Grundfos ALPHA1 L Series Bedienungsanleitung

ALPHA1 L

Installation and operating instructions

GRUNDFOS INSTRUCTIONS

English (GB)

English (GB) Installation and operating instructions

Original installation and operating instructions

These installation and operating instructions describe Grundfos

ALPHA1 L.accepted

Sections 1-5 give the information necessary to be able to unpack,

install and start up the product in a safe way.

Sections 6-12 give important information about the product, as

well as information on service, fault finding and disposal of the

product.

CONTENTS

Page

1. General information

1.1 Symbols used in this document

1.1.1 Warnings against hazards involving risk of death or

personal injury

The text accompanying the three hazard symbols DANGER,

WARNING and CAUTION is structured in the following way:

1.1.2 Other important notes

1. General information 2

1.1 Symbols used in this document 2

2. Receiving the product 3

2.1 Inspecting the product 3

2.2 Scope of delivery 3

3. Installing the product 3

3.1 Mechanical installation 3

3.2 Pump positions 3

3.3 Control box positions 4

3.4 Insulating the pump housing 4

4. Electrical installation 4

4.1 Assembling the installer plug 5

5. Starting up the product 6

5.1 Before startup 6

5.2 Starting up the pump 6

5.3 Venting the system 6

5.4 Venting the pump 7

6. Product introduction 7

6.1 Product description 7

6.2 Applications 7

6.3 Pumped liquids 8

6.4 Identification 8

7. Control functions 9

7.1 Elements on the control panel 9

7.2 Control panel 9

7.3 Pump settings 9

7.4 Control modes 10

7.5 Pump performance 12

8. Setting the product 13

9. Fault finding the product 14

9.1 Deblocking the shaft 14

10. Technical data 15

10.1 Dimensions, ALPHA1 L XX-40, XX-60, XX-65 16

10.2 Guide to performance curves 17

10.3 Curve conditions 17

10.4 Performance curves, ALPHA1 L XX-40 (N) 18

10.5 Performance curves, ALPHA1 L XX-60 (N) 19

10.6 Performance curves, ALPHA1 L XX-65 (N) 20

11. Accessories 21

11.1 Unions and valve kits 21

11.2 Insulating shells 21

11.3 Power supply 22

11.4 Control signal connection (PWM profile A) 22

12. Disposing of the product 22

Read this document and the quick guide before you

install the product. 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 use of the appliance in a

safe way and understand the hazards involved.

Children shall not play with the appliance. Cleaning

and user maintenance shall not be made by children

without supervision.

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.

A blue or grey circle with a white graphical symbol

indicates that an action must be taken.

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.

Tips and advice that make the work easier.

English (GB)

2. Receiving the product

2.1 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

6.4.1 Nameplate.

2.2 Scope of delivery

The box contains the following items:

• ALPHA1 L pump

• installer plug

• two gaskets

• quick guide.

3. Installing the product

3.1 Mechanical installation

3.1.1 Mounting the product

1. The arrows on the pump housing indicate the flow direction

through the pump. See fig. 1.

2. Fit the two gaskets when you mount the pump in the pipe.

Install the pump with a horizontal motor shaft. See fig. 2. See

also section 3.3 Control box positions.

3. Tighten the fittings. See fig. 3.

Fig. 1 Flow direction

Fig. 2 Pump installation

Fig. 3 Tightening the fittings

3.2 Pump positions

Always install the pump with a horizontal motor shaft. Do not

install the pump with a vertical motor shaft. See fig. 4, bottom row.

• Pump installed correctly in a vertical pipe. See fig. 4, top row,

left.

• Pump installed correctly in a horizontal pipe. See fig. 4, top

row, right.

Fig. 4 Pump positions

TM06 8535 1317TM06 8536 1317

TM06 8537 1317TM06 8538 1317

English (GB)

3.3 Control box positions

The control box can be mounted in all positions. See fig. 5.

