Grundfos ALPHA1 L 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.

Sections 1-4 give the information necessary to be able to unpack,

install and start up the product in a safe way.

Sections 5-12 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 Hazard statements

The symbols and hazard statements below may appear in

Grundfos installation and operating instructions, safety

instructions and service instructions.

The text accompanying the three hazard symbols DANGER,

WARNING and CAUTION is structured in the following way:

The hazard statements are structured in the following way:

1. General information 2

1.1 Hazard statements 2

1.2 Notes 3

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 4

3.3 Control box positions 4

3.4 Electrical connection 5

3.5 Insulating the pump housing 6

4. Starting up the product 6

4.1 Before startup 6

4.2 Starting up the pump 6

4.3 Venting the pump 7

5. Product introduction 7

5.1 Product description 7

5.2 Applications 7

5.3 Pumped liquids 7

5.4 Identification 8

5.5 Accessories 9

6. Control functions 11

6.1 Operating panel 11

6.2 Control modes 11

6.3 Control signal 12

6.4 Pump performance 14

7. Setting the product 15

7.1 Setting the PWM input signal 16

8. Servicing the product 16

8.1 Dismantling the product 16

8.2 Dismantling the plug 16

9. Fault finding the product 17

9.1 Deblocking the shaft 17

10. Technical data 18

10.1 Dimensions, ALPHA1 L XX-40, XX-60, 15-65 19

10.2 Dimensions, ALPHA1 L 25-65 20

11. Performance curves 20

11.1 Guide to performance curves 20

11.2 Curve conditions 20

11.3 Performance curves, ALPHA1 L XX-40 21

11.4 Performance curves, ALPHA1 L XX-60 22

11.5 Performance curves, ALPHA1 L XX-65 23

12. Disposal 23

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.

English (GB)

1.2 Notes

The symbols and notes below may appear in Grundfos

installation and operating instructions, safety instructions and

service instructions.

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

5.4.1 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 supplied with the pump when you mount

the pump in the pipe. Install the pump with a horizontal motor

shaft within ± 5 °. 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

Observe these instructions for explosion-proof

products.

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.

CAUTION

Crushing of feet

Minor or moderate personal injury

- Wear safety shoes when opening the box and

handling the product.

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.

CAUTION

Crushing of feet

Minor or moderate personal injury

- Wear safety shoes when opening the box and

handling the product.

Installation must be carried out by trained persons in

accordance with local regulations.

The pump must always be installed with a horizontal

motor shaft within ± 5 °.

The mechanical installation must be carried out by

trained persons in accordance with local regulations.

TM06 8535 0918TM06 8536 0918

English (GB)

Fig. 3 Tightening the fittings

3.2 Pump positions

Always install the pump with a horizontal motor shaft within ± 5 °.

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

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

TM06 8537 0918TM06 8538 0918

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.

CAUTION

Hot surface

Minor or moderate personal injury

- The pump housing may be hot due to the pumped

liquid being scalding hot. Close the isolating valves

on both sides of the pump and wait for the pump

housing to cool down.

CAUTION

Pressurised system

Minor or moderate personal injury

- Before dismantling the pump, drain the system or

close the isolating valves on both sides of the

pump. The pumped liquid may be scalding hot

and under high pressure.

TM06 7297 0918

Step Action Illustration

Make sure that

the inlet and

outlet valves

are closed.

Unscrew the

screws on the

pump head.

TM06 8539 0918

Turn the pump

head to the

desired

position.

TM06 8540 0918

Refit the screws

on the pump

head.

TM06 8541 0918

English (GB)

3.4 Electrical connection

• The motor requires no external motor protection.

• Check that the supply voltage and frequency correspond to

the values stated on the nameplate. See section

5.4.1 Nameplate.

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

with the pump. See steps 1 to 7.

3.4.1 Assembling the installer plug

DANGER

Electric shock

Death or serious personal injury

- All electrical connections must be carried out by a

qualified electrician in accordance with local

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 be accidentally switched on.

DANGER

Electric shock

Death or serious personal injury

- Connect the pump to protective earth.

DANGER

Electric shock

Death or serious personal injury

- In case of an insulation fault, the fault current may

be a pulsating DC. Observe national legislation

about requirements for and selection of Residual

Current Device (RCD) when installing the pump.

The pump is not a safety component and cannot be

used to ensure functional safety in the final

appliance.

Step Action Illustration

Loosen the cable

gland and

unscrew the union

nut in the centre

of the terminal

cover.

TM06 8542 0918

2Detach the

terminal cover.

TM06 8543 0918

Pull the power

cable through the

cable gland and

terminal cover.

TM06 8544 0918

Strip the cable

conductors as

illustrated.

TM06 8545 0918

Loosen the

screws on the

power supply plug

and connect the

cable conductors.

TM06 8546 0918 - TM06 8547 0918

Tighten the

screws on the

power supply

plug.

TM06 8548 0918

0/Off

1/On

42 mm

32 mm

Ø 5.5 - 10 mm

0.5 - 1.5 mm2

8 mm

x 3

English (GB)

3.5 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 section

5.5.2 Insulating shells.

4. Starting up the product

4.1 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. See section 4.3 Venting the pump. The pump is

self-venting through the system.

4.2 Starting up the pump

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 B.

TM06 8549 0918 - TM06 8550 0918

8Tighten the union

nut.

TM06 8551 0918

Tighten the cable

gland onto the

power supply

plug.

TM06 8552 0918

Insert the power

supply plug into

the male plug on

the pump.

TM06 8553 0119

TM06 8564 1317

Do not insulate the control box or cover the operating

panel.

