Grundfos UP Series 200 User manual

GRUNDFOS INSTRUCTIONS
UP Series 200
Installation and operating instructions
In-line, wet-rotor, single-speed, circulator pumps
UP 43-70, UP 43-110, UP 53-45, UP 53-46

3
Table of contents
UP Series 200
English (US)
Installation and operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Español (MX)
Instrucciones de instalación y operación . . . . . . . . . . . . . . . . . . . . . . . . 16
Français (CA)
Notice d'installation et de fonctionnement . . . . . . . . . . . . . . . . . . . . . . . 28

4
English (US)
English (US) Installation and operating instructions
Original installation and operating
instructions.
CONTENTS Page
1. Limited warranty
Products manufactured by GRUNDFOS PUMPS
CORPORATION (Grundfos) are warranted to
the original user only to be free of defects in
material and workmanship for a period of
24 months from date of installation, but not more
than 30 months from date of manufacture.
Grundfos' liability under this warranty shall be
limited to repairing or replacing at Grundfos'
option, without charge, F.O.B. Grundfos' factory
or authorized service station, any product of
Grundfos' manufacture. Grundfos will not be
liable for any costs of removal, installation,
transportation, or any other charges which may
arise in connection with a warranty claim.
Products which are sold but not manufactured
by Grundfos are subject to the warranty
provided by the manufacturer of said products
and not by Grundfos' warranty. Grundfos will not
be liable for damage or wear to products caused
by abnormal operating conditions, accident,
abuse, misuse, unauthorized alteration or repair,
or if the product was not installed in accordance
with Grundfos' printed installation and operating
instructions.
To obtain service under this warranty, the
defective product must be returned to the
distributor or dealer of Grundfos' products from
which it was purchased together with proof of
purchase and installation date, failure date, and
supporting installation data. Unless otherwise
provided, the distributor or dealer will contact
Grundfos or an authorized service station for
instructions. Any defective product to be
returned to Grundfos or a service station must
be sent freight prepaid; documentation
supporting the warranty claim and/or a Return
Material Authorization must be included if so
instructed.
GRUNDFOS WILL NOT BE LIABLE FOR ANY
INCIDENTAL OR CONSEQUENTIAL
DAMAGES, LOSSES, OR EXPENSES ARISING
FROM INSTALLATION, USE, OR ANY OTHER
CAUSES. THERE ARE NO EXPRESS OR
IMPLIED WARRANTIES, INCLUDING
MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE, WHICH EXTEND
BEYOND THOSE WARRANTIES DESCRIBED
OR REFERRED TO ABOVE.
Some jurisdictions do not allow the exclusion or
limitation of incidental or consequential
damages and some jurisdictions do not allow
limit actions on how long implied warranties may
last. Therefore, the above limitations or
exclusions may not apply to you. This warranty
gives you specific legal rights and you may also
have other rights which vary from jurisdiction to
jurisdiction.
1. Limited warranty 4
2. Introduction 5
2.1 Safety warning 5
2.2 Electrical work 5
3. Pre-installation checklist 5
3.1 Confirm you have the correct pump 5
3.2 Check the condition of the pump 5
3.3 Verify electrical requirements 5
3.4 Pumped liquid requirements 6
4. Installation procedures 6
4.1 Electrical preparation 6
4.2 Piping considerations 7
4.3 Connect the pump 7
4.4 Electrical connection 8
5. Starting the pump 9
5.1 Vent the piping system 9
5.2 Voltage selection 9
6. Troubleshooting 10
6.1 Fault finding chart 10
6.2 Preliminary checks 11
6.3 Current measurement 11
6.4 Insulation resistance (lead-to-ground) 12
6.5 Winding resistance (line-to-line) 12
6.6 Winding resistance chart 13
7. Replacing components 14
7.1 Removing the pump head 14
7.2 Fitting the pump head 14
7.3 Replacing the terminal box or
capacitor 15
8. Disposal 15
Warning
Prior to installation, read these
installation and operating
instructions. Installation and
operation must comply with local
regulations and accepted codes of
good practice.
This booklet should be left with the
owner of the pump for future
reference and information
regarding its operation.

