Tucson GBPHR/8/CCW User manual

Gas Boiler Pump Head Replacement
Installation, Operation and Maintenance Manual
Warning Prior to installation, read these installation and operating
instructions. Installation must comply with local regulations and
accepted codes of practice.
General Notes - ErP (Ecological Design) Directive
– The benchmark for the most efficient circulators is EEI ≤ 0.20 Part 3
– Information on recycling/disposal: this product should be disposed of
separately from household waste in line with local laws and regulations.
When this product reaches its end of life, dispose of it at your local
waste collection point/recycling centre.
– The separate collection and recycling of your product at the time
of disposal will help conserve natural resources and ensure that it is
recycled in a manner that protects human health and the environment
ISO9001
COMPLIANT
Part 3
High Efficiency
GBPHR/8/CCW GBPHR/8/CW

2
General Information
The Tucson Gas Boiler Pump Head Replacement or GBPHR is available as
a range of Easy to Install, Retro-fit products for Gas Boilers and is available
as both clockwise and counter-clockwise rotating units. These products are
designed as replacement components to be used across an array of market
leading boilers brands. This range of intelligent frequency conversion
circulation pumps incorporate integrated electronic differential pressure
control technology.
The GBPHR range also incorporates PWM / “Pulse Width Modulation”
technology as standard, allowing for intelligent control of the pump as
required by a boiler unit PCB.
Circulating Pumps incorporate a permanent-magnet motor and variable-
pressure control, enabling continuous adjustment of the pumps performance
to the actual system requirements.
Pump Liquids
Clean, non-aggressive and non-explosive liquids, not containing solid
particles, fibres or mineral oil. In heating systems, the water must meet the
requirements of accepted standards for water quality in a heating system.
Warning!
- Please read the instructions fully before carrying out install.
- Pump must be grounded before connecting to power supply.
- Pump must be installed with leakage protection before use.
- Do not touch the pump during operation.
- Pump system must be able to withstand maximum pressure of pump.
Product Code Definition
Pump Model
Maximum Head (metre)
Rotation
GBPHR 8 CCW/CW

3
3
Control Panel
Gas Boiler Pump Head Replacement
Installation, Operation and Maintenance Manual
Pump Head
Replacement CCW
High Eciency
PP CP AUTO
1 2 3
(
(
Elements on the control panel
Fig. 1
Ref. Description
1 Function button
2 LED light field indicating proportional pressure, constant pressure or
auto mode setting
3 QR code linking to tucsonpumps.ie
4 Rotation direction
Table 1
Light fields indicating the pump setting
The Tucson Gas Boiler Pump Head Replacement has three optional settings
which can be selected with the push-button.
Push button when selecting pump setting
Every time the push button is pressed, the pump setting is changed.
A cycle is twelve button presses.
2
1
3
4
GBPHR 8 CCW/CW

4
Control Panel Operation Procedure
Depress Button Function Function Definition Visual Display LED
0 CS III (Factory
Settings)
Constant curve, speed III
1 AUTO Adaptive mode
2 PP I Proportional pressure curve,
speed I
3 PP II Proportional pressure curve,
speed II
4 PP III Proportional pressure curve,
speed III
5 CP I Constant pressure curve,
speed I
6 CP II Constant pressure curve,
speed II
7 CP III Constant pressure curve,
speed III
8 CS I Constant curve, speed I
9 CS II Constant curve, speed II
10 CS III Constant curve, speed III
/ PWM External control of motor
speed
To select the pumps function, depress the “Function Button” on the
interface panel. Fig 1.

5
Gas Boiler Pump Head Replacement
Installation, Operation and Maintenance Manual
5
Automatic Venting Feature
Function Description Operation
Venting Pump venting/purging
is the process of air
removal from within
the system. Removing
this air is vital to ensure
pump’s operation
efficiency & effectivness
are maximised.
Press & hold the function button for 5 seconds until
LED1+LED2+LED3 light up and then release. The
pump will vent automatically for 5 minutes. All LED
lights flash slowly during venting.
After, it will enter into the previous operation mode
and the LED lights will stop flashing.
Manual
Restart
Restart the pump
manually
(after a long idle time in
the summer).
Press & hold the function button for 8 seconds until
LED1+LED2+LED3+LED4+LED5 all light up and
then release. The pump will start and stop contin-
uously for 5 minutes to unlock. All LED lights flash
quickly during this procedure.
If after the start and stop for 5 minutes, the pump
works as normal, then the LED lights will stop flash-
ing. If it does not work as normal, the pump will
stop running and report a fault code.

