fill system with water. This will result in immedi-
ate lubrication of the bearings.
• Operate the pump for 5 minutes, when control
installation is complete, to purge remaining air
from the bearing chamber. This is especially
important when installing the pump during the off-
season.
Recommended
Optional
DO NOT
Mount Motor Shaft
in Vertical Position
Figure 4C
6.Mounting Control System
Provisions for a 115 V grounded outlet within 6 feet of
the pump mounting location, should be made.
All electrical work should be performed by a
qualified electrician in accordance with the latest

edition of the National Electrical Code, local codes
and regulations.
Install a 2” x 4” duplex electrical box to house low
voltage wiring for connection to the control.
Outdoor Air Temperature Sensor 070
The Outdoor Air Temperature Sensor 070 includes a 10
kW thermistor which provides an accurate measure-
ment of the outdoor temperature. The 070 sensor is
protected by a white U.V. resistant PVC plastic
enclosure (Fig. 6A & 6B).
Note: The outdoor air temperature sensor 070
(thermistor) is built into the PVC plastic enclosure.
• Remove the screw and pull the front cover off the
sensor enclosure.
• The 070 can either be mounted directly onto a
wall or a 2” x 4” electrical box. When the 070 is
wall mounted, the wiring should enter through the
back or bottom of the enclosure. Do not mount
the 070 with the conduit knockout facing upwards
as rain could enter the enclosure and damage the
sensor (Fig. 6C).
Page 8
Figure 6A - Closed
Outdoor Air Temperature
Sensor 070
Sensor
Figure 6B- Open
Outdoor Air Temperature
Sensor 070
Sensor with rear
entry wiring Sensor with bottom
entry wiring Sensor mounted
onto 2" x 4"
electrical box.
Figure 6C - Mounting the Sensor

• In order to prevent heat transmitted through the
wall from affecting the sensor reading, it may be
necessary to install an insulating barrier behind
the enclosure.
• The 070 should be mounted on a wall which best
represents the heat load on the building (a
northern wall for most buildings or a southern
facing wall for buildings with large south facing
glass areas). The 070 should not be exposed to
heat sources such as ventilation or window
openings.
• The 070 should be installed at an elevation above
the ground that will prevent accidental damage or
tampering.
Water Temperature Sensor 071
The Water Temperature 071 Sensor has a zinc sleeve
for fast response and a wide operating range (Fig 6D).
Note: The 071 sensor is designed to mount on a pipe
or in a temperature immersion well.
• The 071 sensor can be strapped directly to the
pipe using the cable tie provided. Insulation
should be placed around the sensor to reduce the
effect of air currents on the sensor measurement
(Fig. 6E).
• The 071 sensor should be placed downstream of
a pump or after an elbow or similar fitting. This is
especially important if large diameter pipes are
used as the thermal stratification within the pipe
can result in erroneous sensor readings. Proper
Page 9
Figure 6E - 071 Mounted Sensor
Figure 6D - 071 Sensor

Page 10
7.Rough-In Wiring
All low voltage wiring terminates in the wiring chamber
on the control. The wiring is roughed-in to the electrical
box prior to installation of the control. All field installed
wiring should meet or exceed requirements for class 2
wiring per article 725 of the National Electrical Code
rated at 30VAC/250VA. Ensure that enough wiring is in
the electrical box to reach the control.
CAUTION: Power must not be applied to any of the
wires during the rough-in wiring stage.
• Run wiring from the outdoor Air Temperature
sensor 070 mounting location to the electrical box
for the control wiring. Do not run the wires parallel
to telephone or power cables. If the sensor wires
are located in an area with strong sources of
electromagnetic interference (EMI) shielded cable
or twisted pair should be used. If using shielded
cable, the shield wire should be connected to the
sensor location requires that the fluid is thor-
oughly mixed within the pipe before it reaches the
sensor.
• Locate the labels attached to each sensor. One
sensor will be identified as the return sensor and
one will be identified as the supply sensor. (Fig 6F
& 6G) Mount the return sensor to the return piping
of the boiler loop. Mount the supply sensor to
supply piping of the system loop.
GRUNDFOS®
071 Sensor
Return Sensor
Supply Sensor
MADE IN CANADA
LR 58223
E150539
5T62
x
Figure 6G - Supply Sensor Label
GRUNDFOS®
071 Sensor
Return Sensor
Supply Sensor
MADE IN CANADA
LR 58223
E150539
5T62
x
Figure 6F - Return Sensor Label