Fig. 5 Possible control box positions

3.3.1 Changing the control box position

3.4 Insulating the pump housing

Fig. 6 Insulating the pump housing

You can reduce the heat loss from the pump and pipe by

insulating the pump housing and the pipe with insulating shells,

which can be ordered as an accessory. See fig. 6.

4. Electrical installation

Carry out the electrical connection and protection in accordance

with local regulations.

• The motor requires no external motor protection.

• Check that the supply voltage and frequency correspond to

the values stated on the nameplate. See section

6.4.1 Nameplate.

• Connect the pump to the power supply with the plug supplied

with the pump. See steps 1 to 7.

TM06 7297 3616

Step Action Illustration

Make sure that

the inlet and

outlet valves

are closed.

Unscrew the

screws on the

pump head.

TM06 8539 1317

Turn the pump

head to the

desired

position.

TM06 8540 1317

Refit the

screws on the

pump head.

TM06 8541 1317

TM06 8564 1317

Do not insulate the control box or cover the control

panel.

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

- Connect the pump to earth.

Connect the pump to an external main switch with

a minimum contact gap of 3 mm in all poles.

English (GB)

4.1 Assembling the installer plug

Step Action Illustration

Loosen the cable

gland and

unscrew the union

nut in the centre

of the terminal

cover.

TM06 8542 1317

2Detach the

terminal cover.

TM06 8543 1317

Pull the power

cable through the

cable gland and

terminal cover.

TM06 8544 1317

Strip the cable

conductors as

illustrated.

TM06 8545 1317

Loosen the

screws on the

power supply plug

and connect the

cable conductors.

TM06 8546 1317 - TM06 8547 1317

Tighten the

screws on the

power supply

plug.

TM06 8548 1317

17 mm

12 mm

Ø 5.5 - 10 mm

Max. 1.5 mm2

x 3

Refit the terminal

cover. See A.

Note: It is possible

to turn the power

supply plug on the

side for a 90 °

cable entry. See

TM06 8549 1317 - TM06 8550 1317

8Tighten the union

nut.

TM06 8551 1317

Tighten the cable

gland onto the

power supply

plug.

TM06 8552 1317

Insert the power

supply plug into

the male plug on

the pump.

TM06 8553 1317

Step Action Illustration

English (GB)

5. Starting up the product

5.1 Before startup

Do not start the pump until the system has been filled with liquid

and vented. Make sure that the required minimum inlet pressure

is available at the pump inlet. See section 10. Technical data.

When using the pump for the first time, the system must be

vented at the highest point. See section 5.3 Venting the system.

The pump is self-venting through the system.

5.2 Starting up the pump

5.3 Venting the system

Fig. 7 Venting the system

When the system has been filled with liquid and the minimum

inlet pressure is available at the pump inlet, do as follows:

1. If turned off, turn on the pump. See section 5.2 Starting up the

pump.

2. If the vent valve is installed in the system, open up the valve

manually. See fig. 7, 1A. If the pump housing has an air

separator installed (ALPHA1 L XX-XX A) and an automatic

vent has been fitted, the air escapes automatically. See fig. 7,

1B.

3. Set the pump to speed III. See fig. 7, 2.

4. Let the pump run for approximately 10 minutes. See fig. 7, 3.

Repeat step 1-3, if necessary.

5. Set the pump according to the recommendations. See section

7. Control functions.

Step Action Illustration

1Open the inlet and

outlet valves.

TM06 8554 1317

2Turn on the power

supply.

TM06 8555 1317

The lights in the

control panel

indicates that the

power supply has

been switched on

and the pump is

running.

TM06 8556 1317

0/Off

1/On

TM06 9069 1617

In heating systems that often contain much air, we

recommend that you install pumps with pump

housing with air separator, that is ALPHA1 L XX-XX

A. The pump housing has an Rp 3/8 tapping for fitting

of an automatic air vent. The vent is not supplied with

the pump.

The pump must not run dry.

= 10 min.

1A 1B

English (GB)

5.4 Venting the pump

Fig. 8 Venting the pump

Small airlocks trapped inside the pump may cause noise when

starting up the pump. However, because the pump is self-venting

through the system, the noise ceases over a period of time.

