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

Page 10
• The 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
sensor location requires that the fluid is thoroughly
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.
7A & 7B) Mount the Return Sensor to the return
piping of the boiler loop. Mount the Supply Sensor
to supply piping of the system loop.
Figure 7A - Return Sensor Label Figure 7B - Supply Sensor Label
Optional Boiler On/Off Output:
The boiler terminals are used to activate a boiler when
the pump is ramped to the boiler enable percentage
30% and is shut off when the pump is ramped to 50%
of the boiler enable percentage. The boiler enable
includes a minimum "ON" time of 3 minutes and a mini-
mum "OFF" time of 20 seconds. Connect field wiring
to control box terminals Boil & Boil (not polar sensitive)
(Fig. 8).
Optional Zone Control Input:
Connect field wiring 24 V (ac) power supply or heat
demand to control box terminals “DEM” and “DEM” (not
polar sensitive) (Fig. 8).

Page 11
Sup
Com
Ret / I
Com(-)
Os / V
Boil
Boil
Dem
Dem
tN4
Signal wires must be min. 300V rating
Class 2
Only
Optional
Boiler On/Off
Output
Return
Sensor
Optional Zone
Control Input
Use copper conductors only
Outside
Temp
Sensor
Supply
Sensor
Fig. 8
Figure 9 - Dip Switches
ON
⇑
5.Settings
Dip switch settings:
POSITION
SWITCH ON OFF DEFAULT
A Permanent 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
ON position
Max supply set at
140°F
ON position
Boiler minimum
set at 135°F
Starting Temp.
70°F
Starting Temp.
75°F

Page 12
Heating Curve - Dial Set Point:
Before adjusting the dial settings, read through the
sequence of operation to ensure that you understand
how this control operates.
The Heating Curve setting deter-
mines 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 - Dial Set Point Example:
System Design Temperature = 120°F
Outdoor Design Temperature = 10°F
Warm Weather Shutdown (WWSD) = 70°F
Dial Set Point = 120 – 70°F = 0.8
70 – 10°F (Table 2)
Figure 10 - Heating
Curve Dial

Page 13
-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,
Heating Curve Dial Set Point
Outdoor Design Temperature °F
°F
WWSD
>
>
>
Heating Curve Table - Dial Set Point
(Warm Weather Shut Down = 70°F)
Table 2
Table 3

Page 14
Performance Indicator LEDs (Fig. 11):
• Power ON: (Green) indicates power is applied.
• % of pump performance: (Yellow) indicates the
speed of the pump by flashing at different rates.
• Call For Heat: (Green) External devise requesting
heat from system
• Pump Perf. Reduced: (Yellow) Indicates the pump
speed is limited due to protection limits.
• Boiler: (Green) Boiler activated for operation
Call for Heat
% Of Pump Perf.
Power On
Pump Perf. Reduced
Boiler
Figure 11 - Performance indicator LEDs
6. Start Up
• DO NOT START THE PUMP UNTIL THE SYSTEM
HAS BEEN FILLED, FLUSHED, PROPERLY
VENTED, AND CHECKED FOR LEAKS.
• Ensure that water does not enter the terminal box
during the installation process.
• Do not use the pump to vent the system. Install
additional ventilation for system purging.
• Never operate the pump dry. The bearings require
water lubrication and will be damaged otherwise.
• Fill system with water. This will result in immediate
lubrication of the bearings.
• Operate the pump for 5 minutes, when control in-
stallation is complete, to purge remaining air from
the bearing chamber. This is especially important
when installing the pump during the off-season.

Whenever a fault is detected in any of the sensors, the
control LEDs will flash in a specific way, to indicate the lo-
cation of the problem, and the control will assume a specific
operating condition.
• Call For Heat LED is flashing (Fig. 12):
– There is a short or open circuit to OATS Sensor
– And the control assumes an outdoor
temperature of 30°F
• Pump Performance Reduced LED is flashing
(Fig. 13):
– There is a short or open circuit to the Supply
Sensor
– And the control runs pump at 10% and
does boiler protection if enabled.
Page 15
Figure 13 - Control Lights
(Pump Performance Reduced)
Call for Heat
% Of Pump Perf.
Power On
Pump Perf. Reduced
Boiler
Figure 12 - Control Lights (Call For heat)
7.Error Messages and
Trouble Shooting
Call for Heat
% Of Pump Perf.
Power On
Pump Perf. Reduced
Boiler