5
English (US)
2. Introduction
2.1 Safety warning
2.1.1 Read this booklet
This booklet is designed to help a certified
installer install, begin operation of and
troubleshoot the Grundfos UP Series 200
pumps. The booklet should be left with the
owner of the pump for future reference and
information regarding its operation. Should the
owner experience any problems with the pump,
a certified professional should be contacted.
2.2 Electrical work
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.
3. Pre-installation checklist
3.1 Confirm you have the correct pump
• Read the pump nameplate to make sure it is
the one you ordered.
• Compare the pump's nameplate data and its
performance curve (for head, GPM, etc.)
with the application in which you plan to
install it.
• Will the pump do what you expect it to do?
3.2 Check the condition of the pump
The shipping carton your pump came in is
specially designed around your pump during
production to prevent damage.
As a precaution, it should remain in the carton
until you are ready to install it. At that point, look
at the pump and examine it for any damage that
may have occurred during shipping.
Examine any other parts of the shipment as well
for any visible damage.
3.3 Verify electrical requirements
Verification of the power supply should be made
to be certain the voltage, phase and frequency
match that of the pump motor. The proper
operating voltage and other electrical
information can be found on the pump
nameplate.
These motors are designed to run on ± 10 % of
the rated voltage.
Wiring diagrams can be found inside the
terminal box cover and later in these installation
and operating instructions. If voltage variations
are larger than ± 10 %, do not operate the pump.
Warning
A faulty motor or wiring can cause
electric shock that could be fatal,
whether touched directly or
conducted through standing water.
For this reason, proper grounding
of the pump to the power supply's
grounding terminal is required for
safe installation and operation.
In all installations, the above-
ground metal plumbing should be
connected to the power supply
ground as described in
Article 250-80 of the National
Electrical Code.

6
English (US)
3.4 Pumped liquid requirements
The pump can be used to circulate the following
liquids:
• potable hot water
• water for hydronic heating
• water/glycol mixtures up to 50/50
• cooling water.
In domestic hot-water systems it is advisable to
use bronze pumps (UP Series 200 or UPS
model) only for water with a degree of hardness
lower than 14 grains per gallon of hardness. For
water with a higher degree of hardness, a direct-
coupled TP pump is recommended. If the pump
is installed in a heating system, the water should
meet the requirements of accepted standards on
water quality in heating systems.
In water/glycol mixtures, in order to prevent the
glycol from degrading, temperatures above
those for which the liquid is rated should be
avoided and time spent at high temperatures
minimized.
It is also important that the system is cleaned
and flushed prior to the installation of the glycol
mixture.
In order to avoid problems with corrosion or
precipitation, the glycol liquids should be
checked and maintained regularly. If further
dilution of the supplied glycol is required, follow
the requirements of the supplier of the glycol.
DEXCOOL®is a registered trademark of
General Motors Corporation, used under license
by Texaco Lubricants NA.
The pump is lubricated and cooled by the
pumped liquid. Therefore, the pumped liquid
must always be allowed to circulate through the
pump. Extended periods without circulation will
cause premature wear to the bearings and
excessive motor heat. The pumped liquid must
also meet the following requirements:
Minimum inlet pressure (during operation)
Liquid temperature range
Continuously:
14 °F (-10 °C) up to 230 °F (110 °C).
Intermittent:
< 284 °F (140 °C) for short periods of time.
Domestic hot water:
< 140 °F (60 °C).
4. Installation procedures
4.1 Electrical preparation
Terminal box position
At the bottom of the stator, closest to the pump
housing, there are eight drain holes to allow
condensed water to escape. The drain holes
must not be blocked. The drain holes must point
downwards. The terminal box must therefore
point upwards in one of the positions shown in
fig. 1. The following terminal box positions apply
whether the piping is mounted vertically or
horizontally.
Fig. 1 Possible terminal box positions
Caution
The UP Series 200 pump is
intended for use with water only.
Caution
Glycol with the trade name
DEXCOOL®can damage the pump.
UP
model
At these liquid temperatures
167 °F/
75 °C 194 °F/ 90 °C 230 °F/ 110 °C
[psi] hf [psi] hf [psi] hf
UP
43-70 0.7 1.6 4.8 11.0 15.4 35.6
UP
43-110 3.6 8.3 8.2 18.9 18.9 43.7
UP
53-45 2.9 6.7 7.5 17.3 18.1 41.6
UP
53-46 1.1 2.5 5.8 13.3 16.4 37.7
Warning
Never make any connections in the
pump terminal box unless the
power supply has been switched
off.
TM03 7296 4706

