Grundfos UP15-42F Owner's manual

Grundfos Variable Speed
Installation and Operation
1 .
2 .
3 .
4 .
5 .
6 .
7 .
Electrical
Pump
Installation
Operational
Limits
General
Features
Shipment
Inspection
Settings
Quick
Reference
GRUNDFOS INSTRUCTIONS
Pumps Incorporating the
(VS) Variable Speed Control
with Date Code 0838 or higher

Page 1
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: 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.
Grundfos Variable Speed 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.

Page 2
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 Variable Speed Pump Package Includes:
• One Grundfos UP15-42 or UP26 Variable Speed
pump with integral control.
• One 6’ line cord with 115V plug, pre-wired into
control box.
• Two flange gaskets
• Installation and Operating Instructions.
2. General Features
• All minimum and maximum settings are operating,
not safety limits. Necessary auxiliary equipment
and safety devices must be added.
• Offset dial provides fine tuning for input signal.
• Manual % dial provides manual speed control.
• Range of signal is selected through Dip Switch A
• Type of signal used is selected through Dip
Switch B
• Minimum speed at 0 or 15% is selected through
Dip Switch C
• Speed control from external signal or manual %
dial is selected through Dip Switch D.
• Pump Exercising: After every three days of no
operation, the control will exercise the pump for
10 seconds. The % Out LED will be on during
exercising
• As variable speed output modulates, the control
flashes the % out LED ON for ¼ second and OFF
for ¼ to 2 1/2 seconds
• The % output is run at 100% for 3 seconds after
power up reset for all modes of operation

Page 3
3. Operational Limits
Control Signal Input Range Options:
Voltage signal range: 0-10V(DC) or 2-10V(DC)
Current signal range: 0-20mA or 4-20mA
Grundfos Variable Speed pumps are designed to pump
liquids compatible with their cast iron pump housing
construction. They are recommended for use in closed
hydronic systems. Grundfos Variable Speed pumps
are for Indoor Use Only.
Grundfos Variable Speed Pumps are intended for use
with water, or a 50/50 mixture by weight of propylene
glycol.
UP15-42F/VS 115V 60 Hz:
Maximum Fluid Temperature: 205°F (96°C)
Maximum Ambient:
• 107°F (42°C) with control module vertical
(Fig. 1).
• 105°F (41°C) with control module on top of
pump and horizontal (Fig 1).
Maximum Working Pressure: 145 PSI
Minimum Inlet Pressure: 5 PSI
UP26-96F/VS 115V 60HZ:
UP26-64F/VS 115V 60HZ:
Maximum Fluid Temperature: 195°F (90°C)
Maximum Ambient:
• 105°F (40°C) with control module vertical
(Fig. 1).
• 92°F (33°C) with control module on top of
pump and horizontal (Fig. 1).
Maximum Working Pressure: 145 PSI
Minimum Inlet Pressure: 5 PSI

Page 4
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.
Arrows on the side or bottom of the pump chamber
indicate direction of flow through the pump.
Page 6
Recommended
Optional
DO NOT
Mount Motor Shaft
in Vertical Position
Figure 1
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
For Indoor Use Only
Preferred Pump & Terminal Box Orientation:
4. Pump Installation

Page 5
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. 1).
• Ensure that water does not enter the terminal box
during the installation process.
• DO NOT START THE 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 immediate
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.
5. Electrical
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 5-7mm of conductor before placement into
control box terminal strip.

Page 6
Ret / I
Com(-)
Os / V
Ret / I
Com(-)
Os / V
Figure 3 - Current
connections to the
(Com(-) & Ret/I)
control
Figure 4 - Voltage
connections to the
(Com(-) & Os/V)
control
Voltage Speed Control Signal Connections:
Connect the voltage signal wires to terminals
“Com(-)” and “Os/V” (Fig 4.).
Electrical Connections To The Control:
CAUTION: The installer should confirm
that no current/voltage is present at any
of the wires.
Current Speed Control Signal Connections:
Connect the current signal wires to terminals
“Com(-)” and “Ret/I” (Fig 3.).
Test the Speed Control Signal Wiring.
Make sure exposed wires and bare terminals are
not in contact with other wires or grounded
surfaces. Turn on the control signal and measure
the voltage/mA across the leads using a voltmeter
to confirm the pump signal is present.
Note: Control signal wires must be run through and
secured by the stain relief on the terminal board.
Note: No speed control signal is necessary if speed
is to be regulated using the manual % dial.