6
Supply Voltage 230V, 50/60Hz
Ingress Protection Rating IP44
Insulation Class E
Relative Ambient Humidity Max. 95%
Maximum System Pressure 10 bar
Suction Inlet Pressure Liquid Temperature Suction Minimum Inlet Pressure
≤+75°C 0.05 bar
≤+90°C 0.28 bar
≤+110°C 1.08 bar
EMC Standard EN61000-6-1, EN61000-6-3
Decibel Rating 43dB
Operating Environment Temperature 0°C - 40°C
Liquid Temperature +2°C - 110°C
Surface Temperature Maximum 125°C
EEI ≤0.23 Part 3
Technical Data
Performance GBPHR/8/CCW & GBPHR/8/CW

7
Gas Boiler Pump Head Replacement
Installation, Operation and Maintenance Manual
Fig. 2
1
2
35
4
7
6
Product Components (Fig. 2 & 3)
1. Pump body model
2. Wet rotor motor
3. Body fixing screws
4. Electronic control board
5. Pump identification plate
6. Function button
7. LED light field
8. PWM control cable (optional) (Fig. 3)
9. Mains power supply (Fig. 3)

8
Fig. 3
9
8
Fig. 4
Fig. 5
AC Power Cable: 230 Vac Brown
Yellow
Blue
Brown: (L) Live
Yellow/Green: Earth
Blue: (N) Neutral
PWM Control Cable
Red
Yellow
Black
Yellow: PWM output (from pump)
Red: PWM imput (from controller)
Black: Ground cable (GND)

9
Gas Boiler Pump Head Replacement
Installation, Operation and Maintenance Manual
Pump Dimensions
Model Dimension (mm)
H H1 L L0 L1 L2 D D1
GBPHR/8/CW 109 60 102 76 99 69 98 6.5
GBPHR/8/
CCW 109 60 102 76 99 68 96 5.5
Fig. 6

10
Electrical Connection
Electrical
connection
Connection
signal PWM
1. Installation position 2. Position the AC
& PWM cable plugs
towards the control box
sockets and firmly insert
3. Completed assembly
The Tucson GBPHR/8/CCW is compatible and interchangable with the
following pump models:
PWM
- Grundfos®UPM3
- Grundfos®UPM2
- Grundfos®ALFA2
- Grundfos®UPS
- Grundfos®UPS2
(The Tucson GBPHR/8/CCW is compatible
as a replacement head on a PWM
controlled or non-PWM controlled pump)
68mm

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11
Gas Boiler Pump Head Replacement
Installation, Operation and Maintenance Manual
The Tucson GBPHR/8/CW is compatible and interchangable with the
following pump models:
PWM
- Wilo™PARA
- Wilo™PICO
- Wilo™YONOS
Old RS xx/X models and other brands
(The Tucson GBPHR/8/CW is compatible
as a replacement head on a PWM
controlled or non-PWM controlled pump)
Replacement Instructions
Preliminary checks of a retro-fit application.
1. - Always ensure the boiler malfunction is not due to other causes. Should
the pump require replacing, ensure the pump failure was not due to the
existing operating conditions.
- Using a Voltmeter, ensure to verify a correct voltage is present from the
AC cable connection of the boiler.
- Measure the Insulation resistance, ensuring this is more than 10Ω.
2. Identify the direction of rotation of the motor to ensure the replacement
motor is a suitable replacement.
69mm

