Grundfos VersaFlo UPS User manual

VersaFlo®UPS
GRUNDFOS INSTRUCTIONS
Installation and operating instructions

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 morethan 30 monthsfrom
date of manufacture. Grundfos' liability under this warranty shall be limited to repair-
ing 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 manu-
facturer 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 sup-
porting the warranty claim and/or a Return Material Authorization must be included
if so instructed.
GRUNDFOS WILL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUEN-
TIAL DAMAGES, LOSSES, OR EXPENSES ARISING FROM INSTALLATION,
USE, OR ANY OTHER CAUSES. THERE ARE NO EXPRESS OR IMPLIED WAR-
RANTIES, 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 conse-
quential 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

3
VersaFlo®UPS
Installation and operating instructions 4
Notice d’installation et d’entretien 20

4
CONTENTS Page
1. Safety warning 4
1.1 Read this booklet 4
1.2 Electrical work 4
2. Pre-installation checklist 4
2.1 Confirm you have the correct pump 4
2.2 Check the condition of the pump 4
2.3 Verify electrical requirements 4
2.4 Pumped liquid requirements 5
3. Installation procedures 5
3.1 Electrical preparation 5
3.2 Piping considerations 6
3.3 Connect the pump 6
3.4 Electrical connection 6
4. Starting the pump 8
4.1 Vent the piping system 8
4.2 Check the direction of shaft rotation 9
4.3 Speed selection 9
5. Troubleshooting 11
5.1 Fault finding chart 11
5.2 Preliminary checks 12
5.3 Current measurement 13
5.4 Insulation resistance (lead-to-ground) 13
5.5 Winding resistance (line-to-line) 14
5.6 Winding resistance chart 16
6. Replacing components 18
6.1 Removing the pump head 18
6.2 Fitting the pump head 18
6.3 Replacing the terminal box or capacitor 19
7. Disposal 19
1. Safety warning
1.1 Read this booklet
This booklet is designed to help a certified installer
install, begin operation of and troubleshoot the
Grundfos VersaFlo UPS pumps. The booklet should
be left with the owner of the pump for future refer-
ence and information regarding its operation. Should
the owner experience any problems with the pump,
a certified professional should be contacted.
1.2 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 regula-
tions.
2. Pre-installation checklist
2.1 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 per-
formance 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?
2.2 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.
2.3 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!
A faulty motor or wiring can cause electri-
cal shock that could be fatal, whether
touched directly or conducted through
standing water. For this reason, proper
grounding of the pump to the power sup-
ply'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.

5
2.4 Pumped liquid requirements
CAUTION: The VersaFlo 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 (VersaFlo 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
VersaFlo 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 pre-
mature wear to the bearings and excessive motor
heat. The pumped liquid must also meet the follow-
ing requirements:
Minimum pump 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).
3. Installation procedures
3.1 Electrical preparation
Terminal box position
At the bottom of the stator, closest to the pump hous-
ing, 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.
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
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 sys-
tem, 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 pres-
sure.
Do not start the pump until the system has
been filled with liquid and vented.

6
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 18 and 19 for additional instruc-
tions.
3.2 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 VersaFlo UPS
may be installed in either vertical or horizontal pip-
ing, the motor shaft must always remain horizontal,
as shown in figures 1 and 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.
3.3 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.
3.4 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 regula-
tions 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 ter-
minals 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 con-
sumption 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 name-
plate.
Figures 4, 6, 7, 9, and 10 on the next pages show the
possible connections.
TM03 7290 4706
WARNING!
The pump must be positioned so that
someone cannot accidentally come into
contact with the hot surfaces of the pump.
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 exter-
nal main power switch.