Testing Sensors:
Warning: No wires connected to control box
during testing
Outdoor Air Temperature Sensor (OATS):
• First measure the ambient air temperature next to
the OATS sensor.
• Disconnect all field wiring from the OATS sensor.
• Measure (ohms) resistance directly at the OATS
sensor location, convert ohms reading to
temperature (Table 4).
• Compare ambient air temperature to the measured
sensor resistance. Both temperatures should be
close +/- 10% (Table 4).
Supply & Return Sensors:
• Disconnect sensor wiring from control box.
• Measure the resistance (ohms) of the Supply then
the Return sensor (Wires have no polarity).
See Table 4.
• Compare fluid temperature to Resistance/
Temperature Chart (Table 4). Both temperatures
should be close +/- 10%.
Possible reasons for short circuit:
• Water in OATS sensor case
• Nail or staple in field wiring
Possible reasons for open circuit:
• Sensor wire jacket has been compromised
• Sensor is disconnected
• Sensor insulation is interfering with sensor at the
pipe location
• Faulty sensor Page 16
• Call For Heat and Pump Performance Reduced LEDs
are flashing (Fig. 14):
– There is a short or open circuit to Boiler Return
Sensor
– Boiler protection is disabled
Figure 14 - Control Lights (PPR & CFH)
Call for Heat
% Of Pump Perf.
Power On
Pump Perf. Reduced
Boiler

Page 17
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.
Page 12
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
oFoC�oFoC�
-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
Table 4
OATS / Return / Supply
Temperature Resistance Chart

Page 18
Maximum Ambient Temperature:
• 107°F (42°C) with Control Box vertical
• 105°F (41°C) with Control Box on top of pump
and horizontal
Outdoor Air Temperature Sensor:
Approvals: CSA, UL
Terminals: Out/V & Com (-)
5V DC +/- 5% Max
0.166 mA DC +/- 5% Max
Operating Range: -67 to 149°F (-55 to 65°C)
Sensor: NTC thermistor, 10Ohms @ 77°F
(25°C +/- 0.2°C), B=3892
Enclosure: White U.V. resistant, PVC,
NEMA 1
Control Box:
Input Voltage: 120V +/- 10%, 50/60Hz, 250vA
Output Rating: 1.8A, 1/12Hp
Supply & Return Temperature Sensors:
Approvals: CSA, UL
Terminals: (Sup & Com) (Ret/I & Com)
5V DC +/- 5% Max
0.166 mA DC +/- 5% Max
Operating Range: 14 to 266°F (-10 to 130°C)
Sensor: NTC thermistor, 10Ohms @ 77°F
(25°C +/- 0.2°C), B=3892
Wire: 8ft., 300V, UL2722, PVC insulation,
105°C
Optional Boiler On/Off Output:
Terminals: Boil & Boil
30 VAC
2.5 Amp Pilot Duty
Optional Zone Control Input:
Terminals: Dem & Dem
20 - 30 VAC
0.1 VA Max
8. MixiMizer Technical Data

UP15 Pump:
Max Working Pressure: 145 PSI
Min. Inlet Pressure: 5 PSI
Approvals: UL, cUL listed
Integrated Check Valve: Yes
UP15-42FC/MR:
Connection: GF 15/26 Flange - (2) 1/2”
Diam. Bolt Holes
Flow Range (GPM): 0 - 9
Head Range (ft.): 0 - 14
Motor: 2 Pole, Single Phase
Amps: 0.74
Watts: 85
Hp: 1/25
Max Fluid Temp: 205°F (96°C)
Volute Material: Cast Iron
UP15-42BUCX/MR:
Motor: 2 Pole, Single Phase
Amps: 0.74
Watts: 85
Hp: 1/25
Max Fluid Temp: 205°F (96°C)
Volute Material: Silicon Bronze
BUC5:
Flow Range (GPM): 0 - 8.5
Head Range (ft.): 0 - 14.5
Connection: 1/2” Sweat
BUC7:
Flow Range (GPM): 0 - 16
Head Range (ft.): 0 - 15
Connection: 3/4” Sweat
Page 19