Grundfos ALPHA series User manual

GRUNDFOS INSTRUCTIONS
ALPHA
Variable speed circulators with AutoADAPT™
Installation and operating instructions
3191277

2
English (US)
English (US) Installation and operating instructions
Original installation and operating
instructions.
CONTENTS Page
1. Limited warranty
Products manufactured by GRUNDFOS PUMPS
CORPORATION (Grundfos) are warranted to
the original user only to be free of defects in
material and workmanship for a period of
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.
1. Limited warranty 2
2. Symbols used in this document 3
3. Product introduction 3
3.1 Introduction 3
3.2 Delivery and handling 3
3.3 Applications 3
4. Identification 3
4.1 Nameplate 3
5. Installation 4
5.1 Quick install tips 4
5.2 Mechanical installation 4
5.3 Changing the power head position 5
5.4 Electrical installation 5
6. Operation 6
6.1 Control display 6
6.2 Performance * and operation mode
selection 7
7. Fault finding 8
8. Technical data 9
8.1 Approvals 10
9. Disposal 10
Warning
Prior to installation, read these
installation and operating
instructions. Installation and
operation must comply with local
regulations and accepted codes of
good practice.

3
English (US)
2. Symbols used in this document
The safety instructions are identified by the
following symbols:
3. Product introduction
3.1 Introduction
Grundfos Alpha is suitable for systems with
constant or variable flows where it is desirable to
optimize the setting of the pump duty point.
3.2 Delivery and handling
3.2.1 Shipment inspection
Examine the components carefully to make sure
no damage has occurred to the pump during
shipment. Care should be taken to ensure the
pump is NOT dropped or mishandled.
Check to see that these are included:
• One Grundfos Alpha pump
• One line cord or terminal box
• Two gaskets
• One installation and operating instructions
• One check valve
• One "Check Valve Installed" sticker
3.3 Applications
Grundfos Alpha is designed for pumping clean
water, or up to 50/50 mixtures by weight of
glycol and water.
For glycol usage as well as additional liquid
information see section 8. Technical data.
4. Identification
4.1 Nameplate
Fig. 1 Nameplate
Warning
If these safety instructions are not
observed, it may result in personal
injury.
Caution
If these safety instructions are not
observed, it may result in
malfunction or damage to the
equipment.
Note
Notes or instructions that make the
job easier and ensure safe
operation.
Warning
The pump must not be used for the
transfer of flammable liquids such
as diesel oil, gasoline, and similar
liquids.
Pump not for pool or marine use.
TM04 3419 3511
Pos. Description
1 Product Number
2 Voltage (V):
3Rated current (A): • Min.: Minimum Current (A)
• Max.: Maximum Current (A)
4Input power (W): • Min.: Minimum Power (W)
• Max.: Maximum Power (W)
5 Max. fluid temperature (°F)

4
English (US)
5. Installation
5.1 Quick install tips
1. To insure proper air venting of your system,
place Alpha in Fixed Speed III mode until all
air has been removed. Isolating zones during
this process will ensure proper air removal.
2. For balancing manifold zone(s) applications,
utilizing Constant Pressure mode 1 or 2 and
only one zone at a time during balancing will
ensure proper flow rate to each zone.
3. Always review your boiler minimum flow
rate requirements if utilizing Alpha as a
primary pump. Select one of the fixed
speed modes for boiler primary pump
applications.
4. In general, for maximum energy savings and
comfort level, start with the AUTOADAPT™
mode.
5. You may change hydraulic selection while
pumping. No permanent damage will occur.
In fact, Grundfos encourages testing the
various hydraulic modes with your hydronic
system to ensure maximum energy savings
and comfort level.
6. Zone panel control applications - when there
is a call for heat and power has been sent to
the Alpha pump, the Alpha will remember
and restart from the last duty point and
hydraulic mode.
5.2 Mechanical installation
When making piping connections, be sure to
follow piping manufactures recommendations
and all code requirements for piping material.
• System should be properly flushed of debris
before pump installation.
• Insert check valve only if required, see fig. 2.
• Arrows on the pump housing indicate the
liquid flow direction through the pump.
• Install the pump with the motor shaft
horizontal; see fig. 3.
• Fit the two gaskets supplied to pump ends.
Fig. 2 Check valve installation
Fig. 3 Installation positions
Warning
Do not energize pump until
properly installed.
Risk of electric shock - this pump
has not been investigated for use in
swimming pool or marine areas.
TM 3422 4408
TM04 3417 4408
UL