7
3.4.1 VersaFlo UPS 1 x 115 V and 1 x 230 V
terminal box
Fig. 3 VersaFlo UPS 1 x 115 V and 1 x 230 V
terminal box
All VersaFlo 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.
3.4.2 VersaFlo UPS 3 x 208-230 V terminal box
Fig. 5 VersaFlo UPS 3 x 208-230 V terminal box
All VersaFlo 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 con-
tacts) for start/stop push button station.
Fig. 7 External impulse contacts
TM03 7744 4806TM03 7743 4806
Protection
module
Speed
switch
L1 L2
1 x 115 V supply
1 x 230 V supply
TM03 7742 4806TM03 7892 5106TM03 7740 4806
Standard
module
Speed
switch
K
K
Stop/Start
L1L2L3T2T1
L1L2L3
K
K
K
Stop
Start
L1L2L3T2T1
L1L2L3

8
3.4.3 VersaFlo UPS 3 x 460 V and 575 V
terminal box
Fig. 8 VersaFlo UPS 3 x 460 V and 575 V
terminal box
All VersaFlo 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 page 10.
All pumps are equipped with an internal thermal
overload switch (terminals P1 and P2) to be con-
nected 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.
Figure 10 shows the electrical connections when
using external impulse contacts (momentary con-
tacts) for start/stop push button station.
Fig. 10 External impulse contacts
4. Starting the pump
4.1 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.
TM03 7739 4806TM03 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
TM03 7737 4806
WARNING!
If the vent screw is to be loosened, care
should be taken to ensure that the escap-
ing 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

9
4.2 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, pages
11 and 12).
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, discon-
nect the power and interchange any two power
leads in the terminal box.
6. Check once again for proper counterclockwise
rotation. When it is rotating correctly, replace the
vent plug.
Fig. 11 Vent plug and direction of rotation
Fig. 12 Removing the vent plug
4.3 Speed selection
4.3.1 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 reduc-
tion in energy consumption and less noise in the sys-
tem.
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
TM03 7750 4806TM03 7277 4706
Vent plug Directionof
rotation
Inspection screw
Inspection screw/
vent plug
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

10
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 perma-
nently on or flashing.
NOTE: The speed switch module must never be
used as an on/off switch.
4.3.2 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 posi-
tions appears in the table below (also see fig. 13 on
page 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)
Fig. 17 Terminal box
Speed step Speed in % of maximum 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 4806TM03 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
TM03 7739 4806
L1
L2
L3
P1
P2
T6
T4
T5 T1
T2
T3

11
5. Troubleshooting
5.1 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 thermal
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 run-
ning.
The red and green
indicator lights are
on.
a) The pump is running with
the wrong direction of
rotation.
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.

12
5.2 Preliminary checks
Supply voltage
To check the voltage being supplied to the motor,
use a voltmeter.
Fig. 18 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 electri-
cal supply and can cause damage to the motor wind-
ings. 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.
7. Single-phase
pumps with protec-
tion module (only).
The pump does not
run.
The red indicator
light is on.
The green indicator
light is off.
a) 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 automati-
cally when it has cooled to normal temperature.
NOTE: If the thermal overload switch has cut out
the pump three times within a short period, the
pump must be restarted manually by switching
off the electrical supply.
b) The speed switch module
has not been fitted. Switch off the electrical supply by means of the external mains switch and fit the speed switch
module.
Fault Cause Remedy
WARNING!
Be careful, since power is still being sup-
plied to the pump. Do not touch the volt-
meter leads together while they are in con-
tact with the power lines.
Single-phase motors Three-phase motors
Touch one voltmeter
lead to each of the lines
supplying power to the
pump:
• L and N for 115 V
circuits
• L1 and L2 for 230 V
circuits.
Touch a voltmeter lead
to:
• Power leads
L1 and L2
• Power leads
L2 and L3
• Power leads
L3 and L1.
These tests should give
a reading of full line
voltage.
TM03 7749 4806
L 1
L 2

13
5.3 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 informa-
tion on the motor nameplate.
5. Repeat for the other legs.
Evaluation
If the current draw exceeds the listed nameplate
amps, or if the current imbalance is greater than 5%
between each leg on three-phase units, 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 wind-
ing 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. 19 Current measurement
5.4 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 electrical 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. L1 to ground; L2 to ground, etc.).
Fig. 20 Insulation resistance measurement
Evaluation
The resistance values for new motors must exceed
1,000,000 ohms. If they do not, replace the motor.
TM03 7293 4706
TM03 7293 4706