To speed up the venting process, do as follows:

1. Set the pump to speed III for approximately 10 minutes. How

fast the pump is vented depends on the system size and

design.

2. When you have vented the pump, that is when the noise has

ceased, set the pump according to the recommendations. See

section 7. Control functions.

6. Product introduction

6.1 Product description

ALPHA1 L model C is a complete range of circulator pumps.

See section 10. Technical data for further information.

6.1.1 Model type

These installation and operating instructions cover ALPHA1 L

model C. The model type is stated on the packaging.

6.2 Applications

The ALPHA1 L is designed for circulating liquids in all kinds of

heating applications. The pumps are suitable for the following

systems:

• Systems with constant or variable flows where it is desirable to

optimise the pump duty point.

• Systems with variable flow-pipe temperature.

ALPHA1 L is especially suitable for the following:

• Installation in existing systems where the differential pressure

of the pump is too high during periods of reduced flow

demand.

• Installation in new systems for automatic adjustment of the

performance to flow demands without the use of bypass

valves or similar expensive components.

High-efficiency ECM (Electronically Commutated Motor) pumps,

such as ALPHA1 L, must not be speed-controlled by an external

speed controller varying or pulsing the supply voltage.

The speed can be controlled by a low-voltage PWM (Pulse Width

Modulation) signal.

TM06 8575 1617

The pump must not run dry.

The pump is from factory set to radiator heating

mode.

= 10 min.

TM06 8557 1317

75 °C 95 °C

0.005 MPa 0.05 MPa

0.05 bar 0.5 bar

Max. 1.0 MPa (10 bar)

Min. 2 °C 0 °C

Max.95 °C 55 °C

English (GB)

6.3 Pumped liquids

In heating systems, the water must meet the requirements of

accepted standards on water quality in heating systems, for

example the German standard VDI 2035.

The pump is suitable for clean, thin, non-aggressive and

non-explosive liquids, not containing solid particles, fibres or

mineral oil. The pump must not be used for the transfer of

flammable liquids, such as diesel oil, petrol and similar liquids.

• Maximum water/propylene glycol mixture is 50 %

• Maximum 10 mm2/s viscosity

Note: The water/propylene glycol mixture reduces the

performance due to higher viscosity.

See section 10. Technical data for further information.

6.4 Identification

6.4.1 Nameplate

Fig. 9 Nameplate

CAUTION

Flammable material

Minor or moderate personal injury

- Do not use the pump for flammable liquids, such

as diesel oil and petrol.

WARNING

Biological hazard

Death or serious personal injury

- In domestic hot-water systems, the temperature of

the pumped liquid must always be above 50 °C

due to the risk of legionella.

WARNING

Biological hazard

Death or serious personal injury

- In domestic hot-water systems, the pump is

permanently connected to the mains water.

Therefore, do not connect the pump by a hose.

CAUTION

Corrosive substance

Minor or moderate personal injury

- Do not use the pump for aggressive liquids, such

as acids and seawater.

TM06 8664 1717

Pos. Description

1 Pump name

2 Minimum current [A]

3 Maximum current [A]

4 CE mark and approvals

5 Energy Efficiency Index, EEI

6 Voltage [V]

7 Product number

8 Serial number

9 Country of manufacture

10 Frequency [Hz]

11 Part, according to EEI

12 Enclosure class

13 Manufacturer’s name and address

14 Minimum input power [W]

15 Maximum input power [W]

16 Maximum system pressure

17 VDE code

18 Average compensated power input PL, avg [W]

19 TF class

20 Minimum liquid temperature

Production code:

• 1st and 2nd figures: year

• 3rd and 4th figures: week

l1/1(A)

Grundfos Holding A/S,

DK-8850 Bjerringbro

P1(W) MPa

Min.

Max.

X.XX

XXX X.X

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;;;9a;;;;+],3;;;7);;;

31;;;;;;;;3&;;;;;;;;

61;;;;;;;;

Made in XXXXXXX

*)1;;

L.avg.

