Grundfos alpha2 l User manual

GRUNDFOS INSTRUCTIONS
ALPHA2
Variable-speed circulators with AutoADAPT™
Installation and operating instructions
3191277
Listed
Conforms to ANSI/UL Std. 778
Certified to CAN/CSA Std. C22.2 No. 108

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English (US)
English (US) Installation and operating instructions
Original installation and operating
instructions
These installation and operating instructions
describe Grundfos ALPHA2.
Sections 1-5 give the information necessary to
be able to unpack, install and start up the
product in a safe way.
Sections 6-11 give important information about
the product, as well as information on service,
fault finding and disposal of the product.
CONTENTS
Page
1. Limited warranty
New equipment manufactured by the seller or
service supplied by the seller is warranted to be
free from defects in material and workmanship
under normal use and service for a minimum of
twelve (12) months from the date of installation,
eighteen (18) months from the date of shipment,
unless otherwise stated in the product warranty
guide (available upon request). In the case of
spare or replacement parts manufactured by the
seller, the warranty period shall be twelve
months from shipment. The seller's obligation
under this warranty is limited to repairing or
replacing, at its option, any part found to its
satisfaction to be defective, provided that such
part is, upon request, returned to the seller's
factory from which it was shipped, transportation
prepaid. Parts replaced under the warranty shall
be warranted for twelve months from the date of
the repair, not to exceed the original warranty
period. This warranty does not cover damage to
parts resulting from decomposition from
chemical action or wear caused by abrasive
materials, nor does it cover damage resulting
from misuse, accident, neglect, or from improper
operation, maintenance, installation, modification
or adjustment. This warranty does not cover
parts repaired outside the seller's factory without
prior written approval. The seller makes no
warranty as to starting equipment, electrical
apparatus or other material not of its
manufacture. If the purchaser or any other party
repairs, replaces or adjusts equipment or parts
without the seller's prior written approval, the
seller is relieved of any further obligation to the
purchaser under this paragraph with respect to
such equipment or parts, unless such repair,
replacement or adjustment was made after the
seller, within a reasonable time, failed to satisfy
1. Limited warranty 2
2. General information 3
2.1 Symbols used in this document 3
3. Receiving the product 4
3.1 Inspecting the product 4
3.2 Scope of delivery 4
4. Installing the product 4
4.1 Quick installation tips 5
4.2 Mechanical installation 5
4.3 Changing the power head position 6
4.4 Insulating the pump housing 7
4.5 Electrical connection 8
5. Starting up the product 10
5.1 Venting the pump 10
5.2 First startup 10
6. Product introduction 10
6.1 Product description 10
6.2 Applications 10
6.3 Pumped liquids 11
7. Identification 12
7.1 Nameplate 12
7.2 Type key 12
7.3 Approvals 12
8. Control functions 13
8.1 Elements on the control panel 13
8.2 Display 13
8.3 Setting the pump 13
8.4 Selection of control mode by
application 13
8.5 Pump control 14
8.6 Pump performance and operating
mode selection 15
9. Fault finding the product 16
10. Technical data 18
10.1 Operating conditions 18
11. Disposing of the product 19
Prior to installation, read this
document. Installation and operation
must comply with local regulations
and accepted codes of good practice.
This appliance can be used by
children aged from 8 years and above
and persons with reduced physical,
sensory or mental capabilities or lack
of experience and knowledge if they
have been given supervision or
instruction concerning the use of the
appliance in a safe way and
understand the hazards involved.
Children must not use or play with the
appliance. Cleaning and user
maintenance shall not be made by
children without supervision.
Successful operation depends on
careful attention to the procedures
described in this manual. Keep this
manual for future use.

