Grundfos UP XL User manual

GRUNDFOS INSTRUCTIONS
Grundfos UP XL
maintenance-free circulators
with insulation shell
Installation and operating instructions
Conforms to UL STD 514C
Certified to CSA STD C22.2 No. 18.2
3191277
http://waterheatertimer.org/Water-heater-recirculation-system.html

Grundfos UP XL
maintenance-free circulators
3
Table of contents
English (US)
Installation and operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Français (CA)
Notice d'installation et de fonctionnement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Español (MX)
Instrucciones de instalación y funcionamiento. . . . . . . . . . . . . . . . . . . . . . . . . .30

4
(QJOLVK86
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 36
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.
2. Safety warning
2.1 Read this booklet
This booklet is designed to help a certified
installer to install, begin operation of, and
troubleshoot the Grundfos Small UP and UPS
pumps.
Following the instructions will ensure safe,
trouble-free operation.
This 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.
1. Limited warranty 4
2. Safety warning 4
2.1 Read this booklet 4
2.2 Electrical work 4
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 5
4. Installation procedures 6
4.1 Piping considerations 6
4.2 Changing the terminal box position 7
4.3 Electrical connection 8
4.4 Insulation shell 9
5. Starting the pump 10
5.1 Vent the piping system 10
5.2 Speed selection 10
6. Troubleshooting 11
6.1 Fault finding chart 11
6.2 Preliminary checks 12
6.3 Current measurement 12
6.4 Insulation resistance
(lead-to-ground) 12
6.5 Winding resistance (line-to-line) 13
6.6 Resistance charts 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. Additional technical data 15
9. Disposal 15

5
(QJOLVK86
3. Pre-installation checklist
3.1 Confirm you have the correct pump
• Read the pump nameplate to ensure 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?
3.1.1 Pump to system type
recommendations
•Open systems (i.e. potable water):
Stainless steel or bronze volute (pump
housing) only.
•Closed systems (i.e. airless, non-potable
water): Cast iron, stainless steel, or bronze
volute (pump housing).
Other considerations regarding Grundfos Small
UP and UPS pumps:
• These pumps are intended for indoor use
only.
• If installed outdoors the pump must be
protected by an appropriate, well ventilated,
water-tight enclosure to keep out moisture
and dirt.
• Minimum ambient temperatures must be no
lower than 33 °F (1 °C).
• For ambient and fluid temperature see
sections 3.4 Pumped liquid requirements
and 7. Additional technical data.
3.2 Check the condition of the pump
The pump’s shipping carton is specially
designed around the 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. Once the pump has
been removed from the box, care should be
taken NOT to drop or mishandle the pump.
Box contents:
• one pump
• two gaskets (flanged units only)
• one Installation and Operation Instruction
(I&O).
3.3 Verify electrical requirements
Verify the electrical supply 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.
This pump’s motor is designed to run on
+ / - 10 % of the nameplate-rated voltage.
3.4 Pumped liquid requirements
The pump can be used to circulate:
• Potable hot water.
• Water containing glycol for hydronic heating
(see section 7. Additional technical data for
additional limitations).
• Cooling water.
In domestic hot-water systems it is advisable to
use stainless steel pump housing versions of
this pump.
All pump types (stainless, bronze or cast iron
pump housing) should not be used in water with
a degree of hardness lower than 14 grains per
gallon of hardness.
Fluids should be clean and should not contain
solid particles, fibers, or mineral oils.
If the pump is installed in a heating system, the
water should meet the requirements of accepted
standards on water quality in heating systems.
The fluid should not contain solid particles,
fibers, or mineral oils.
Warning!
A faulty motor or wiring can cause
electrical 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 the
National Electrical Code. All
wiring must comply with the
National Electrical Code, state,
and local regulations.
Warning!
The Grundfos Small UP/UPS
pump is intended for use with
water only. The pump must not be
used for the transfer of
flammable liquids such as
diesel oil, gasoline, and similar
liquids.
The pump is not for pool or
marine use.

