Grundfos MixiMizer Owner's manual

Grundfos MixiMizer™
Installation and Operation
1 .
2 .
3 .
4 .
5 .
6 .
7 .
8 .
Settings
Sensor
Installation
Pump
Installation
General
MixiMizer
Features
Shipment
Inspection
Start Up
Error Messages
& Trouble Shooting
MixiMizer
Technical Data
GRUNDFOS INSTRUCTIONS
Pumps Incorporating the
(MR) Mixing Reset Control
with Date Code 0718 or higher

Page 1
MixiMizer™
The hot water heating system can now be accurately
and comfortably controlled by modulating the hot water
supply. As the outdoor temperature changes, the
MixiMizer will automatically calculate the pump speed
required, to ensure proper water temperature for your
heating system.
For maximum performance and proper installation,
please follow the simple instructions in this manual.
1. Shipment Inspection
Check the contents of this package. Care should be
taken to ensure the pump is NOT dropped or mishan-
dled; dropping will damage the pump.
Grundfos MixiMizer Injection Pump Package Includes:
• One Grundfos UP15-42 MixiMizer pump with
integral control.
• Two Water Temperature Sensors (Supply & Re-
turn) – Pre-wired into control box with 8’ of wire.
• One 6’ line cord with 115 V plug, pre-wired into
control box.
• One Outdoor Air Temperature Sensor (OATS)
• Two flange gaskets
• Installation and Operating Instructions.
• Four sensor (Supply & Return) cable ties.

When installing and using this electrical equipment, basic
safety precautions and local code requirements should
always be followed, including the following:
CAUTION: 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 harm-
ful 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, relocat-
ing 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 Outdoor Air Temperature
Sensor (OATS) and Pump Control Box enclosures do
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 supply-
ing 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 attach-
ment 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
2. General MixiMizer Features
• 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 a DIP
switch.
• The system supply maximum temperature is fixed
at 140°F. This function can be disabled by a DIP
switch.
• Heating curve parallel shift: The heating curve can
be shifted 5°F parallel to the default curve. This
function can be enabled by the DIP switch.
• 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.
• Optional Boiler On/Off Output: is activated
when the pump speed is raised to the boiler
enable percentage (30% pump speed) and is de-
activated when the pump speed falls to 50% of the
boiler enable percentage (15% pump speed). The
boiler enable relay has a minimum activation time
of 3 minutes and a minimum de-activation time of
20 seconds.

Page 4
• Optional Zone Control Input: The unit can
accept external “Call For Heat” input signal. This
must be a powered signal (20 to 30 V AC .1 VA).
This function can be enabled by a 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.
Summer Service Instructions
When the outdoor temperature is greater than 70oF and
the warm weather shutdown (WWSD) feature is active,
the pump will normally not be in operation. To allow the
pump to be tested, disconnect one of the wires from
the air temperature sensor in the control box. This will
simulate an open circuit in the outdoor sensor and the
control assumes an outdoor temperature of 30oF. This
will allow the pump to operate for testing and/or service.
Remember to re-connect the outdoor temperature sensor
wire when finished.
3. Pump Installation
Warning: Consult piping manufactures
for material selection before installing
this pump. Absence of pumping fluid
may damage some piping materials.
Caution: Thoroughly clean and flush the system prior
to pump installation
Pump: For Indoor Use Only
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, review standard primary-secondary piping
techniques described below. See figure 1.

Page 5
Note 1: The injection piping (Supply and Return) must
be at least one pipe diameter smaller than the piping of
the boiler and system loops.
Note 2: 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 3: 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.
Note 4: To prevent convective heat transfer through
the injection loop, there should be a minimum of 1 foot
drop to create a thermal trap.
System
Loop
Grundfos
Note 3
Note 4
MixiMizer Pump
Boiler
Loop
Balancing
Valve
{
Note 1
{
Note 3
{
{
Note 2
{
Figure 1 - Injection loop without thermal trap.

Page 6
Design Injection Nominal Injection MixiMizer
Flow Rate (GPM) Pipe Diameter Pump Model
0-8 3/4" UP15-42BUC5/MR
UP15-42BUC7/MR*
Warning: *Can produce flow velocity
greater than 8 ft/sec in this size.
0-5 1/2" UP15-42BUC5/MR*
UP15-42FC/MR*
UP15-42FC/MR
0-16 1" UP15-42BUC7/MR
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
loop into the system loop.
The pump must be installed with the motor shaft posi-
tioned horizontally. Under no circumstances should the
pump be installed with the shaft vertical or where the
shaft falls below the horizontal plane (Fig.2).
Table 1
Recommended
Optional
DO NOT
Mount Motor Shaft
in Vertical Position
Figure 2
Preferred 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

Page 7
4. Sensor Installation
Warning: 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.
CAUTION: Power must not be applied to any of the
wires during the rough-in wiring stage.
CAUTION: All field wiring must pass through a suitable
listed conduit fitting, to ensure proper strain relief.
CAUTION: 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 control box to
reach the terminal strip.
NOTE: All field wiring shall have insulation stripped
exposing 6.0mm of conductor before placement into
control box terminal strip.
If the terminal box position needs to be changed, ensure
that the electrical supply is turned off and close the
isolation valves before removing the Allen screws.
To change control 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 disas-
sembly/reassembly process.

Outdoor Air Temperature Sensor (OATS):
The Outdoor Air Temperature Sensor includes a built
in 10 kW (ohm) thermistor which provides an accurate
measurement of the outdoor temperature. The OATS
sensor is protected by a white U.V. resistant PVC plastic
enclosure (Fig. 3A & 3B).
• Remove the screw and pull the front cover off the
sensor enclosure.
• The OATS can either be mounted directly onto a
wall or in a 2” x 4” electrical box. When the OATS
is wall mounted, the wiring should enter through
the back or bottom of the enclosure. Do not
mount the OATS with the conduit knockout fac-
ing upwards as rain could enter the enclosure
and damage the sensor (Fig. 4).
• 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 OATS enclosure.
• The OATS should be mounted on a wall which
best represents the heat load on the building (a
northern wall for most buildings or a southern fac-
ing wall for buildings with large south facing glass
areas). The OATS should not be exposed to heat
sources such as ventilation or window openings.
Page 8
Figure 3A - Closed
Outdoor Air Temperature
Sensor (OATS)
Sensor
Figure 3B - Open Outdoor
Air Temperature Sensor
(OATS)

• The OATS should be installed at an elevation
above the ground that will prevent accidental dam-
age or tampering.
• Install field wiring from the OATS mounting loca-
tion to the control box for the control wiring. Do
not run field wires parallel to telephone or power
cables. If the sensor wires are located in an area
with strong sources of electromagnetic interfer-
ence (EMI), shielded cable or twisted pair should
be used. If using shielded cable, the shield wire
should be connected to the Com (–) terminal on
the control and not to earth ground.
• Connect the two field wires from the OATS directly
to the control box “Com (-)” and “Os/V” (not polar
sensitive) terminals (Fig. 8).
Water Temperature Sensors (Supply & Return):
The Water Temperature
Sensor has a zinc sleeve
for fast response and a
wide operating range (Fig
5). Factory Pre-wired
Note: Sensors are designed to mount on a pipe or in a
temperature immersion well.
• The 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. 6).
Page 9
Figure 5 - Sensor
Sensor with rear
entry wiring
Sensor with bottom
entry wiring
Sensor mounted
onto 2" x 4" electrical
box.
Figure 4 - Mounting the Outdoor Air Temperature Sensor (OATS)
Figure 6 - Mounted Sensor