14
5.5 Winding resistance (line-to-line)
To check the winding resistance of the motor wind-
ings, a megohmmeter is required.
To do so, follow these steps:
1. Turn the POWER OFF.
2. Disconnect all electrical 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 charts below 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 (RA, RS1, RS2, R) all
readings.
5. Compare your readings to the matching model,
phase and voltage on the chart on pages 16
and 17.
Evaluation
The resistance values must fall within the tolerances
listed on page 16 or 17. If they do not, replace the
motor.
Internal wiring
UPS
Terminal plug in stator
Single-phase Three-phase 208-230 V
RA: 6-1 or 6-1, 7-2
RS1: 12-8 or 12-8, 14-9
RS2: 4-10 or 4-10, 5-11
R: 5-9 or 5-9, 7-14
R: 11-12 or 11-12, 1-10
R: 4-6 or 4-6, 8-2
RA: Main winding
RS1: Auxiliary winding
RS2: Auxiliary winding

15
Internal wiring
UPS
Terminal plug in stator
Three-phase 460/575 V
1
7
3
9
5
11
13
15

16
5.6 Winding resistance chart
60 Hz
Pump type Voltage
[Ω] 68ºF - 122ºF (20ºC - 50ºC)
RRARS
1RS2
UPS 32-40/4
1 x 115 V 17.8 - 23.2 3.95 - 5.20 9.40 - 12.4
1 x 230 V 70.0 - 91.5 17.0 - 22.2 39.5 - 52.0
3 x 208 - 230 V 180 - 236
3 x 460 V 360 - 470
3 x 575 V 575 - 750
UPS 32-80/2
1 x 115 V 9.55 - 12.6 3.05 - 4.00 6.70 - 8.80
1 x 230 V 19.4 - 25.5 5.45 - 7.10 12.6 - 16.4
3 x 208 - 230 V 44.0 - 57.5
3 x 460 V 83.5 - 110
3 x 575 V 132 - 174
UPS 32-160/2
1 x 115 V 4.15 - 5.45 1.20 - 1.56 2.65 - 3.50
1 x 230 V 8.30 - 10.8 2.20 - 2.90 5.05 - 6.65
3 x 208 - 230 V 26.0 - 34.0
3 x 460 V 53.5 - 70.0
3 x 575 V 84.5 - 110
UPS 40-40/4
1 x 115 V 11.4 - 15.0 2.95 - 3.85 5.60 - 7.35
1 x 230 V 50.5 - 66.5 14.0 - 18.4 25.5 - 34.0
3 x 208 - 230 V 118 - 154
3 x 460 V 234 - 310
3 x 575 V 360 - 475
UPS 40-80/2
1 x 115 V 5.60 - 7.35 1.84 - 2.42 4.50 - 5.90
1 x 230 V 11.0 - 14.4 3.95 - 5.20 8.55 - 11.2
3 x 208 - 230 V 32.0 - 42.0
3 x 460 V 64.0 - 84.0
3 x 575 V 102 - 132
UPS 40-80/4
1 x 115 V 4.15 - 5.45 1.94 - 2.55 3.30 - 4.35
1 x 230 V 8.10 - 10.6 3.05 - 4.00 4.60 - 6.05
3 x 208 - 230 V 46.5 - 61.0
3 x 460 V 90.5 - 118
3 x 575 V 164 - 216
UPS 40-160/2
1 x 115 V 2.85 - 3.75 1.10 - 1.44 1.94 - 2.55
1 x 230 V 5.60 - 7.35 2.02 - 2.66 3.75 - 4.95
3 x 208 - 230 V 22.8 - 30.0
3 x 460 V 45.5 - 59.5
3 x 575 V 72.0 - 95.0
UPS 40-240/2
1 x 230 V 6.80 - 8.95 2.02 - 2.65 3.70 - 4.85
3 x 208 - 230 V 11.0 - 14.4
3 x 460 V 22.0 - 29.0
3 x 575 V 35.0 - 45.5