Page 7
Page 7
Setting Dip Switches
Figure 7A -
Dip Switches
�
Dip switch settings
POSITION
Feature Explanation
Dip switch C - minimum speed off/minimum speed
15%. When dip switch C is in the ON position the
variable speed of the pump will have a range from
minimum speed = off to maximum speed = 100%.
When dip switch C is in the OFF position the variable
speed of the pump will have a range from minimum
speed = 15% to a maximum speed = 100%.
Dip switch D - speed control external/speed control
maximum % dial. When dip switch D is in the ON
position an external V(dc)/mA signal will cause the
pump speed to vary and the dial on the terminal box
will function in the -5% to +5% mode. When dip switch
D is in the OFF position turning the manual % dial will
vary the pump speed. The pump will not respond to an
external V(dc)/mA signal even if one is present. The
terminal box and the dial will function in the minimum
to 100% mode.
7. Settings
ON OFF DEFAULT
SWITCH
mA (V) DC mA
0-10V
0-20mA
2-10V
4-20mA
min speed
15%
min speed
off
speed control
external
2-10V
4-20mA
min speed
off
speed control
manual % dial
speed control
external
A
B
C
D
6. Settings
Setting Dip Switches:
Figure 5 -
Dip Switches
Dip Switch Settings:
Feature Explanation
Dip Switch C - minimum speed off/minimum speed
15%. When dip switch C is in the ON position the
variable speed of the pump will have a range from
minimum speed = off to maximum speed = 100%.
When dip switch C is in the OFF position the variable
speed of the pump will have a range from minimum
speed = 15% to a maximum speed = 100%.
Dip Switch D - speed control external/speed control
maximum % dial. When dip switch D is in the ON
position an external V(dc)/mA signal will cause the
pump speed to vary and the dial on the terminal box
will function in the -5% to +5% mode. When dip switch
D is in the OFF position turning the manual % dial will
vary the pump speed. The pump will not respond to an
external V(dc)/mA signal even if one is present. The
terminal box and the dial will function in the minimum
to 100% mode.
Page 7
Setting Dip Switches
Figure 7A -
Dip Switches
�
Dip switch settings
POSITION
Feature Explanation
Dip switch C - minimum speed off/minimum speed
15%. When dip switch C is in the ON position the
variable speed of the pump will have a range from
minimum speed = off to maximum speed = 100%.
When dip switch C is in the OFF position the variable
speed of the pump will have a range from minimum
speed = 15% to a maximum speed = 100%.
Dip switch D - speed control external/speed control
maximum % dial. When dip switch D is in the ON
position an external V(dc)/mA signal will cause the
pump speed to vary and the dial on the terminal box
will function in the -5% to +5% mode. When dip switch
D is in the OFF position turning the manual % dial will
vary the pump speed. The pump will not respond to an
external V(dc)/mA signal even if one is present. The
terminal box and the dial will function in the minimum
to 100% mode.
7. Settings
ON OFF DEFAULT
SWITCH
mA (V) DC mA
0-10V
0-20mA
2-10V
4-20mA
min speed
15%
min speed
off
speed control
external
2-10V
4-20mA
min speed
off
speed control
manual % dial
speed control
external
A
B
C
D