7
English (US)
Rotating the terminal box
To rotate the terminal box, follow these steps:
1. Remove the four hex socket head screws
holding the pump head onto the pump
housing.
2. Carefully lift the pump head and rotate it so
the terminal box is in the desired position.
DO NOT locate the terminal box beneath the
pump. Make sure the O-ring is properly
seated in the pump housing.
3. Replace the pump head onto the pump
housing.
4. Tighten the hex socket head screws evenly.
Torque to:
8 mm............15 ft lbs
10 mm..........25 ft lbs.
5. Check to make sure the rotor turns freely.
Do this by removing the vent plug in the
middle of the pump nameplate. Insert a
medium size flat-blade screwdriver into the
slot at the exposed end of the shaft.
Gently turn the shaft. If it does not turn
easily, repeat steps 1 to 4 above.
6. The position of the nameplate can be
changed by easing the outer edge of the
plate at the cutout with a screwdriver.
Turn the nameplate to the required position
and push into place.
7. Refer to pages 11 and 12 for additional
instructions.
4.2 Piping considerations
Thoroughly clean and flush all dirt and sediment
from the system before attempting to install the
pump.
Location in the piping line
The pump should never be located at the lowest
point of the piping system, where dirt and
sediment collect. Nor should it be located at the
highest point of the piping system, where air
accumulates.
Mounting positions
The arrows on the flanges of the pump indicate
the direction of water flow. Although the
UP Series 200 may be installed in either vertical
or horizontal piping, the motor shaft must always
remain horizontal, as shown in figures 1 and 2.
Fig. 2 Direction of water flow through the
pump
4.3 Connect the pump
Install the pump into the piping system.
Grundfos recommends that pressure gauges be
installed in the inlet and discharge flanges or
pipes to check pump and system performance.
Warning
If the pump is already installed in
the system, the system must be
drained or the isolation valves on
both sides of the pump must be
closed before the hex socket head
screws are removed as the pumped
liquid may be scalding hot and/or
under pressure.
Do not start the pump until the
system has been filled with liquid
and vented.
TM03 7290 4706
Note
Pumps installed outdoors must be
protected by a ventilated,
watertight cover to keep out
moisture and dirt.
Warning
The pump must be positioned so
that no one can accidentally come
into contact with the hot surfaces
of the pump.

8
English (US)
4.4 Electrical connection
The electrical connection and protection should
be carried out by a qualified electrician in
accordance with the latest edition of the National
Electrical Code, local codes and regulations.
The operating voltage and frequency are
marked on the pump nameplate. Make sure that
the motor is suitable for the power supply it is
being installed to.
The pump should be grounded to protect against
indirect contact and a ground fault interrupter
can be used as extra protection.
Dual-voltage pump (single-phase)
All single-phase pumps are equipped with built-
in, automatic resetting, thermal overload
protection. The pump is protected at both 115 V
and 230 V. The pump may also be protected by
using an external contactor or motor starter.
If the pump is protected by means of a motor
starter, the starter must be set to the current
consumption of the pump. The current
consumption is stated on the pump nameplate.
Figures 4 and 6 show the possible connections.
All UP Series 200 pumps (fig. 3 and fig. 5) come
with a dual-voltage terminal box. The voltage is
changed by the orientation of the jumpers as
shown in fig. 9. All pumps are equipped with an
internal automatic resetting thermal overload
switch (terminals P1 and P2).
Fig. 3 UP Series 200 dual-voltage terminal
box (1 x 115 V supply)
Wiring diagram
Figure 4 shows the electrical connections when
using built-in motor protection with 1 x 115 V
supply.
Fig. 4 Electrical connections (1 x 115 V
supply)
Fig. 5 UP Series 200 dual-voltage terminal
box (1 x 230 V supply)
Warning
Never make any connections in the
pump terminal box unless the
power supply has been switched
off.
The pump must be grounded.
The pump must be connected to an
external main power switch.
TM03 7304 4706
N
L
T5
P1
P2 T2
T3
T1 T8
T4
Jumpers
for 115 V
operation
TM03 7298 4706
TM03 7306 4706
P1
P2
T5 T4 T8
T1 T3 T2
Capacitor
L N
N
LT5
P1
P2 T2
T3
T1 T8
T4
Jumpers
for 230 V
operation