5
English (US)
5.3 Changing the power head position
The power head orientation change should be
made before filling the system with fluid.
Pump liquid may be scalding hot and under high
pressure.
The power head can be rotated in steps of 90 °.
Review fig. 4for possible/permissible positions.
Only use orientations C and D for CSA
Enclosure Type 2.
Fig. 4 Changing the power head position
Procedure:
1. If fluid is present, drain system fluid from
pump or isolate system fluid from pump.
2. Loosen 4 mm screws and turn the pump
head to desired position; see fig. 4.
3. Insert and cross-tighten the screws to:
7 ft-lbs torque.
5.4 Electrical installation
All electrical work should be performed by a
qualified electrician in accordance with the latest
edition of the National Electric Code and state,
local codes and regulations.
• The motor of Grundfos Alpha is protected by
the electronics in the control box and
requires no external motor protection.
• Check that the supply voltage and frequency
correspond to the values stated on the
pump.
• Only connect the pump to the mains with the
line cord or through the terminal box
supplied; see fig. 5and 5.
• Do not modify and only use cord set supplied
• Lights on the control panel indicate electrical
supply has been switched on.
Warning
Before starting any work on this
circulator, make sure electrical
supply has been switched off and
that it cannot be accidentally
switched on.
TM04 3418 1010
UL
UL
UL
UL
Power head
orientation A
Power head
orientation B
Power head
orientation C
Power head
orientation D
Warning
Do not energize pump until
properly installed.
Risk of electric shock - this pump
has not been investigated for use
in swimming pool or marine areas.
Warning
Risk of electrical shock - This pump
is supplied with a grounding
conductor and grounding-type
attachment plug. To reduce the risk
of electric shock, be certain that it
is connected only to a properly
grounded, grounding-type
receptacle in accordance with the
National Electric Code and any
state, local governing codes and
regulations.

6
English (US)
5.4.1 For line cord models
Follow procedure outlined in fig. 5.
Fig. 5 Connecting and removing power
plug for line cord models
5.4.2 Terminal box models
Wiring procedure:
1. Loosen terminal box screw from terminal box
cover.
2. Utilize either conduit port for wiring entrance.
3. Gently push open wiring terminal levers
(L-N-G) for wiring installation.
4. Slide terminal box cover over terminal box
body.
5. Tighten terminal box screw Phillips #1
(5 in-lbs).
6. Apply power.
7. Lights on the control panel indicate electrical
supply has been switched on.
Fig. 6 Terminal box wiring, 1 x 115 V
6. Operation
6.1 Control display
Fig. 7 Control display
TM04 3420 1010TM04 7035 1410
1
2
3
To remove cord plug from pump
(bottom view):
Insert line cord plug onto pump
(side view):
1. Insert 1/8 in. flat blade
screwdriver into slot.
2. Rotate screwdriver.
3. Pull cord to remove.
White
Black
Green
Wiring terminal levers
TM04 3421 3511
Pos. Description
1 LED showing Watt or flow indicator
2 Production code:
• 1st and 2nd figures = year
• 3rd and 4th figures = week
3 LED indicating fixed speed
4 LED indicating constant pressure
5 LED AUTOADAPT
6Push-button for selection of pump
setting

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English (US)
6.2 Performance* and operation mode selection
* Hydraulic performance without check valve.
TM04 6882 1110
AUTOADAPT
Operating range
(maximum - minimum)
Pos. Description
• Push-button for selection of pump setting
• Every time the push-button is pressed, the circulator setting is changed
III
High Fixed Speed
• Runs at a constant speed and consequently on a constant curve. In Speed III, the pump
is set on the maximum curve under all operating conditions. Quick Vent of the pump
can be obtained by setting the pump to Speed III for a short period.
II Medium Fixed Speed
• Runs at a constant speed and consequently on a constant curve. In Speed II, the pump
is set on the medium curve under all operating conditions.
ILow Fixed Speed
• Runs at a constant speed and consequently on a constant curve. In Speed I, the pump
is set on the minimum curve under all operating conditions.
Constant Pressure I
• The duty point of the pump will move left and right along the lowest constant-pressure
curve depending on water demand in the system. The pump head (pressure) is kept
constant, irrespective of the water demand.
Constant Pressure II
• The duty point of the pump will move left and right along the middle constant-pressure
curve depending on water demand in the system. The pump head (pressure) is kept
constant, irrespective of the water demand.
Constant Pressure III
• The duty point of the pump will move left and right along the highest constant-pressure
curve depending on water demand in the system. The pump head (pressure) is kept
constant, irrespective of the water demand.
AUTOADAPT (Factory Setting)
• This function controls the pump performance automatically within the defined
performance range (shaded area). AUTOADAPT will adjust the pump performance to
system demands over time.