Page 8
Multi Function Dial On Terminal Box
Offset Dial (When dip switch D is on)
The Offset dial allows the user to fine tune the input
signal. The input signal may be varied plus or minus 1-
5%. This offset will affect the signal through it's entire
range. The factory default is 0. The offset setting
cannot increase the output to greater than 100% or less
than the selected minimum output of either 0% or 15%.
Example:
The measured input signal is 2.1-10.1V and as a result
the pump does not shut off because the signal doesn't
drop to 2V. The dial is set to -5%
and the input signal is offset
down to 2.0-9.6V. The pump
will now shut off, however the
pump will not reach the full 10V
speed now, due to the offset.
Manual % Dial (When dip switch D is off)
The manual % dial allows the speed of the pump to be
manually adjusted and set by the user. The speed of
the pump may be manually adjusted anywhere from
min to 100%, but once set remains fixed at that speed.
The "min" position on the dial will either be equal to
"OFF" or "15%" depending on the position of dip switch
C. The factory default is 50%.
Performance Indicator LEDs (Fig. 7c)
Power ON (green) indicates power is applied.
% Out (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.
Page 8
Figure 7C - Performance
indicator LEDs
Figure 7B - % Offset
Offset /
Manual %
-5%
0
-1
-2
-3
-4
+1
+2
+3
+4
+5%
Min 100%
Multi Function Dial On Terminal Box:
Offset Dial (When dip switch D is ON)
The Offset dial allows the user to fine tune the input
signal. The input signal may be varied plus or minus 1-
5%. This offset will affect the signal through it’s entire
range. The factory default is 0. The offset setting
cannot increase the output to greater than 100% or less
than the selected minimum output of either 0% or 15%.
Example:
The measured input signal is 2.1-10.1V and as a result
the pump does not shut off because the signal doesn’t
drop to 2V. The dial is set to -5%
and the input signal is offset
down to 2.0-9.6V. The pump
will now shut off, however the
pump will not reach the full 10V
speed now, due to the offset.
Figure 6 - % Offset
Manual % Dial (When dip switch D is OFF)
The manual % dial allows the speed of the pump to be
manually adjusted and set by the user. The speed of
the pump may be manually adjusted anywhere from
min to 100%, but once set remains fixed at that speed.
The “min” position on the dial will either be equal to
“OFF” or “15%” depending on the position of dip switch
C. The factory default is 50%.
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. 7)
Power ON (green) indicates power is applied.
% Out (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.
Figure 7 - Performance
indicator LEDs
Multi Function Dial On Terminal Box
Offset Dial (When dip switch D is on)
The Offset dial allows the user to fine tune the input
signal. The input signal may be varied plus or minus 1-
5%. This offset will affect the signal through it's entire
range. The factory default is 0. The offset setting
cannot increase the output to greater than 100% or less
than the selected minimum output of either 0% or 15%.
Example:
The measured input signal is 2.1-10.1V and as a result
the pump does not shut off because the signal doesn't
drop to 2V. The dial is set to -5%
and the input signal is offset
down to 2.0-9.6V. The pump
will now shut off, however the
pump will not reach the full 10V
speed now, due to the offset.
Manual % Dial (When dip switch D is off)
The manual % dial allows the speed of the pump to be
manually adjusted and set by the user. The speed of
the pump may be manually adjusted anywhere from
min to 100%, but once set remains fixed at that speed.
The "min" position on the dial will either be equal to
"OFF" or "15%" depending on the position of dip switch
C. The factory default is 50%.
Performance Indicator LEDs (Fig. 7c)
Power ON (green) indicates power is applied.
% Out (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.
Page 8
Figure 7C - Performance
indicator LEDs
Figure 7B - % Offset
Offset /
Manual %
-5%
0
-1
-2
-3
-4
+1
+2
+3
+4
+5%
Min 100%