9
English (US)
Wiring diagram
Figure 6 shows the electrical connections when
using built-in motor protection with 1 x 230 V
supply.
Fig. 6 Electrical connections (1 x 230 V
supply)
5. Starting the pump
5.1 Vent the piping system
After the pump has been installed and the
electrical connections made, the piping system
must be vented.
Instead, follow these steps:
1. Fill and pressurize the system with liquid,
and vent all trapped air from the piping by
suitable means.
2. If isolation valves are used, make sure they
are OPEN.
5.2 Voltage selection
Change the pump input voltage as follows:
The voltage is changed by the position of the
jumpers in the terminals. The jumpers are fitted
according to:
• figure 7 for 115 V AC
• figure 8 for 230 V AC.
Fig. 7 Jumper position for 115 V AC
Fig. 8 Jumper position for 230 V AC
Fig. 9 Terminal box
TM03 7297 4706
Caution
Never operate the pump dry - the
system must first be filled with
liquid and vented.
Note
Do not vent the piping system
through the pump.
Warning
If the vent screw is to be loosened,
care should be taken to ensure that
the escaping scalding hot liquid
does not cause personal injury or
damage to components.
Warning
Never make any connections in the
pump terminal box unless the
power supply has been switched
off.
P1
P2
T5 T4 T8
T1 T3 T2
Capacitor
L N
TM02 5757 3902TM02 5758 5002TM03 7304 4706
LN
P1
P2 T1 T3 T2
T5 T4 T8
Jumper wire
L N
LN
P1
P2 T1 T3 T2
T5 T4 T8
Jumper wire
L N
N
L
T5
P1
P2 T2
T3
T1 T8
T4

10
English (US)
6. Troubleshooting
6.1 Fault finding chart
Warning
Before removing the terminal box cover, make sure that the power supply has been
switched off and that it cannot be accidentally switched on.
The pumped liquid may be scalding hot and under high pressure. Before any removal
or dismantling of the pump, the system must be drained or the isolation valves on
both sides of the pump must be closed.
Fault Cause Remedy
1. The pump does
not run. a) One fuse in the installation is blown. Replace the fuse.
b) External circuit breaker is
switched off. Switch the circuit breaker on.
c) Current-/voltage-operated
ground fault interrupter
has tripped.
Repair the insulation defects and reset
the interrupter.
d) The pump has been cut
out by the thermal
overload switch due to
high liquid temperature or
blocked rotor.
Check that the liquid temperature falls
within the specified range. The pump will
restart automatically when it has cooled
to normal temperature.
e) Rotor blocked, but the
pump hasn't been cut out
by the thermal overload
switch.
Switch off the electrical supply and
clean/repair the pump.
2. Noise in the
system. a) Air in the system. Vent the system.
b) The pump flow is too high. Reduce the pump performance.
c) The pressure is too high. Reduce the pump performance.
3. Noise in the pump. a) Air in the pump. Vent the pump.
b) The inlet pressure is too
low. Increase the inlet pressure and/or check the air volume in the expansion tank
(if installed).
4. Insufficient heat in
some places in the
heating system.
a) The pump performance is
too low. Increase the pump performance, if possible, or replace the pump with a
pump with higher flow.