Step Action Illustration

1Open the inlet and

outlet valves.

TM06 8554 0918

2Switch on the

power supply.

TM06 8555 1317

The lights in the

operating panel

indicate that the

power supply has

been switched on

and the pump is

running.

TM06 8556 0918

0/Off

1/On

English (GB)

4.3 Venting the pump

Fig. 7 Venting the pump

Small air pockets 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 using the button on the operating

panel.

2. Let the pump run for minimum 30 minutes. How fast the pump

is vented depends on the system size and design.

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

ceased, set the pump according to the recommendations. See

section 6. Control functions.

5. Product introduction

5.1 Product description

ALPHA1 L can be used as stand-alone or integrated circulator

pump in existing systems as replacement or in new systems with

either variable or constant flow rate.

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

Modulation) signal.

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.

5.1.1 Model type

These installation and operating instructions cover ALPHA1 L.

The model type is stated on the packaging and nameplate.

5.2 Applications

The pump is designed for circulating liquids in heating systems.

The pumps are suitable for the following systems:

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

optimise the pump duty point.

• 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.

5.3 Pumped liquids

The pump is suitable for clean, thin, 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 on water quality in heating systems, for

example the German guideline VDI 2035.

Mixtures of water with antifreeze media such as glycol with a

kinematic viscosity lower than 10 mm2/s (10 cSt). When selecting

a pump, the viscosity of the pumped liquid must be taken into

consideration. If the pump is used for a liquid with a higher

viscosity, the hydraulic performance of the pump is reduced. See

section 10. Technical data for further information.

TM07 0153 0918

The pump must not run dry.

The pump is from factory set to radiator heating

mode.

Minimum 30 min

In domestic hot-water systems, we recommend that

you keep the liquid temperature below 65 °C to

eliminate the risk of lime precipitation.

CAUTION

Flammable material

Minor or moderate personal injury

- Do not use the pump for flammable liquids, such

as diesel oil and petrol.

CAUTION

Corrosive substance

Minor or moderate personal injury

- Do not use the pump for aggressive liquids, such

as acids and seawater.

English (GB)

5.4 Identification

5.4.1 Nameplate

Fig. 8 Nameplate

5.4.2 Type key

TM06 8664 1717

l1/1(A)

Grundfos Holding A/S

DK-8850 Bjerringbro

P1(W) MPa

Min.

Max.

X.XX

XXX X.X

((,;;3DUW;

XXXV ~ XX/XXHz IPXXX TFXXX

P/N:XXXXXXXX

S/N:XXXXXXXX

Made in XXXXXXX

PL.avg.<XXW

Denmark

14 1511 12 13

Min.XX°CModel:XXXXXX X

GFNXX

PC:P1XXXX

ALPHA1 L 25-65

ALPHA1 L XX-40/60/65

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 Average power input PL, avg (Ecodesign regulation)

8 Model designation

9 Product number

10 Serial number

11 Country of origin

12 Frequency [Hz]

13 Part, according to EEI

14 Enclosure class

15 Manufacturer's name and address

Production code:

• 1st and 2nd figures: production site code

• 3rd and 4th figures: year

• 5th and 6th figures: week

17 Minimum liquid temperature

18 Product mark (legal product code)

19 TF class

20 Crossed-out wheeled bin according to EN 50419

21 Maximum system pressure

22 Maximum input power [W]

23 Minimum input power [W]

Example ALPHA1 L 25 -40 180

Pump type

Nominal diameter (DN) of inlet and outlet

ports [mm]

Maximum head [dm]

[ ]: Cast-iron pump housing

Port-to-port length [mm]

English (GB)

5.5 Accessories

5.5.1 Unions and valve kits

G-threads have a cylindrical form in accordance with the EN ISO

228-1 standard and are not sealing the thread. It requires a flat

gasket. You can only screw cylindrical male G-threads, into

female G-threads. The G-threads are standard thread on the

pump housing.

R-threads are tapered external threads in accordance with the

EN 10226-1 standard.

Rc- or Rp-threads are internal threads with either tapered or

cylindrical threads. You can screw conical male R-threads into

female Rc- or Rp-threads. See fig. 9.

Fig. 9 G-threads and R-threads

5.5.2 Insulating shells

The accessory set is tailored to the individual pump type. The

insulating shells enclose the entire pump housing and are easy to

fit around the pump.

Product numbers, unions

ALPHAx

Connection

3/4 1 1 1/4 1 1 1/4

25-xx G 1 1/2 529921 529922 529821 529925 529924

32-xx G 2 509921 99672033

TM07 7425

RRp

Pump type Product number

ALPHA1 L XX-XX 99270706

English (GB)

5.5.3 Cables and plugs

The pump has two electrical connections: the power supply and

the control signal connection.

Power supply connection

The installer plug is both supplied with the pump and available as

an accessory.

Power cable adapters are also available as accessories.

Control signal connection

The control signal cable connection has three conductors: the

signal input, the signal output and the signal reference. Connect

the cable to the control box by a mini superseal plug. See section

7.1 Setting the PWM input signal. The optional signal cable is

available as an accessory. The cable length must not exceed 3

metres.

Fig. 10 Mini superseal plug

TM06 4414

Conductor Colour

Signal input Brown

Signal reference Blue

Signal output Black

Product Product description Length

[mm]

Product

number

Installer plug 99439948

Mini superseal signal cable (PWM input signal) 2000 99165309

Superseal power cable 2000 99198990

Power cable adapter: Superseal Molex cable

adapter, overmoulded 150 99165311

Power cable adapter: Superseal Volex cable

adapter, overmoulded 150 99165312

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