6
(QJOLVK86
The pump is lubricated and cooled by the
liquid being pumped. 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 meet the temperature
requirements listed in the following charts.
Note: Fluid must never be allowed to freeze
during non-operational periods.
4. Installation procedures
4.1 Piping considerations
When making piping connections, be sure
to follow the piping manufacturer’s
recommendations and all code requirements for
piping material.
Thoroughly clean and flush all dirt and
sediment from the system before attempting to
install the pump.
4.1.1 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).
When installing the pump into the piping
system, Grundfos recommends that pressure
gauges be installed in the inlet and discharge
flanges or pipes. This will allow the pump and
system performance to be checked.
Do not block the pipe plugs in the pump
housing flanges by locating the terminal box
over these plugs.
Open systems
(domestic, potable hot water):
Fluid Ambient
Min. 36 °F (2 °C) 33 °F (1 °C)
Max. < 149 °F (65 °C) 100 °F (38°C)
&DXWLRQ
Caution!
In domestic hot-water systems,
it is recommended to keep the
liquid temperature below 149 °F
(65 °C) to eliminate the risk of lime
precipitation.
Closed systems
(non-potable heating or cooling airless fluid):
Pump
models Fluid Ambient
Min. All 36 °F
(2 °C) 33 °F (1 °C)
Max.
UPS 26-150 230 °F
(110 °C) 100 °F (38°C)
UPS 43-100 230 °F
(110 °C) 100 °F (38°C)
UPS 50-60 212 °F
(100 °C) 100 °F (38°C)
Water and glycol mix:
Max. 50 % glycol @ 15 °F (-9.5 °C) fluid
(Hydraulic performance change can be expected.)
Warning!
Never make any connections in the
pump terminal box unless the
electrical supply has been
switched off.
The pump should not be
connected to the electrical
system until it has been properly
installed in the piping system.
Risk of electrical shock — this
pump has not been investigated
for use in swimming pool or
marine areas.
Warning!
The pump must be positioned
so that someone cannot
accidentally come into contact with
the hot surfaces of the pump.
&DXWLRQ

7
(QJOLVK86
4.1.2 Mounting positions
The arrows on the pump housing indicate the
direction of water flow. The pump may be
installed in vertical or horizontal piping, but the
motor shaft must always remain
horizontal, as shown in fig. 1.
Fig. 1 Installation positions
4.1.3 Terminal box position
At the bottom of the stator, closest to the pump
housing, there are three drain holes to allow
condensed water to escape. The drain holes
shall not be blocked for any reason and one
drain hole must always point downward.
There is not a drain hole directly below the
terminal box; therefore the terminal box must be
positioned in one of the positions shown in fig. 1
or fig. 2.
4.2 Changing the terminal box
position
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
and the pressure released/relieved by removing
the vent plug.
Only after the pressure has been relieved and
the pump drained should you proceed with the
next steps.
4.2.1 Rotating the terminal box
To change the position of the terminal box,
follow these steps:
1. Remove the four (5 mm) allen-head screws
holding the pump head onto the pump
housing.
2. Carefully lift/slide the pump head out and
away from the pump housing. Next rotate the
pump head and locate the terminal box in the
desired position. The terminal box can be
rotated in steps of 90 °. Review
fig. 1 and fig. 2 for possible/permissible
positions. DO NOT locate the terminal box
beneath the pump.
3. Make sure the O-ring is properly seated in
the pump housing.
4. Replace the pump head onto the pump
housing.
5. Diagonally tighten the 5mm allen-head
screws evenly.
Torque to: 7 ft lbs. / 9.5 Nm.
6. Check to ensure 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 through 5 above.
If the rotor spins freely, proceed to step 7. Do
not put the vent plug back into the pump until
the end of step 9.
7. 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.
8. Follow electrical instructions in section 3.3.
9. Refill the system, open the isolation valves
and vent the system. Also allow air to vent
out of the pump; once water flows out the
vent hole, replace the vent plug removed in
step 6. See additional instructions in
section 4.1.
10.Fig. 2 shows acceptable terminal box
positions along with recommended drip
loops (dashed lines) in the electrical wiring
harness based on entry point.
TM04 5646 3609
Warning!
Before starting any work on this
circulator, be sure electrical
supply has been switched off
and it cannot be accidentally
switched on.
&DXWLRQ
Caution!
Exercise caution when draining
the system or removing the vent
plug as the fluid in the system may
be scalding hot and under
pressure.
&&DXWLRQ
Caution!
Use caution as the rotor
assembly can fall out of the pump
head or pump housing if the pump
head is pulled too far away from
the pump housing.

8
(QJOLVK86
Fig. 2 Acceptable terminal box positions
4.3 Electrical connection
Proper operating voltage and other electrical
information can be found on the pump
nameplate attached to the top of the motor.
• The motor is thermally protected on all three
speeds and no additional external
protection is needed.
• See fig. 3 for proper grounding and supply
power connection locations (115V and
208-230V).
• The terminal connections are toggle/lever
push design. Push the lever down and insert
the field wiring. Push the lever down and pull
to remove wires.
• Next, use care when installing the terminal
box cover with speed switch (rough
handling can damage the run light LED on
the printed circuit board (PCB)). Insert the
Phillips head screw through the cover and
tighten to a snug fit.
• An external "Drip Loop" is recommended in
the electrical wiring harness; see fig. 2.
• Where an external "Drip Loop" is not
possible, or if the wiring enters through the
upward facing (top) surface of the box, then
an internal "Drip Loop" is recommended; see
fig. 3.
Fig. 3 Examples of ground and power
supply connections (115V and
108-230 V) with internal drip loop
TM04 5636 3609
Warning!
Risk of electrical shock!
The electrical connection and
protection should be carried out in
accordance with the latest edition
of the National Electrical Code,
local codes and regulations by a
qualified electrician.
The safe operation of this pump
requires that it be grounded in
accordance with the National
Electrical Code and any state, local
governing codes and
regulations.
Ground wires should be copper
conductors of at least the size of
the circuit conductor supplying
power to the pump. Connect the
ground wire to the grounding point
in the terminal box and then to an
acceptable ground. Do not ground
to gas or water supply line.
All wire sizes should be copper and
size-based on the ampacity
(current carrying properties of a
conductor) as required by the
National Electrical Code or local
regulations. Additionally UL
requires the following wire sizes to
be used: 18-12 Solid or 14-12
Stranded.
Both the power and grounding
wires must be suitable for at least
194 °F (90 °C).
Terminal box
position A
Terminal box
position B
Terminal box
position C
TM04 5634 3609
CAPACITOR
Black
White
Green
SPEED SWITCH
CAPACITOR
Black
White
Green