11
English (US)
6.2 Preliminary checks
Supply voltage
To check the voltage being supplied to the
motor, use a voltmeter.
Single-phase motors
Touch one voltmeter lead to each of the lines
supplying power to the pump, L and N.
Fig. 10 Checking single-phase power
Evaluation
When the motor is under load, the voltage
should be within 10 % (+ or -) of the nameplate
voltage. Any variation larger than this may
indicate a poor power supply and can cause
damage to the motor windings. The motor
should not be operated under these conditions.
Contact your power supplier to correct the
problem or change the motor to one requiring
the voltage you are receiving.
6.3 Current measurement
To check the current, use an ammeter.
To do so, follow these steps:
1. Make sure the pump is operating.
2. Set the ammeter to the proper scale.
3. Place the tongs of the ammeter around the
leg to be measured.
4. Compare the results with the amp draw
information on the nameplate.
Evaluation
If the current exceeds the listed nameplate
amps, then check the following:
• The voltage supplied to the pump may be too
high or too low.
• The contacts on the motor starter may be
burned.
• The terminals in the starter or terminal box
may be loose.
• There may be a winding defect. Check the
winding and insulation resistance.
• The motor windings may be shorted or
grounded.
• The pump may be damaged in some way
and may be causing a motor overload.
• A voltage supply or balance problem may
exist.
Fig. 11 Current measurement
Warning
Be careful, since power is still
being supplied to the pump. Do not
touch the voltmeter leads together
while they are in contact with the
power lines.
TM03 7302 4706
TM03 7802 4906
N
L
5T
P1
P2 2T
3T
1T 8T
4
T

12
English (US)
6.4 Insulation resistance
(lead-to-ground)
To check the insulation resistance (lead-to-
ground) of the motor and leads, a megohmmeter
is required.
To do so, follow these steps:
1. Turn the POWER OFF.
2. Disconnect all leads to the motor.
3. Set the scale selector on the megohmmeter
to R x 100K, touch its leads together, and
adjust the indicator to zero.
4. Touch the leads of the megohmmeter
individually to each of the motor leads and to
ground (i.e. L to ground; N to ground, etc.).
Fig. 12 Insulation resistance measurement
Evaluation
The resistance values for new motors must
exceed 1,000,000 ohms. If they do not, replace
the motor.
6.5 Winding resistance (line-to-line)
To check the winding resistance of the motor
windings, a megohmmeter is required.
To do so, follow these steps:
1. Turn the POWER OFF.
2. Disconnect all leads to the motor.
3. Set the scale selector on the megohmmeter
to R x 1, touch its leads together and adjust
the indicator to zero.
4. Using the following chart for reference, touch
the leads of the megohmmeter to the
appropriate pair of connectors. Check all
pairs that are present and write down and
label (RA1, RA2, RS) all readings.
5. Compare your readings to the matching
model, phase and voltage on the chart in
section 6.6 Winding resistance chart.
Evaluation
The resistance values must fall within the
tolerances listed in section 6.6 Winding
resistance chart. If they do not, replace the
motor.
TM03 7803 4906
Internal wiring
UP
Terminal plug in stator
Single-phase
RA1: Main winding
RA2: Main winding
RS: Auxiliary winding
3
11
5
7
1
9
A
1 A 2
S
15
13

13
English (US)
6.6 Winding resistance chart
UP dual voltage
60 Hz
[Ω] 68 ºF - 122 ºF (20 ºC - 50 ºC)
Pump type Voltage RA1RA2RS
UP 43-70 1 x 115 V 13.4 - 17.8 10.6 - 14.2 4.50 - 6.00
1 x 230 V 13.4 - 17.8 10.6 - 14.2 4.50 - 6.00
UP 43-110 1 x 115 V 4.75 - 6.20 3.85 - 5.05 2.10 - 2.75
1 x 230 V 4.75 - 6.20 3.85 - 5.05 2.10 - 2.75
UP 53-45 1 x 115 V 13.4 - 17.8 10.6 - 14.2 4.50 - 6.00
1 x 230 V 13.4 - 17.8 10.6 - 14.2 4.50 - 6.00
UP 53-46 1 x 115 V 9.4 - 11.6 7.3 - 9.1 1.6 - 2.0
1 x 230 V 9.4 - 11.6 7.3 - 9.1 1.6 - 2.0