<XXW

Denmark

1310 11 12

0LQ;;&

English (GB)

6.4.2 Type key

7. Control functions

7.1 Elements on the control panel

Fig. 10 Control panel

7.2 Control panel

The control panel shows the following:

• the settings, after pressing the button

• operating status

• alarm status.

7.2.1 Operating status

During operation, the control panel shows the actual operating

status or the alarm status. See section 7.2.2 Alarm status.

7.2.2 Alarm status

If the pump has detected one or more alarms, the first LED

switches from green to red. When the fault has been resolved the

control panel switches back to operating status.

See section 9. Fault finding the product.

7.3 Pump settings

The pump has seven different control modes. The pump can be

set to the following:

Fig. 11 Pump setting table

To learn more about each control mode, see section 7.4 Control

modes.

Example ALPHA1 L 25 -40 180

Pump type

Nominal diameter (DN) of inlet and outlet

ports [mm]

Maximum head [dm]

[ ]: Cast-iron pump housing

A: Pump housing with air separator

N: Stainless-steel pump housing

Port-to-port length [mm]

TM06 7286 4616

Symbol Description

Push-button

I, II, III Constant-speed curve I, II and III

Radiator heating mode (proportional pressure)

Underfloor heating mode (constant pressure)

Setting Description

I Constant curve or constant speed I

II Constant curve or constant speed II

III Constant curve or constant speed III

Factory setting:

Radiator heating mode

Underfloor heating control mode

Fixed proportional curve

Externally controlled:

PWM profile A

3 s.

English (GB)

7.4 Control modes

7.4.1 Radiator heating mode

The radiator heating mode adjusts both flow and pressure to the

actual heat demand. The pump performance follows the selected

performance curve.

Fig. 12 Selection of pump setting for system type

Recommended and alternative pump settings according to fig.

12:

Factory setting: Radiator heating mode.

7.4.2 Fixed proportional-pressure curve

An option to the radiator heating mode is a fixed

proportional-pressure curve. The pump performance follows the

selected performance curve.

7.4.3 Underfloor heating mode

The underfloor heating mode adjusts the flow to the actual heat

demand in the system while at the same time keeping a constant

pressure. The pump performance follows the selected

performance curve.

Fig. 13 Selection of pump setting for system type

Recommended and alternative pump settings according to fig.

13:

Factory setting: Radiator heating mode. See section

7.4.1 Radiator heating mode.

7.4.4 Constant curve or constant speed, I, II or III

At constant-curve or constant-speed operation, the pump runs at

a constant curve. The pump performance follows the selected

performance curve, I, II or III. See fig. 14 where II has been

selected. For further information, see section 10.2 Guide to

performance curves.

Fig. 14 Three constant-curve/constant-speed settings

The selection of the constant-curve or constant-speed setting

depends on the characteristics of the heating system in question.

7.4.5 Pump setting for one-pipe heating systems

Recommended and alternative pump settings:

Factory setting: Radiator heating mode. See section

7.4.1 Radiator heating mode.

TM06 8815 1217

System type

Pump setting

Recommended Alternative

Two-pipe

system

Radiator heating

mode

Constant curve or constant

speed I, II, III, see section

7.4.4 Constant curve or

constant speed, I, II or III,

and fixed control curve.

See section 7.4.2 Fixed

proportional-pressure

curve

See also section 10.2 Guide to performance curves.

TM06 8816 1217

System type

Pump setting

Recommended Alternative

Underfloor

heating

system

Underfloor heating

mode

Constant curve or constant

speed, I, II or III. See

section 7.4.4 Constant

curve or constant speed, I,

II or III

See also section 10.2 Guide to performance curves.

TM06 8822 1217

System type

Pump setting

Recommended Alternative

One-pipe

heating

system

Constant curve or

constant speed, I, II or III.

See section

7.4.4 Constant curve or

constant speed, I, II or III

Underfloor heating

mode. See section

7.4.3 Underfloor

heating mode

See also section 10.2 Guide to performance curves.

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