Com (–) terminal on the control and not to earth
ground.
• Run wires from the 24-30 V (ac) power source or
heat demand to the electrical box for the wiring.
Use a clean power source to ensure proper
operation.
Wiring and Testing the Outdoor Air Temperature
Sensor 070
CAUTION: No wires should be connected to the
control during testing.
CAUTION: Do not apply voltage to the 070 at any time
as damage to the 070 may result.
A good quality test meter capable of measuring up to
5,000 kW (1kW = 1000 W) is required to measure the
sensor resistance. In addition to this, the actual
temperature must be measured with either a good
quality digital thermometer, or if a thermometer is not
available, a second 070 sensor can be placed
alongside the one to be tested and the readings
compared.
Connect the wire to the two terminals provided in the
PVC enclosure (Fig. 7A).
First measure the temperature using the thermometer
and then measure the resistance of the 070 sensor at
the control. The wires from the 070 sensor must not be
connected to the control while the test is performed.
Using the Resistance/Temperature Chart (page 12),
estimate the temperature measured by the 070 sensor.
The 070 sensor and thermometer readings should be
close. If the test meter reads a very high resistance,
there may be a broken wire, a poor wiring connection
or a defective sensor. If the resistance is very low, the
Figure 7A - Sensor Wire Connection
Page 11

Page 12
wiring may be shorted, there may be moisture in the
070 or the 070 may be defective. To test for a
defective 070 sensor, measure the resistance directly at
the 070 sensor location.
Replace the front cover of the 070 sensor enclosure.
Test the Power Supply or Heat Demand.
Make sure exposed wires and bare terminals are not in
contact with other wires or grounded surfaces. Turn on
the power or provide a heat demand and measure the
voltage across the leads. The voltmeter should read
between plus and minus 4 volts of the supplied voltage.
Temperature Resistance Temperature Resistance
oFoCΩΩ
ΩΩ
ΩoFoCΩΩ
ΩΩ
Ω
-50 -46 490,813 90 32 46,218
-45 -43 405,710 95 35 7,334
-40 -40 336,606 100 38 5,828
-35 -37 280,279 105 41 5,210
-30 -34 234,196 110 43 4,665
-25 -32 196,358 115 46 4,184
-20 -29 165,180 120 49 3,760
-15 -26 139,402 125 52 3,383
-10 -23 118,018 130 54 3,050
-5 -21 100,221 135 57 2,754
0 -18 85,362 140 60 2,490
5 -15 72,918 145 63 2,255
10 -12 62,465 150 66 2,045
15 -9 53,658 155 68 1,857
20 -7 46,218 160 71 1,689
25 -4 39,913 165 74 1,538
30 -1 34,558 170 77 1,403
35 2 29,996 175 79 1,281
40 4 26,099 180 82 1,172
45 7 22,763 185 85 1,073
50 10 19,900 190 88 983
55 13 17,436 195 91 903
60 16 15,311 200 93 829
65 18 13,474 205 96 763
70 21 11,883 210 99 703
75 24 10,501 215 102 648
80 27 9,299 220 104 598
85 29 8,250 225 107 553
Temperature/Resistance Chart

Setting Dip Switches
Figure 8A - Dip Switches
Electrical Connections To The Control
CAUTION: The installer
should confirm that no
voltage is present at any of
the wires.
Pull wires through the wiring
cover and install the wiring
cover over the wiring
chamber.
24 V (ac) Power or Heat
Demand Connections:
Connect the 24 V (ac) power supply or heat demand to
terminals “Demand” and “DEM/I” (Fig. 7B).
Outdoor Air Temperature Sensor 070 Connections:
CAUTION: Do not apply power to these terminals at
any time as this will damage the control.
Connect the two wires from
the Outdoor Air Tempera-
ture Sensor 070 directly to
the “Com (-)” and “Out/V”
terminals (Fig. 7C).
Note: Demand and outdoor tempera-
turesensorwiresmust berun through
and secured by the stain relief on the
terminal board.
Demand
Dem/I
Com (-)
Out/V
Figure 7C - Electrical (Com/
Out) connections to the control
Demand
Dem/I
Com (-)
Out/V
Figure 7B - Electrical
(demand) connections to the
control
ON
⇑⇑
⇑⇑
⇑
8.Settings
Page 13