17
UPS 50-40/4
1 x 115 V 6.55 - 8.55 2.12 - 2.80 4.30 - 5.65
1 x 230 V 25.0 - 33.0 8.30 - 10.8 15.0 - 19.8
3 x 208 - 230 V 57.5 - 75.0
3 x 460 V 114 - 148
3 x 575 V 184 - 242
UPS 50-80/2
1 x 115 V 4.15 - 5.45 1.20 - 1.56 2.65 - 3.50
1 x 230 V 8.30 - 10.80 2.20 - 2.90 5.05 - 6.65
3 x 208 - 230 V 26.0 - 34.0
3 x 460 V 33.5 - 70.0
3 x 575 V 84.5 - 110
UPS 50-80/4
1 x 115 V 2.75 - 3.60 1.74 - 2.30 2.85 - 3.75
1 x 230 V 5.50 - 7.25 2.65 - 3.50 4.95 - 6.50
3 x 208 - 230 V 37.0 - 49.0
3 x 460 V 79.0 - 104
3 x 575 V 120 - 156
UPS 50-160/2
1 x 230 V 6.80 - 8.95 2.02 - 2.65 3.70 - 4.85
3 x 208 - 230 V 12.4 - 16.2
3 x 460 V 24.2 - 31.5
3 x 575 V 37.5 - 49.5
UPS 50-240/2
3 x 208 - 230 V 7.80 - 10.2
3 x 460 V 15.6 - 20.6
3 x 575 V 25.0 - 33.0
UPS 53-55/57
1 x 115 V 4.15 - 5.45 1.20 - 1.56 2.65 - 3.50
1 x 230 V 8.30 - 10.80 2.20 - 2.90 5.05 - 6.65
3 x 208 - 230 V 26.0 - 34.0
3 x 460 V 33.5 - 70.0
3 x 575 V 84.5 - 110
UPS 75-69
1 x 230 V 6.80 - 8.95 2.02 - 2.65 3.70 - 4.85
3 x 208 - 230 V 12.4 - 16.2
3 x 460 V 24.2 - 31.5
3 x 575 V 37.5 - 49.5
UPS 80-40/4
3 x 208 - 230 V 46.5 - 61.0
3 x 460 V 90.5 - 118
3 x 575 V 164 - 216
UPS 80-80/4 3 x 208 - 230 V 23.6 - 31.0
UPS 80 -160/2
3 x 208 - 230 V 7.80 - 10.2
3 x 460 V 15.6 - 20.6
3 x 575 V 25.0 - 33.0
UPS 100-40/4
3 x 208 - 230 V 27.5 - 36.0
3 x 460 V 54.5 - 71.5
3 x 575 V 86.0 - 114
Pump type Voltage
[Ω] 68ºF - 122ºF (20ºC - 50ºC)
RRARS
1RS2

18
6. Replacing components
6.1 Removing the pump head
1. Disconnect or TURN OFF the power supply.
2. Close any isolation valves on either side of the
pump to avoid draining the system of liquid.
3. Disconnect the electrical leads from the terminal
box.
4. Disconnect and remove the conduit from the
terminal box.
5. Loosen and remove the four allen-head screws
(8 or 10 mm) which connect the pump head
housing 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. 21 Removing and fitting the pump head
6.2 Fitting the pump head
1. Carefully remove the new pump head assembly
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 hous-
ing. 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 housing over the
rotor and rotate it so the terminal box is in the
position you wish, see section 3.1 under
"Terminal box position".
6. Make sure the pump head housing is properly
seated on the pump housing.
Do not force the two together - if there is bind-
ing, disassemble them and repeat steps 2 to 6.
Tighten the allen-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 3.1 under "Rotating the
terminal box".
TM03 7292 4706
Pump housing
Thrust bearing
Grooves
O-ring
Pump head housing
Allen-head
screws (4)
Terminal box Impeller/rotor
assembly
Bearing plate