8
English (US)
7. Fault finding
Warning
Before starting any work on this circulator, make sure electrical supply has been
switched off and that it cannot be accidentally switched on.
Pump liquid may be scalding hot and under high pressure.
Fault Control panel Remedy
1. The pump does not run
LED off
Check power supply (voltage) and
circuit breaker.
Check zone control, voltage, control
options, and thermostat.
Check all power connections.
Damaged circulator / replace.
LED on Check that the electricity supply falls
within the specified range.
Impeller blocked by impurities.
"___ ___"Requires turning power OFF and back
On to pump. Check for air, locked rotor
and/or voltage.
2. Noise in the system
LED on
Install air eliminator.
Reduce the pump speed.
Fluid velocities too high; reduce pump
speed.
Emitter or piping expanding.
3. Noise in the pump
LED on
Let the circulator run, will vent over time.
Increase the inlet pressure or check the
air volume in the expansion tank, if
installed.
No fluid (dry running).
Damaged circulator / replace.
4. Insufficient heat
LED on
Increase circulator speed or constant
pressure.
Circulator in proper operating mode.
Check for air, piping, zone(s) and
emitter(s).
Check thermostat(s).
Check all valving.
Heat emitter large enough.
Check direction of flow.
Check water temperature from boiler
and boiler functions.
Check proper sizing of circulator.
Check T calculation.

9
English (US)
8. Technical data
Supply voltage:
1 x 115 V, + 10 %/- 10 %, 60 Hz.
Motor protection:
The pump requires no external motor protection.
Enclosure class:
Indoor use only, IP42.
CSA Enclosure Type 2.
Insulation class:
F.
Relative air humidity:
Maximum 95 %.
Maximum discharge pressure:
150 psi (10.34 bar).
Inlet pressure:
Sound pressure level:
43 dB (A).
Ambient temperature:
32 °F (0 °C) to 104 °F (40 °C).
Liquid temperature:
36 °F (2 °C) to 230 °F (110 °C).
To avoid condensation in the control box and
stator, the liquid temperature must always be
higher than the ambient temperature.
Maximum glycol concentrations with clean
water:
50 % glycol @ 36 °F (2 °C).
Hydraulic performance change can be expected.
Watt readings:
Accuracy: ± 1 Watt.
Flow indicator:
Provides a relative indication of flow - should not
be used in lieu of a flow meter.
Check valve:
Use of check valve may reduce pump hydraulic
performance (up to -10 %).
Use check valve in parallel pumping
applications.
Curve conditions:
Test liquid: Airless water.
Curves apply to a density of 983.2 kg/m3and a
liquid temperature of 140 °F (60 °C).
All curves show average values and should not
be used as guarantee curves. If a specific
minimum performance is required, individual
measurements must be made.
Curves apply to a kinematic viscosity of
0.474 cSt.
Approximate power usage:
Liquid temperature Min. inlet pressure
167 °F (75 °C) 0.75 psi (0.05 bar)
194 °F (90 °C) 4.06 psi (0.28 bar)
230 °F (110 °C) 15.7 psi (1.08 bar)
Ambient
temperature
[°F (°C)]
Liquid temperature
Min. [°F (°C)] Max. [°F (°C)]
32 °F
(0 °C) 36 °F (2 °C) 230 °F (110 °C)
50 °F
(10 °C) 50 °F (10 °C) 230 °F (110 °C)
68 °F
(20 °C) 68 °F (20 °C) 230 °F (110 °C)
86 °F
(30 °C) 86 °F (30 °C) 230 °F (110 °C)
95 °F
(35 °C) 95 °F (35 °C) 194 °F (90 °C)
104 °F
(40 °C) 104 °F (40 °C) 158 °F (70 °C)
Warning
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.
Speed setting Min. Max.
High fixed speed III 39 W 45 W
Medium fixed speed II 15 W 30 W
Low fixed speed I 5 W 8 W
Constant pressure 8 W 45 W
Constant pressure 14 W 45 W
Constant pressure 22 W 45 W
AUTOADAPT 5 W 45 W

10
English (US)
8.1 Approvals
FCC Sections:
Section 15.19 (a) 3:
This device complies with Part 15 of the FCC
Rules. Operation is subject to the following two
conditions: (1) this device may not cause
harmful interference, and (2) this device must
accept any interference received, including
interference that may cause undesired
operation.
Section 15.21:
Any changes or modifications to this equipment
not expressly approved by the party responsible
for compliance could void the user's authority to
operate this equipment.
Section 15.105 (b):
NOTE: This equipment has been tested and
found to comply with the limits for a Class B
digital device, pursuant to Part 15 of the FCC
Rules. These limits are designed to provide
reasonable protection against harmful
interference in a residential installation.
This equipment generates, uses, and can
radiate radio frequency energy and, if not
installed and used in accordance with the
instructions, may cause harmful interference to
radio communications. However, there is no
guarantee that interference will not occur in a
particular installation. If this equipment does
cause harmful interference to radio or television
reception, which can be determined by turning
the equipment off and on, the user is
encouraged to try to correct the interference by
one or more of the following measures:
• Reorient or relocated the receiving antenna.
• Increase the separation between the
equipment and receiver.
• Connect the equipment into an outlet on a
circuit different from that to which the
receiver is connected.
• Consult the dealer or an experienced radio/
TV technician for help.
Canadian EMC Standard:
ICES-003
This Class B digital apparatus complies with
Canadian ICES-003.
9. Disposal
This product or parts of it must be disposed of in
an environmentally sound way; please use the
public or private waste collection service.
Subject to alterations.
3191277

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www.grundfos.us
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