Page 9
Page 7
Setting Dip Switches
Figure 7A -
Dip Switches
�
Dip switch settings
POSITION
Feature Explanation
Dip switch C - minimum speed off/minimum speed
15%. When dip switch C is in the ON position the
variable speed of the pump will have a range from
minimum speed = off to maximum speed = 100%.
When dip switch C is in the OFF position the variable
speed of the pump will have a range from minimum
speed = 15% to a maximum speed = 100%.
Dip switch D - speed control external/speed control
maximum % dial. When dip switch D is in the ON
position an external V(dc)/mA signal will cause the
pump speed to vary and the dial on the terminal box
will function in the -5% to +5% mode. When dip switch
D is in the OFF position turning the manual % dial will
vary the pump speed. The pump will not respond to an
external V(dc)/mA signal even if one is present. The
terminal box and the dial will function in the minimum
to 100% mode.
7. Settings
ON OFF DEFAULT
SWITCH
mA (V) DC mA
0-10V
0-20mA
2-10V
4-20mA
min speed
15%
min speed
off
speed control
external
2-10V
4-20mA
min speed
off
speed control
manual % dial
speed control
external
A
B
C
D
7.Quick Reference
Page 7
Setting Dip Switches
Figure 7A -
Dip Switches
�
Dip switch settings
POSITION
Feature Explanation
Dip switch C - minimum speed off/minimum speed
15%. When dip switch C is in the ON position the
variable speed of the pump will have a range from
minimum speed = off to maximum speed = 100%.
When dip switch C is in the OFF position the variable
speed of the pump will have a range from minimum
speed = 15% to a maximum speed = 100%.
Dip switch D - speed control external/speed control
maximum % dial. When dip switch D is in the ON
position an external V(dc)/mA signal will cause the
pump speed to vary and the dial on the terminal box
will function in the -5% to +5% mode. When dip switch
D is in the OFF position turning the manual % dial will
vary the pump speed. The pump will not respond to an
external V(dc)/mA signal even if one is present. The
terminal box and the dial will function in the minimum
to 100% mode.
7. Settings
ON OFF DEFAULT
SWITCH
mA (V) DC mA
0-10V
0-20mA
2-10V
4-20mA
min speed
15%
min speed
off
speed control
external
2-10V
4-20mA
min speed
off
speed control
manual % dial
speed control
external
A
B
C
D
Voltage Speed Control Signal Circuit Rating:
Terminals : Com(-) & Os/V
0-10VDC
5mA Max
Current Speed Control Signal Circuit Rating:
Terminals : Com(-) & Ret/I
0-20mA DC
5VDC Max
Dip Switches

Page 10
Power: 120 ±10% 50/60 Hz 240 VA
Demand: 20-30 V (ac) 0.1 VA
Var. Speed: 120 V (ac) 1.8 A 1/12 hp
Relay: 30 V (ac), 2.5 A pilot duty
Grundfos GVSPD PCB layout
Part Nº: 1008-02 Version: 4
The information and drawings contained herein are the sole
property of tekmar Control Systems Ltd. and shall not be
disclosed to 3rd parties without express written consent of tekmar.
tekmar Control Systems Ltd.
Checked by: SS
Scale: Full size
Date: Jan. 17, 2007
Notes:
• Printing on PCB is white.
• Label affixed to transformer top showing tekmar no. (1008-02), Grundfos part no.
(599395), Date code, and Lot no.
MOV
100µ
0.1µF R
Signal wires must be min. 300V rating
Sup
Com
Ret / I
Com(-)
Os / V
Boil
Boil
Dem
Dem
tN4
Fuse
Transformer 1 VA
115 V : 18 V
100 ȝH 6 A inductor
Pot
0.1 ȝF
250V
R
Class 2
only
Off
On
A B C D
1008-02 599395
May 2006 12345
Made in Canada
Meets Class B: Canadian ICES Fcc Part 15
Use copper conductors only
Changes V3 to V4:
1. Adjusted relay rating to show new relay
rating of 2.5 A pilot duty
Grundfos Variable Speed Control Board

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 operation 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 sup-porting installation data. Unless otherwise
provided, the distributor or dealer will contact the GRUNDFOS factory
or authorized service station for instructions. Any defective product
to be returned to the factory or service station must be sent freight
prepaid; documentation supporting the warranty claim and/or a Return
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
limitations 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.
Grundfos Pumps Corporation
17100 W. 118th Terrace
Olathe, Kansas 66061
Telephone: [phone]
Fax: [phone]
Grundfos Canada, Inc.
2941 Brighton Rd.
Oakville, Ontario L6H 6C9
Telephone: [phone]
Fax: [phone]
Bombas Grundfos de Mexico, S.A. de C.V.
Boulevard TLC #15,
Parque Industrial Stiva Aeropuerto
C.P. 66600 Apodaca, N.L. Mexico
Telephone: [phone]
Fax: [phone]
L-UP-TL-042 9/08
PRINTED IN USA