12
Dimension of the fixing flange: Rotational direction of the motor:
ATTENTION
The rotating direction is determined by looking at the
data plate on the front of the motor.
Grundfos®
Model code - diameter - delivery - height
UPM x 15 - 50 - xxx
ALFA x 15 - 50 - xxx
UPS - 15 - 60 - xxx
Wilo™
Model code - diameter - delivery - type of body - height
PARA 25/6/xxxxx/xxx
PICO 25/6/xxxxx/xxx
YONOS 25/6/xxxxx/xxx
RS 25/6/xxxxx/xxx
The delivery head detail of the old circulator is shown on the original data
plate of the circulator to be replaced. Usually the detail on the data plate
shows first the diameter of the fittings and then the delivery head.
It is preferred to use motors with similar or higher metric delivery than
the old circulator. The motor circulator with AUTO ADAPT function is self
regulating and reduces its power in relation to the real and variable needs of
the system.
68mm
or
69mm
68mm
or
69mm

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13
Gas Boiler Pump Head Replacement
Installation, Operation and Maintenance Manual
Motor Replacement Installation
1. Disconnect the electrical mains power supply.
2. Using a Voltmeter ensure there is no electrical power present.
3. Disconnect the electrical cable from the circulation pump to be replaced.
4. Ensure to Isolate the Boiler’s water supply or drain down the system.
5. Once the boilers original failed pump is isolated both electrically and of
liquid, select a 4-5mm diamention Allen Key with T handle.
Proceed to loosen the two or four Manifold/Volute studs, these will be
visible from the front of the pump.
These fix the Pump Head to the Pump Manifold or Volute.
6. On Loosening the studs, allow any remaining water to bleed from the
pump, before removing the faulty pump head.
7. Insert the Tucson GBPHR Pump into the Boiler pump manifold ensuring
to utilize the O-Ring washer supplied.
8. Insert the suitable studs supplied and tighten the pump head into
position.
9. Ensure to tighten the studs gradually and evenly.
10.Re-open the boilers water isolation valves and fill until the desired water
level has been achieved.
11.Check that there are no leaks between the pump flange and motor.
12.Connect the electrical supply cable to the pump. This can be done
by using the Grundos®or Wilo™electrical Plug Adapters or using the
stripped cable adapter connector supplied with the pump.
13.Once the replacement is complete, it is advised that you set the function
of the circulator correctly with button (fig. 1 ref. 1).
The function of the circulator is factory pre-set to CS mode three
(constant speed).

14
Electrical Cable Connection Adapter Options
ATTENTION: In some old circulator model bodies it is necessary
to apply a second washer in order to avoid the impellor rubbing
off the pump body. Therefore, before fixing the bolts, check that
the coupling does not cause the impellor to rub off the body, in
which case you will need to insert a second washer.
14.As a boilers performance is determined by achieving an optimal flow rate
from the integrated pump, please refer to boiler opertators manual to
accertain the flow rate in litres per minute L/m or metres cubed per hour
(m3/Hr).
Once this value is attained, refer to the Tucson GBPHR performance curve
on page 6. Viewing the performance curve, select the desired flow rate at
the base of the graph, (m3/Hr) - follow vertically until reaching the pump
curve that best matches the operating mode type and head requirement
for the system. Using the function button, set the pump mode setting to
this operating mode.
Please Note: If after removing the motor, you notice the prescence of
sludge, fine sand or dirt on the old body of the circulator, it’s advised that
you flush and add inhibitor as recommended by the boiler manufacturer to
the system to avoid possible and repeated blockage of the motor.
Warning!
Before proceeding, ensure the power supply is isolated and safe.
Warning!
One of the two AC connector wires supplied must be used in the
installation. Do not attempt to connect any other AC connectors
directly to the pump. Connecting a different AC connector may
result in a short and could damage the pump or boiler.

15
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Gas Boiler Pump Head Replacement
Installation, Operation and Maintenance Manual
1. Replacing a Grundfos®Pump with plug connection:
Use the adapter cable as shown in Fig 7. This adapter allows the
installer to connect directly onto the original boiler panel electrical cable
connection, allowing for a quick and safe retro-fit.
Note: some Grundfos®pumps are wired directly into the pumps electrical
junction box without a plug, for these applications, follow the stripped
cable connection adapter option procedure below.
2. Replacing a Wilo™Pump with plug connection: Use the Adapter cable as
shown in Fig 8. This adapter allows the installer to connect directly onto
the original boiler panel electrical cable connection, allowing for a quick
and safe retro-fit.
Note: some Wilo™pumps are wired directly into the pumps electrical
junction box without a plug, for these applications, follow the stripped
cable connection adapter option procedure below.
Warning!
Before proceeding, ensure the power supply is isolated and safe.
Fig. 7
Fig. 8