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English (US)
his obligations under this paragraph. The seller's
liability for breach of these warranties (or for
breach of any other warranties found by a
competent court to have been given by the
seller) shall be limited to: (a) accepting return of
such equipment exw plant of manufacture, and
(b) refunding any amount paid thereon by the
purchaser (less depreciation at a rate of 15 %
per year if the purchaser has used the
equipment for more than thirty [30] days), and
canceling any balance still owing on the
equipment, or (c) in the case of service, at the
seller's option, redoing the service, or refunding
the purchase order amount of the service or a
portion thereof upon which such liability is
based. These warranties are expressly in lieu of
any other warranties, express or implied, and
the seller specifically disclaims any implied
warranty of merchantability or fitness for a
particular purpose, and in lieu of any other
obligation or liability on the part of the seller,
whether a claim is based upon negligence,
breach of warranty or any other theory or cause
of action. In no event shall the seller be liable for
consequential, incidental, indirect, special or
punitive damages of any kind. For the purposes
of this paragraph, the equipment warranted shall
not include equipment, parts and work not
manufactured or performed by the seller. With
respect to such equipment, parts or work, the
seller's only obligation shall be to assign to the
purchaser the warranties provided to the seller
by the manufacturer or supplier providing such
equipment, parts or work. No equipment
furnished by the seller shall be deemed to be
defective by reason of normal wear and tear,
failure to resist erosive or corrosive action of any
fluid or gas, the purchaser's failure to properly
store, install, operate or maintain the equipment
in accordance with good industry practices or
specific recommendations of the seller,
including, but not limited to the seller's
installation and operation manuals, or the
purchaser's failure to provide complete and
accurate information to the seller concerning the
operational application of the equipment.
2. General information
2.1 Symbols used in this document
The text accompanying the three hazard
symbols DANGER, WARNING and CAUTION
will be structured in the following way:
Example
DANGER
Indicates a hazardous situation which,
if not avoided, will result in death or
serious personal injury.
WARNING
Indicates a hazardous situation which,
if not avoided, could result in death or
serious personal injury.
CAUTION
Indicates a hazardous situation which,
if not avoided, could result in minor or
moderate personal injury.
SIGNAL WORD
Description of hazard
Consequence of ignoring the warning.
- Action to avoid the hazard.
DANGER
Electric shock
Death or serious personal injury.
- Switch off the power supply before
starting any work on the product.
Make sure that the power supply
cannot be accidentally switched on.
A blue or grey circle with a white
graphical symbol indicates that an
action must be taken to avoid a
hazard.
A red or grey circle with a diagonal
bar, possibly with a black graphical
symbol, indicates that an action must
not be taken or must be stopped.
If these instructions are not observed,
it may result in malfunction or damage
to the equipment.
Notes or instructions that make the
work easier and ensure safe
operation.

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English (US)
3. Receiving the product
3.1 Inspecting the product
Check that the product received is in
accordance with the order.
Check that the voltage and frequency of the
product match voltage and frequency of the
installation site. See section 7. Identification for
information on the nameplate.
3.2 Scope of delivery
The box contains the following items:
• one Grundfos ALPHA2 pump
• one insulation shell
• one line cord or terminal box
• two gaskets
• installation and operating instructions
• one check valve
• one "Check Valve Installed" sticker.
4. Installing the product
WARNING
Pressurized system
Death or serious personal injury.
- Before dismantling the pump, drain
the system or close the isolating
valve on either side of the pump
before the screws are removed.
The pumped liquid may be scalding
hot and under high pressure.
DANGER
Electric shock
Death or serious personal injury.
- Switch off the power supply before
starting any work on the product.
Make sure that the power supply
cannot be accidentally switched on.
DANGER
Electric shock
Death or serious personal injury.
- This pump has not been
investigated for use in swimming
pool or marine areas.

