Grundfos UPS 200 Series User manual

GRUNDFOS INSTRUCTIONS
UPS Series 200
Circulator pumps
Installation and operating instructions

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English (US) 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
18 months from date of installation, but not more
than 24 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 2
2. Introduction 3
2.1 Safety warning 3
3. Pre-installation checklist 3
3.1 Confirm you have the correct pump 3
3.2 Check the condition of the pump 3
3.3 Verify electrical requirements 3
3.4 Pumped liquid requirements 4
4. Installation procedures 5
4.1 Electrical preparation 5
4.2 Piping considerations 5
4.3 Connect the pump 6
4.4 Electrical connection 6
5. Starting the pump 8
5.1 Vent the piping system 8
5.2 Check the direction of shaft rotation 8
5.3 Speed selection 9
6. Troubleshooting 10
6.1 Fault finding chart 10
6.2 Preliminary checks 11
6.3 Current measurement 12
6.4 Insulation resistance
(lead-to-ground) 12
6.5 Winding resistance (line-to-line) 13
6.6 Winding resistance chart 15
7. Replacing components 17
7.1 Removing the pump head 17
7.2 Fitting the pump head 17
7.3 Replacing the terminal box or
capacitor 18
8. Disposal 18
Warning
Prior to installation, read these
installation and operating instruc-
tions. Installation and operation
must comply with local regulations
and accepted codes of good prac-
tice.
This booklet should be left with the
owner of the pump for future refer-
ence and information regarding its
operation.

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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 trouble-
shoot the Grundfos UPS 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.
2.1.2 Electrical work
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 electrical 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 nameplate-rated voltage.
Wiring connection 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
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.
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 Article
250-80 of the National Electrical
Code.

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3.4 Pumped liquid requirements
CAUTION: The UPS pump is intended for use
with water only.
The pump can be used to circulate:
• Potable hot water
• Water for hydronic heating
• Cooling water
• In domestic hot-water systems it is advisable
to use bronze pumps (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 Grundfos 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.
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
also meet the following requirements:
Minimum pump inlet pressure
(during operation)
UPS
model
At these liquid temperatures
167°F/75°C 194°F/90°C 230°F/110°C
[psi] hf [psi] hf [psi] hf
32-40/4 0.7 1.6 2.2 5.1 21.0 48.5
32-80/2 0.7 1.6 5.1 11.8 23.9 55.2
32-160/2 11.6 26.8 16.0 37.0 34.1 78.8
40-40/4 0.7 1.6 4.4 10.2 23.2 53.6
40-80/4 0.7 1.6 1.5 3.5 18.1 41.8
40-80/2 6.5 15.0 10.9 25.2 29.0 67.0
40-160/2 5.1 11.8 9.4 21.7 27.6 63.8
40-240/2 11.6 26.8 16.0 37.0 34.1 78.8
50-40/4 0.7 1.6 2.9 6.7 21.8 50.4
50-80/4 0.7 1.6 4.4 10.2 23.2 53.6
50-80/2 4.4 10.2 8.7 20.1 26.8 61.9
50-160/2 11.6 26.8 16.0 37.0 34.1 78.8
50-240/2 10.2 23.6 14.5 33.5 32.6 75.3
53-55/57 4.4 10.2 8.7 20.1 26.8 61.9
75-69 11.6 26.8 16 37 34.1 78.8
80-40/4 11.6 26.8 16.0 37.0 34.1 78.8
80-80/4 14.5 33.5 18.9 43.7 37.0 85.5
80-160/2 21.8 50.4 26.1 60.3 43.5 100.5
100-40/4 27.6 63.8 31.9 73.7 50.0 115.5

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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
shall 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
Rotating the terminal box
To change the position of the terminal box,
follow these steps:
1. Remove the four allen-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 allen-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 p. 17 and p. 18 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 UPS
may be installed in either vertical or horizontal
piping, the motor shaft must always remain
horizontal, as shown in fig. 1 and fig. 2.
Fig. 2 Direction of water flow through the
pump
NOTE: Pumps installed outdoors must be
protected by a ventilated, watertight cover to
keep out moisture and dirt.
Warning
Never make any connections in the
pump terminal box unless the
electrical supply has been switched
off.
TM03 7296 4706
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 allen-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
Warning
The pump must be positioned so
that someone cannot accidentally
come into contact with the hot
surfaces of the pump.