14
English (US)
7. Replacing components
7.1 Removing the pump head
1. Disconnect or TURN OFF the power supply.
2. Close isolation valves on either side of the
pump to avoid draining the system of liquid.
3. Disconnect the leads from the terminal box.
4. Disconnect and remove the conduit from the
terminal box.
5. Loosen and remove the four hex socket
head screws (8 or 10 mm) which connect the
pump head to the pump housing.
6. Remove the pump head from the pump
housing.
7. Clean the machined surfaces in the pump
housing of any foreign material.
Fig. 13 Removing and fitting the pump head
7.2 Fitting the pump head
1. Carefully remove the new pump head from
its packaging. Separate the impeller/rotor
assembly from the new pump head.
2. While holding the thrust bearing, carefully
place the impeller/rotor assembly into the
pump housing. The bearing plate should fit
snugly into the lowest machined surface in
the pump housing.
3. Make sure that the impeller/rotor assembly
can rotate freely.
4. Place the O-ring over the rotor and locate it
into the inner diameter of the pump housing.
5. Carefully place the pump head over the rotor
and rotate it so the terminal box is in the
position you wish, see section 4.1 Electrical
preparation under "Terminal box position".
6. Make sure the pump head is properly seated
on the pump housing.
Do not force the two together - if there is
binding, disassemble them and repeat steps
2 to 6. Tighten the hex socket head screws
evenly to secure the pump head.
Torque to:
8 mm............15 ft lb
10 mm...........25 ft lb.
7. Check to make sure the motor shaft turns
freely, as explained in section 4.1 Electrical
preparation under "Rotating the terminal
box".
TM03 7292 4706
Terminal box
Pump head
Impeller/rotor
assembly
Hex socket head
screws (4)
O-ring Grooves
Thrust bearing
Bearing plate
Pump housing

15
English (US)
7.3 Replacing the terminal box or capacitor
Fig. 14 Terminal box
If the terminal box is going to be replaced, make
certain the electrical information listed on the
new box matches the information listed on the
old box, and that it is compatible with the pump
and incoming power supply.
For all terminal boxes, it is very important to
tightly secure the frame grounding screw
through the terminal box, so that a proper
connection between the terminal box and motor
is made.
8. Disposal
This product or parts of it must be disposed of in
an environmentally sound way:
1. Use the public or private waste collection
service.
2. If this is not possible, contact the nearest
Grundfos company or service workshop.
Subject to alterations.
TM03 7304 4706
N
L
T5
P1
P2 T2
T3
T1 T8
T4
Frame ground
screw hole
All 1. Before replacing the terminal box or capacitor, make sure the power is OFF.
2. Remove the terminal box cover by completely loosening all four torx/standard
screws.
Capacitor
a.3. Capacitor replacement: Disconnect the two capacitor leads from the terminals and unscrew the complete plastic strain relief nut.
Remove capacitor wire and strain relief.
a.4. Screw in new complete strain relief nut and connect capacitor wires to terminals. Pull excess sheathed cable out of terminal box, being sure to leave
at least 1/8" of sheath inside of terminal box.
Terminal box
b.3. Terminal box replacement: Disconnect all wiring, remove the three Phillips- head screws holding the terminal box in place and remove the terminal box by
pulling firmly and evenly on both sides.
b.4. Check that the clear rubber gasket is in place around the terminal box connector stem, carefully press the terminal box into the stator socket,
replace the three Phillips-head terminal box screws and replace wiring.
All 5. Replace the terminal box cover and tighten all four torx/standard screws.
6. Switch on power supply. The pump is now ready for operation.

Grundfos companies
USA
GRUNDFOS Pumps Corporation
17100 West 118th Terrace
Olathe, Kansas 66061
Phone: [phone]
Telefax: [phone]
Canada
GRUNDFOS Canada Inc.
2941 Brighton Road
Oakville, Ontario
L6H 6C9
Phone: [phone]
Telefax: [phone]
México
Bombas GRUNDFOS de México S.A.
de C.V.
Boulevard TLC No. 15
Parque Industrial Stiva
Aeropuerto
Apodaca, N.L.C.P. 66600
Phone: [phone]
Telefax: [phone]

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