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English (US)
4.1 Quick installation tips
1. To ensure proper air venting of your system,
place the pump 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 the pump 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. With zone panel control applications, when
there is a call for heat and power has been
sent to the pump, the pump will remember
and restart from the last duty point and
hydraulic mode.
4.2 Mechanical installation
When making pipe connections, follow the
piping manufacturer's recommendations and all
code requirements for the piping material.
• Flush the system of debris before
installation.
• Insert the check valve if required. See fig. 1.
• Refer to the arrows on the pump housing
indicating the direction of the liquid flow
through the pump.
• Install the pump with horizontal motor shaft.
See fig. 2.
• Fit the two gaskets supplied to the pump
ends.
Fig. 1 Check valve installation
Fig. 2 Installation positions
TM04 3422 4408
TM04 3417 4408
UL

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English (US)
4.3 Changing the power head position
• Make any change to the power head
orientation before filling the system with
liquid. You can turn the power head in steps
of 90 °.
• See fig. 3for permissible positions.
• Only use orientations C and D for CSA,
enclosure type 2.
Proceed as follows:
1. If liquid is present, drain the liquid from the
pump or isolate the liquid from the pump.
2. Remove the four socket head cap screws.
3. Turn the pump head to the desired position.
See fig. 3.
4. Cross-tighten the screws to: 7 ft-lbs torque.
Fig. 3 Changing the power head position
Fig. 4 Remove the four socket head cap
screws on the power head to
change the power head position
CAUTION
Hot surface
Minor or moderate personal injury.
- Position the pump so that persons
cannot accidentally come into
contact with hot surfaces.
DANGER
Electric shock
Death or serious personal injury.
- Switch off the power supply before
starting any work on the product.
Make sure that the power supply
cannot be accidentally switched on.
WARNING
Pressurized system
Death or serious personal injury.
- Before dismantling the pump, drain
the system or close the isolating
valve on either side of the pump
before you remove the screws. The
pumped liquid may be scalding hot
and under high pressure.
If you change the position of the
power head, fill the system with the
liquid to be pumped or open the
isolating valves.
TM04 3418 1010
TM06 7559 3616
Power head
orientation A
Power head
orientation B
Power head
orientation C
Power head
orientation D

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English (US)
4.4 Insulating the pump housing
Fig. 5 Insulating the pump housing
You can reduce the heat loss from the pump and
pipes by insulating the pump housing and the
pipes. See figures 5and 6.
• Insulating shells are supplied with ALPHA2
cast iron flanged versions. See fig. 6.
• For pumps in air-conditioning and cooling
systems (down to +14 °F (-10 °C)), it is
required to apply a silicon sealant to the
internal contours of the shell in order to
eliminate any air gaps and prevent
condensation between the insulating shell
and pump housing. Alternatively, you can
insulate the pump manually in accordance
with standard insulating requirements for
heating and cooling systems.
• The fitting of insulating shells will increase
the pump dimensions.
Fig. 6 Fitting insulating shells to the pump
TM06 7711 3816
Limit the heat loss from the pump
housing and pipes.
Do not insulate the control box or
cover the control panel.
TM06 7589 4716TM06 7588 3516

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English (US)
4.5 Electrical connection
• The motor 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 power supply
with the line cord or through the terminal box
supplied with the pump; see sections
4.5.1 For pump models with line cord and
4.5.2 For pump models with terminal box.
• Do not modify and only use the line cord
supplied.
• The lights on the control panel indicate that
the electrical supply has been switched on.
4.5.1 For pump models with line cord
Follow the procedure as shown in fig. 7.
Fig. 7 Connecting and removing the power
plug for line cord models
DANGER
Electric shock
Death or serious personal injury.
- All electrical work must be carried
out by a qualified electrician in
accordance with the latest edition
of the National Electric Code and
state, local codes and regulations.
DANGER
Electric shock
Death or serious personal injury.
- Switch off the power supply before
starting any work on the product.
Make sure that the power supply
cannot accidentally switched on.
DANGER
Electric shock
Death or serious personal injury.
- This pump has not been
investigated for use in swimming
pool or marine areas.
DANGER
Electric shock
Death or serious personal injury.
- 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.
TM04 3420 1010
1
2
3
How to remove the cord plug from the
pump (bottom view):
How to insert the line cord plug onto the
pump (side view):
1. Insert a 1/8 in. flat blade
screwdriver into the slot.
2. Twist the screwdriver.
3. Pull the cord to remove it.