16
1 2 3 Cable connection:
1. Brown: L (Live)
2. Blue: N (Neutral)
3. Yellow/Green: PE ( )
Connect the wire of the supplied
connecting cable by observing the
arrangement of the terminals and
their reference colour. Make sure
that the grounding connection
(yellow/green) is effective.
Connect the power connector to
the socket of the pump control
box (Fig. 3).
Fig. 9
3. Note: Should it not be possible to utilize the electrical adapter cable
options supplied with this pump, the installer must use the stripped cable
connection adapter option supplied and shown in Fig 9.
This stripped cable connection adapter provides and IP Rated connection.
This option allows the installer to connect the pump safely and securely to
the boilers electrical cable without opening the boilers electrical panel.
To apply, cut the plug connection off the faulty pump and shorten the
cable as required. Strip these wires and insert into the adapter connection
as indicated in the diagram, once complete, plug into the electrical socket
on the pump head and return the electrical supply and test the that the
pump is operational.

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Gas Boiler Pump Head Replacement
Installation, Operation and Maintenance Manual
Adjustment Modes and Functions
Recommended in such cases of heating
systems with delivery and return pipes with
radiators, for the reduction of flow noise on
thermostatic valves and zone disconnectors.
The pump halves the delivery in case of flow
reduction in the pipeline network (radiators
or closed areas). Electrical energy is saved by
adapting the delivery to the required flow rate
and reduced flow speed. Three predefined
characteristic curves including (I, II, III) are
provided by the pump setting.
Recommended in such cases of radiant
panels (floor systems) or large pipes and
for all applications without variable system
characteristic curves, (e.g. circulation in
accumulators or heaters) and single-pipe
heating systems with radiators.
The regulation maintains the set delivery
regardless of the conveyed flow rate.Three
predefined characteristic curves including
(I, II, III) are provided by the pump setting.
Recommended for systems with steady
resistance that require a constant flow rate.
The pump operates in three stages
corresponding to numbers of preset fixed
speeds (I, II, III).
Factory setting: (CS III)
Constant speed, curve, speed III
Variable differential
pressure
Constant differential
pressure
Constant Speed

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External Adjustment via
iPWM signal
The pump speed is controlled according to the
PWM input signal, when corrected.
If there is no PWM signal or if the cable is not
connected, the pump operation is controlled
by internal logic.
In PWM mode, the rotation speed of the
pump is regulated according to the input
signal (PWM).
PWM = External adjustment
with iPWM signal

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PWM Input Signal (P1 heating systems for Modulex Hybrid models)
Gas Boiler Pump Head Replacement
Installation, Operation and Maintenance Manual
At high PWM signal rates (duty cycles), a hysteresis prevents the circulation
pump from starting and stoping if the input signal fluctuates around the
change point.
At low PWM signal rates the speed of the circulation pump is high for safety
reasons. In the event of cable breakage in a system with a gas boiler, the
circulation pump will continue to run at maximum speed to transfer heat
from the primary heat exchanger.
PWM input signal (%) Pump status
0 Switch the pump to non-PWM
mode (internal control)
0<PWM<10 Maximum speed: max
10<PWM<84 Variable speed: from max. to min.
84<PWM<91 Minimum speed: min.
91<PWM<95 Hysteresis area: on/off
95<PWM<100 Standby mode: off

20
20
PWM Input Signal (P2 solar systems for Modulex Solar models)
With a low percentage of PWM signal (duty cycles), a hysteresis prevents
the circulation pump from starting and stopping if the input signal
oscillates around the change point.
Without PWM signal percentage, the circulation pump will stop for
safety reasons. If a signal is missing, e.g. due to a break in the cable, the
circulator will stop preventing overheating.
PWM input signal (%) Pump status
0 Stop
0<PWM<5 Standby mode: off
5<PWM<8 Hysteresis area: on/off
8<PWM<15 Minimum speed: min.
15<PWM<90 Variable speed: from min. to max.
90<PWM<100 Maximum speed: max.