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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.
4.4 Electrical connection
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 operating voltage and frequency are
marked on the pump nameplate. Make sure that
the motor is suitable for the electrical 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.
Multi-speed pump (single-phase)
All single-phase pumps are equipped with
built-in, automatic resetting, thermal overload
protection. The pump is protected at all three
speeds.
Multi-speed pump (three-phase)
The pump must be connected to the electrical
supply via an external contactor. The contactor
must be connected to the built-in thermal
overload switch terminals T1 and T2 (3 x
208-230 V) or P1 and P2 (3 x 460 V and 575 V)
to protect the pump against overloading at all
three speeds.
OR: If the pump is protected by means of a
motor starter, the starter must be set to the
current consumption of the pump at the selected
speed. The motor starter setting must be
changed every time the pump speed is changed.
The current consumption at the individual
speeds is stated on the pump
nameplate.
Figures 4, 6, 7, 9, and 10 on the next pages
show the possible connections.
4.4.1 UPS 1 x 115 V and 1 x 230 V terminal
box
Fig. 3 UPS 1 x 115 V and 1 x 230 V
terminal box
All UPS single-phase pumps come with a
protection module and a speed switch as shown
in fig. 3. All pumps are equipped with built-in,
automatic resetting, thermal overload protection.
The pump is protected at all three speeds.
Wiring diagrams
Figure 4 shows the electrical connections for
a single-phase pump with protection module.
Fig. 4 1 x 115 V and 1 x 230 V supply
NOTE: Provide electrical disconnect and current
protection as per local electrical codes.
K = External contactor sized to FL and LR pump
current.
Warning
Never make any connections in the
pump terminal box unless the
electrical supply has been switched
off.
The pump must be grounded.
The pump must be connected to an
external main power switch.
TM03 7744 4806TM03 7743 4806
Protection
module
Speed
switch
L1 L2
1 x 115 V supply
1 x 230 V supply

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4.4.2 UPS 3 x 208-230 V terminal box
Fig. 5 UPS 3 x 208-230 V
terminal box
All UPS pumps with three-phase x 208-230 V
come with a standard module and a speed
switch as shown in fig. 5. All pumps are
equipped with an internal thermal overload
switch (terminals T1 and T2, to be connected to
an external contactor) to protect the pump at all
three speeds.
Wiring diagrams
Figure 6 shows the electrical connections when
using an external changeover contact (safety
circuit) for start/stop push button station.
Fig. 6 External changeover contact
Auxiliary contacts rated for supply voltage.
Figure 7 shows the electrical connections when
using external impulse contacts (momentary
contacts) for start/stop push button station.
Fig. 7 External impulse contacts
4.4.3 UPS 3 x 460 V and 575 V terminal box
Fig. 8 UPS 3 x 460 V and 575 V
terminal box
All UPS pumps with three-phase x 460 V and
575 V terminal boxes (fig. 8) come with a special
two-speed terminal box. The speed is changed
by the orientation of the jumpers as shown on
p. 9. All pumps are equipped with an internal
thermal overload switch (terminals P1 and P2)
to be connected to external contactor.
Wiring diagrams
Figure 9 shows the electrical connections when
using an external changeover contact (safety
circuit) for start/stop push button station.
Fig. 9 External changeover contact
Auxiliary contacts rated for supply voltage.
TM03 7742 4806
TM03 7892 5106
TM03 7740 4806
Standard
module
Speed
switch
K
K
Stop/Start
L1L2L3T2T1
L1L2L3
K
K
K
Stop
Start
L1L2L3T2T1
L1L2L3
TM03 7739 4806
TM03 7738 5106
L1
L2
L3
P1
P2
T6
T4
T5 T1
T2
T3
Jumpers
K
K
L3
L2
L1
Start/stop
L3
L1
L2
P1
P2
T3 T2 T1