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English (US)
4.5.2 For pump models with terminal box
1. Loosen the terminal box screw from the
terminal box cover.
2. Utilize either conduit port for the wiring
entrance.
3. Wirethe plug connector as illustrated in the
section Wiring procedure below, steps 3a-
3d. Then complete steps 4-7.
Wiring procedure
4. Slide the terminal box cover over the
terminal box body.
5. Tighten the cross-head screw on the terminal
box to 5 in-lbs.
6. Switch on the power supply.
7. The lights on the control panel will then
indicate that the power supply has been
switched on.
Be sure to connect the ground cable
conductor (green) of the pump to the
ground cable conductor of the power
supply.
Step Action Illustration
3a Strip the ends of the cable conductors as
illustrated.
TM06 8250 4816
3b
Align the end of each of the pump's cable
conductors, including any frayed strands,
with the end of the corresponding cable
conductor from the power supply.
Green conductor: ground
Black conductor: line
White conductor: neutral
TM06 8253 4816
3c
Insert the ends of the cable conductors
into the connector.
Push the cable conductors fully into the
connector.
TM06 8251 4816
3-d Twist the connector until you see two
twists in the cable conductors.
TM06 8252 4816
0.4 in.
(10 mm)
Cable conductor
from the pump
Cable conductor
from the power
supply

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English (US)
5. Starting up the product
The required minimum inlet pressure must be
available at the pump inlet.
5.1 Venting the pump
The pump is self-venting. It need not be vented
before startup.
Air in the pump may cause noise. This noise
ceases after a few minutes running.
You obtain quick venting of the pump by setting
the pump to speed III for a short period. How
fast the pump is vented depends on the system
size and design.
When you have vented the pump, i.e. when the
noise has ceased, set the pump according to the
recommendations. See section 8.3 Setting the
pump.
You cannot vent the system through the pump.
5.2 First startup
• The light in the control panel shows that the
power supply has been switched on. See
fig. 9.
• Factory setting: AUTOADAPT.
6. Product introduction
6.1 Product description
The ALPHA2 circulator pump incorporates a
permanent-magnet motor and differential-
pressure control enabling continuous
adjustment of the pump performance to the
actual system requirements.
The pump has a user-friendly front-mounted
control panel. See sections 7. Identification and
8. Control functions.
When you install an ALPHA2, it means:
• Easy installation and start-up.
– The pump is easy to install.
Thanks to the AUTOADAPT function
(factory setting), you can start the pump,
in most cases, without making any
settings.
• High degree of comfort.
• Minimum noise from valves, etc.
• Low energy consumption.
– Low energy consumption compared to
conventional circulator pumps.
6.2 Applications
The ALPHA2 circulator pump is designed for the
circulation of water in heating systems, domestic
hot-water systems as well as air-conditioning
and cold-water systems.
Cold-water systems are defined as systems
where the ambient temperature is higher than
the temperature of the pumped liquid.
The pump is the best choice for the following
systems:
• underfloor heating systems
• one-pipe systems
• two-pipe systems.
The pump is suitable for the following:
• systems with constant or variable flows
where you want to optimize the setting of the
pump duty point.
• systems with variable flow-pipe temperature.
• balancing of domestic heating systems.
Do not start the pump until the system
has been filled with liquid and vented.
The pump must not run dry.
DANGER
Explosion hazard
Death or serious personal injury.
- Do not use the pump for transfer of
flammable liquids such as diesel
oil, gasoline, and similar liquids.
DANGER
Electric shock
Death or serious personal injury.
- This pump has not been
investigated for use in swimming
pool or marine areas.