9
(QJOLVK86
4.4 Insulation shell
For pumps with provided insulation shell, the
following procedures are required to insure safe
and proper installation.
1. Pump and mating piping flange bolts need to
be installed towards the pump as illustrated
in fig. 4.
2. Apply water proof, heat resistant, silicon
based sealant to insulation shell. Care
should be taken to not block weep slots for
pump motor when applying sealant. Failure
to follow proper sealant location procedures
could damage motor and insulation shell.
See fig. 5 for proper locations when applying
sealant.
3. Mate the two insulation shells over the pump
volute as illustrated in fig. 6. If the shells do
not mate; flange bolts are installed in the
wrong direction, review step one and or
switch mating shell location.
4. Proper amount of time should be allowed for
sealant to set-up before any additional
installation work is performed. See sealant
manufactures recommended time for sealant
set-up. See fig. 7 for final configuration.
Fig. 4 Connect pump to piping, installing
flange bolts toward the pump
Fig. 5 Applying silicon sealant (dotted
areas indicate sealant)
Fig. 6 Insulation shell installation (dotted
areas indicate sealant)
Fig. 7 Ready for insulation wrap
TM05 1888 3811
Insert flange bolts
toward pump
Insert flange bolts
toward pump
TM05 1889 3811TM05 1890 3811TM05 1891 3811
Do not block
weep slots
Do not block
weep slots

10
(QJOLVK86
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.
NOTE: Do not vent the piping system through
the pump. 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 any isolation valves are used, make sure
they are OPEN.
3. Vent the pump by removing the vent plug.
When water exists through the port, the
pump is fully vented / primed.
4. Reinstall the vent plug.
Fig. 8 Vent screw/plug removal for pump
venting
5.2 Speed selection
UPS models
Speeds can be changed via the speed switch on
the terminal box cover. Power must be turned off
before changing speeds. The speed in the three
positions appears in the following table; also see
fig. 10.
UP models
Speed is fixed on Speed 3 (High) and cover
does not have a switch (cover is solid).
Fig. 9 Terminal box cover/lid with speed
switch in medium speed (Speed 2)
Changing to lower speeds offers considerable
reduction in energy consumption and less noise
in the system.
Fig. 10 Pump performance at speed
settings
&DXWLRQ
Caution!
Never operate the pump dry — the
system must first be filled with
liquid and vented.
Warning!
If the vent screw/plug 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.
TM04 5644 3609
Inspection screw/
vent plug
TM04 5641 3609
Switch position Speed in % of max. speed
Low (Speed 1) approx. 60 %
Medium (Speed 2) approx. 80 %
High (Speed 3) 100%
TM04 5640 3609
Low
HHH
Medium High
QQ Q
H = Head and Q = Flow

11
(QJOLVK86
6. Troubleshooting
6.1 Fault finding chart
Warning!
Before removing the terminal box cover, make sure that the electrical 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. None of the
indicator lights are
on.
a) External circuit breaker
is switched off. Switch the circuit breaker on.
b) Current-/voltage-
operated ground fault
interrupter has tripped.
Repair the insulation defects and reset
the interrupter.
2. The pump does not
run. The green
indicator light is on.
a) Rotor is blocked. Switch off the electrical supply and clean
/repair the pump.
b) The speed switch is not
fully positioned (is
between speeds)
Switch off the electrical supply at the
external circuit breaker and change speed
switch into position.
c) The pump has been cut
out by the thermal
overload switch due to
high liquid temperature.
Check that the liquid temperature falls
within the specified range. The pump will
restart automatically when it has cooled to
normal temperature.
3. Noise in the system.
The green indicator
light is on.
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.
4. Noise in the pump.
The green indicator
light is on.
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).
5. The pump runs, but
the indicator light is
off.
a) The LED diode was
damaged when
installing the terminal
box cover or is burned
out.
Switch off the power and change the
printed circuit board or replace the
complete terminal box.
6. Insufficient heat in
some places in the
heating system.
a) The pump performance
is too low. Increase the pump performance, if possible. Flow too fast through the
boiler/heat exchanger may not allow for
the proper BTU transfer to the fluid. If fluid
is too slow, fluid may be cooling too much
before returning from the system. If
changing speeds does not resolve the
problem, replacing the pump with a
properly sized pump may be required.
b) The performance is too
high.