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Figure 10 shows the electrical connections when
using external impulse contacts (momentary
contacts) for start/stop push button station.
Fig. 10 External impulse contacts
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.
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.
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.
5.2 Check the direction of shaft rotation
Applies to 460 V and 575 V two-speed models
only
(The direction of rotation of three-speed pumps
is checked by means of the fault finding chart,
p. 10 and p. 11).
1. Make sure that the power is OFF.
2. Unscrew and remove the vent plug located
at the center of the nameplate.
3. Insert a small, flat-blade screwdriver into the
slot in the end of the motor shaft (see fig.
12). Rotate the shaft with the screwdriver to
make sure it does so freely.
4. Bump the pump and watch to see which
direction the shaft rotates. The shaft must
rotate in the counterclockwise direction as
shown on the nameplate (see fig. 11).
5. If the pump shaft is rotating incorrectly,
disconnect the power and interchange any
two power leads in the terminal box.
6. Check once again for proper counterclock-
wise rotation. When it is rotating correctly,
replace the vent plug.
Fig. 11 Vent plug and direction of rotation
Fig. 12 Removing the vent plug
TM03 7737 4806
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
(see fig. 12).
L3
L1
L2
K
K
L3
L2
L1
Start K
Stop
P1
P2
T3 T2 T1
TM03 7750 4806
TM03 7277 4706
Vent plug Directionof
rotation
Inspection scre
Inspection
screw/
vent plug

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5.3 Speed selection
5.3.1 Three-speed pumps, all models except
3 x 460 V and 575 V
The speed switch in the terminal box can be
turned to three positions. The speed in the three
positions appears in the table below (also see
fig. 13).
Changing to lower speeds offers considerable
reduction in energy consumption and less noise
in the system.
Fig. 13 Pump performance at speed
settings
Change the pump performance as follows:
1. Switch off the electrical supply to the pump
at the main circuit breaker. The green
indicator light in the terminal box must be off.
2. Remove the terminal box cover by loosening
the four screws in the cover.
3. Pull out the speed switch module and
re-insert it so that the desired speed is
visible through the window in the terminal
box (see fig. 14).
Fig. 14 Speed switch module
NOTE: When changing to and from speed 1, the
cover of the speed switch module must be
removed and fitted on the other side of the
switch.
4. Fit the terminal box cover back onto the
terminal box and tighten the four screws in
the cover.
5. Switch on the electrical supply.
Check that the green indicator light is
permanently on or flashing.
NOTE: The speed switch module must never be
used as an on/off switch.
5.3.2 Two-speed pumps, 3 x 460 V and 575 V
The speed setting in the terminal box can be
changed to two positions. The speed in the two
positions appears in the table below (also see
fig. 13 on p. 9).
Change the pump performance as follows:
The speed is changed by the position of the
jumpers in the terminals. The jumpers are fitted
according to:
• figure 15 for speed 1 - low speed
• figure 16 for speed 2 - high speed.
Fig. 15 Speed 1 (low speed)
Fig. 16 Speed 2 (high speed)
Switch
position
Speed in % of maximum speed
Single-phase
pumps
Three-phase
pumps
1 approx. 60% approx. 70%
2 approx. 80% approx. 85%
3 100% 100%
TM03 7736 4806
Warning
Never make any connections in the
pump terminal box unless the
electrical supply has been switched
off.
TM03 7735 4806
H
Q
12
Q
HH
Q
3
H = head and Q = flow
SPEED
1SPEED 2SPEED 3
Speed step Speed in % of max. speed
1 approx. 75%
2 100%
Warning
Never make any connections in the
pump terminal box unless the
electrical supply has been switched
off.
TM03 7734 4806
TM03 7733 4806
L3
L1
L2
P1
P2 T5 T4 T6
T3 T2 T1
Jumper wire
L3
L1
L2
P1
P2 T5 T4 T6
T3 T2 T1
Jumper wire

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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) 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's internal ther-
mal overload switch has
cut out (standard module
only).
Check that the liquid temperature falls
within the specified range.
With external on/off changeover
contact:
The pump will restart automatically when it
has cooled to normal temperature.
With external on/off impulse contacts:
The pump can be restarted when it has
cooled to normal temperature.
2. The pump does
not run.
The green
indicator light is
on.
a) 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.
b) The speed switch module
has not been fitted. Switch off the electrical supply at the external circuit breaker and fit the speed
switch module into position.
3. Three-phase
pumps only:
The pump is
running.
The red and
green indicator
lights are on.
a) The pump is running with
the wrong direction of rota-
tion.
Switch off the electrical supply at the
external circuit breaker and interchange
any two phases (leads) in the pump
terminal box.
4. 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.
5. 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).
6. 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.