Heating Curve Dial
Before adjusting the dial settings, read through the
sequence of operation to ensure that you understand
how the control operates.
During outdoor reset operation, the
Heating Curve setting determines
the number of degrees the supply
water temperature is raised for each
one degree drop in outdoor
temperature. The Heating Curve
dial position can be calculated from
the following formula.
Heating Curve =
Design supply temperature – occupied temperature
Occupied temperature – design outdoor temperature
Example: A system is designed to supply 120°F
(49°C) water when the outdoor temperature is 10°F
(-12°C). The Occupied temperature is 70°F (21°C).
Heating Curve = 120 - 70°F (49 - 21°C)
70 - 10°F (21 – (-12°C))
50°F (28°C)
60°F (33°C)
Page 14
=
= 0.8
Figure 8B -
Heating Curve Dial
Dip switch settings
POSITION
SWITCH ON OFF DEFAULT
APermanent External ON position
Demand Demand Permanent Demand
Max system Max system ON position
Bsupply set supply feature supply set at
at 140oF is off 140oF
Boiler return Boiler return ON position
Cminimum set minimum feature minimum set at
at 135oF is off 135oF
DHeating curve Heating Curve 5oF On position
No shift Parallel shift No shift

Page 15
-20-1001020304050607080
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.6
3.6 3.0
Heating Curve
System Design Temperature, °F
WWSD

Heating CurveTable (Warm Weather Shut Down = 70°F)
Page 16

Figure 8C - Performance indicator LEDs
Page 17
If the design supply water temperature is unknown, the
Heating Curve dial can be set to a trial value using the
typical design supply temperatures given below.
Typical design supply temperatures:
• Hydronic radiant floors: 100 to 130°F
(38 to 54°C)
• Baseboard convectors: 160 to 190°F
(71 to 88°C)
• Fan coils: 180 to 210°F
(82 to 99°C)
Factory default setting is 1.0.
Install control onto the pump.Insert the 115 V plug on
the line cord from the pump into a properly grounded
115 V outlet.This will apply power to the pump/control.
Performance Indicator LEDs (Fig. 8c)
Power ON (green) indicates power is applied.
Call For Heat (Green) indicates demand is applied
from permanent or external source.
Pump Perf. Reduced (Yellow) Indicates the pump
speed is limited due to protection limits.
% of pump performance (Yellow) indicates the speed
of the pump by flashing at different rates.
Before You Leave
• Place this brochure, and all other brochures
relating to the installation, in a conspicuous
location near the control for future reference.
• It is important to explain the operation of this
control within the system to the end user and to
anyone else who may be operating the system.

Whenever a fault is detected in any of the sensors, the
control LEDs will flash in a specific way, to indicate the
location of the problem, and the control will assume a
specific operating condition.
• Call For Heat LED is flashing (Fig 9A):
– Then the outdoor sensor is short or open
circuit
– And the control assumes an outdoor
temperature of 30°F
• Pump Performance Reduced LED is flashing
(Fig. 9B):
– Then the system supply sensor is short
or open circuit
– And the control runs pump at 10% and
does boiler protection if enabled.
• Call For Heat and Pump Performance Reduced
LEDs are flashing (Fig. 9C):
– Then the boiler return sensor is short or open
circuit
– And the control disables boiler protection.
Page 18
Figure 9B - Control Lights
(Pump Performance Reduced)
Figure 9C - Control Lights (PPR & CFH)
Figure 9A - Control Lights (Call For heat)
9. Error Messages and
Control Response

10.Quick Reference
Dip Switch Settings
Temperature Sensors Circuit Ratings
Outdoor Temperature Sensor Circuit Rating
Terminals: Out/V & Com (-)
5V DC ± 5% Max
0.166 mA DC ± 5% Max
Supply Temperature Sensor Circuit Rating
Terminals: Sup & Com
5V DC ± 5% Max
2.3 mA DC ± 5% Max
Return Temperature Sensor Circuit Rating
Terminals: Ret & Com
5V DC ± 5% Max
2.3 mA DC ± 5% Max
Demand Input Circuit Rating
Terminals: Dem & Dem/I
20-30 VAC
0.1 VA Max
WARNING!
All field wiring to be low voltage. Power for control
is provided through the power cord supplying
power to the pump.
Use copper conductors only.
Disconnect all power sources prior to servicing.
POSITION
SWITCH ON OFF DEFAULT
APermanent External ON position
Demand Demand Permanent Demand
Max system Max system ON position
Bsupply set supply feature Permanent Demand
at 140oF is off 140oF
Boiler return Boiler return ON position
Cminimum set minimum feature Permanent Demand
at 135oF is off 135oF
DHeating curve Heating Curve 5oF On position
No shift Parallel shift No shift
Page 19