19
6.3 Replacing the terminal box or capacitor
Fig. 22 Terminal box
If the terminal box is replaced, make certain the elec-
trical information listed on the new box matches the
information listed on the old box, and that it is com-
patible with the pump and incoming electrical supply.
For all terminal boxes, it is very important to tightly
secure the frame grounding screw through the termi-
nal box, so that a proper connection between the ter-
minal box and motor is made.
7. 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.
TM03 7742 4806
Frame ground
screw hole
Standard
module
Speed
switch
Electrical information
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.
3. Remove the speed switch (noting its position) by pulling firmly and evenly on both
sides of it. (Not for 460/575 V).
Capacitor
a.4. Capacitor replacement, single-phase pumps only: Disconnect the two connec- tor clips from the capacitor and unscrew the complete plastic strain relief nut.
Remove capacitor wire and strain relief.
a.5. Screw in new complete strain relief nut and connect new clip connectors. 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.4. 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.5. 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
6. Replace the speed switch to its proper position, making sure to push it all the way
in. (Not for 460/575 V).
7. Replace the terminal box cover and tighten all four torx/standard screws.
8. Switch on electrical power supply. The pump is now ready for operation.
Subject to alterations.

20
GARANTIE LIMITÉE
Les produits fabriqués par GRUNDFOS PUMPS CORPORATION (Grundfos) sont
couverts par une garantie à l'utilisateur initial à l'effet qu'ils sont exempts de vices attri-
buables aux matériaux et à la fabrication pour une période de 24 mois après la date
d'installation, mais sans excéder une période de 30 mois après la date de fabrication.
Selon les termes de cette garantie, la responsabilité de Grundfos se limitera à réparer
ou à remplacer sans frais, à la discrétion de Grundfos et FAB de l'usine de Grundfos
ou d'un poste de service autorisé, tout produit provenant de l'usine de Grundfos.
Grundfos ne sera pas responsable des frais d'enlèvement, d'installation, de transport,
ou de tous les autres frais pouvant être encourus dans le cadre d'une demande
d'indemnité concernant la garantie. Les produits vendus, mais qui ne sont pas fabri-
qués par Grundfos, sont couverts par la garantie offerte par les fabricants de ces
produits, et ils ne sont pas couverts par la garantie de Grundfos. Grundfos ne sera pas
responsable de la détérioration des produits ou des produits endommagés dans les
cas suivants : conditions d'utilisation anormales, accidents, abus, mauvais usage,
modification ou réparation non autorisée, ou lorsque le produit n'a pas été installé
conformément aux instructions écrites de Grundfos concernant l'installation et l'exploi-
tation.
Pour obtenir un service selon les termes de cette garantie, vous devez retourner le
produit défectueux au distributeur ou au fournisseur de produits Grundfos qui vous
a vendu le produit, incluant la preuve d'achat et la date d'installation, la date de la
défaillance, et les informations concernant l'installation. Sauf disposition contraire,
le distributeur ou le fournisseur contactera Grundfos ou un poste de service autorisé
pour obtenir les instructions. Tout produit défectueux doit être retourné "fret payé à
l'avance" à Grundfos ou à un poste de service. Les documents décrivant la demande
d'indemnité aux termes de la garantie et/ou une autorisation de retour de marchandise
doivent être inclus si exigé.
GRUNDFOS NE SERA PAS RESPONSABLE DES DOMMAGES INDIRECTS OU
CONSÉCUTIFS, DES PERTES, OU DES FRAIS DÉCOULANT DE L'INSTALLATION,
L'UTILISATION, OU DE TOUTE AUTRE CAUSE. IL N'EXISTE AUCUNE GARANTIE
EXPRESSE OU IMPLICITE, INCLUANT LA QUALITÉ MARCHANDE OU L'ADAPTA-
TION À UNE FIN PARTICULIÈRE, QUI OUTREPASSE LES GARANTIES DÉCRITES
OU RÉFÉRENCÉES CI-DESSUS.
Certaines juridictions ne permettent pas l'exclusion ou la limitation des dommages
indirects ou consécutifs, et certaines juridictions ne permettent pas de limiter la durée
des garanties implicites. Il est donc possible que les limitations ou que les exclusions
mentionnées précédemment ne s'appliquent pas à vous. Cette garantie vous accorde
des droits légaux spécifiques, et vous pouvez également avoir d'autres droits qui
varient d'une juridiction à l'autre.