Grundfos Alpha2 l Bedienungsanleitung

ALPHA2 L

Model C

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 ALPHA 2 L.

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 Target group

1.2 Hazard statements

The symbols and hazard statements below may appear in

Grundfos installation and operating instructions, safety

instructions and service instructions.

The hazard statements are structured in the following way:

1. General information 2

1.1 Target group 2

1.2 Hazard statements 2

1.3 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 Positioning the pump 4

3.3 Control box positions 4

3.4 Insulating the pump housing 4

4. Electrical installation 5

4.1 Assembling the plug 5

4.2 Dismantling the plug 6

5. Starting up the product 6

5.1 Before startup 6

5.2 First startup 6

5.3 Venting the pump 7

6. Product introduction 7

6.1 Product description 7

6.2 Applications 8

6.3 Pumped liquids 8

6.4 Identification 8

7. Control functions 9

7.1 Elements on the operating panel 9

7.2 Display 9

7.3 Light fields indicating the pump setting 9

7.4 Control modes 10

7.5 Pump performance 12

8. Fault finding the product 13

9. Technical data 14

9.1 Data and operating conditions 14

9.2 Dimensions 15

10. Performance curves 16

10.1 Guide to performance curves 16

10.2 Curve conditions 16

10.3 Performance curves, ALPHA2 L, XX-40 17

10.4 Performance curves, ALPHA2 L, XX-60 18

11. Accessories 19

11.1 Unions 19

11.2 Insulating shells 20

11.3 ALPHA plugs 20

12. Disposing of the product 20

Read this document and the quick guide before

installing 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)

1.3 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 the

voltage and frequency of the installation site. See section

6.4.1 Nameplate.

2.2 Scope of delivery

The box contains the following items:

• ALPHA2 L pump

• ALPHA plug

• insulating shells

•two gaskets

• quick guide.

3. Installing the product

3.1 Mechanical installation

3.1.1 Mounting the product

Fig. 1 Mounting the product

The arrows on the pump housing indicate the flow direction

through the pump. See fig. 1 (A).

1. Fit the two gaskets when you mount the pump in the pipe. See

fig. 1 (B).

2. Install the pump with a horizontal motor shaft. See fig. 1 (C).

See also section 3.3 Control box positions.

3. Tighten the fittings.

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.

TM07 1193 1118

English (GB)

3.2 Positioning the pump

Fig. 2 Control box positions

Always install the pump with a horizontal motor shaft.

• Pump installed correctly in a vertical pipe. See fig. 2 (A).

• Pump installed correctly in a horizontal pipe. See fig. 2 (B).

• Do not install the pump with a vertical motor shaft. See fig. 2

(C and D).

3.3 Control box positions

3.3.1 Positioning of the control box

You can position the control box so that the plug is positioned at

3, 6 and 9 o'clock. See fig. 3.

Fig. 3 Control box positions, heating systems

3.3.2 Positioning the control box in air-conditioning and

cold-water systems

Position the control box so that the plug is pointing downwards in

applications where liquid temperature is below 2 °C. See fig. 4.

Fig. 4 Control box position, air-conditioning and cold-water

systems

3.3.3 Changing the control box position

Fig. 5 Changing the control box position

You can turn the control box in steps of 90 °.

1. Remove the four screws.

2. Turn the pump head to the desired position.

3. Insert and cross-tighten the screws.

3.4 Insulating the pump housing

Fig. 6 Insulating the pump housing

You can reduce the heat loss from the pump by insulating the

pump housing with the insulating shells supplied with the pump.

See fig. 6.

TM06 9089 4520TM07 7828 4520TM06 9091 4520

WARNING

Pressurised system

Minor or moderate personal injury

- Before dismantling the pump, drain the system or

close the isolating valves on either side of the

pump. The pumped liquid may be scalding hot and

under high pressure.

CAUTION

Hot surface

Minor or moderate personal injury

- Position the pump so that persons cannot

accidentally come into contact with hot surfaces.

If you change the position of the control box, fill the

system with the liquid to be pumped or open the

isolating valves.

TM06 9092 4520TM06 9093 4520

Do not insulate the control box or cover the operating

panel.

English (GB)

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.

4.1 Assembling the plug

WARNING

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

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.

WARNING

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.

Step Action Illustration

Fit the cable gland

and plug cover to

the cable. Strip the

cable conductors

as illustrated.

TM05 5538 3812

Connect the cable

conductors to the

power supply plug.

TM05 5539 3812

Bend the cable

with the cable

conductors

pointing upwards.

TM05 5540 3812

Pull out the

conductor guide

plate and throw it

away.

TM05 5541 3812

Click the plug

cover onto the

power supply plug.

TM05 5542 3812

Screw the cable

gland onto the

power supply plug.

TM05 5543 3812

Insert the power

supply plug into

the male plug in

the pump control

box.

TM07 1194 1118

12 mm

17 mm

7 mm

Ø 5.5 -10 mm

0.5 - 1.5 mm

English (GB)

4.2 Dismantling the plug

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 9. Technical data. For

instructions on how to vent the system, see section 5.3 Venting

the pump.

5.2 First startup

After installing the product, see section 3. Installing the product,

turn on the power supply. The light in the operating panel shows

that the power supply has been switched on. See fig. 7.

The pump is factory set to intermediate proportional-pressure

curve, PP2.

Fig. 7 Starting the pump

Step Action Illustration

Loosen the cable

gland and remove it

from the plug.

TM05 5545 3812

Pull off the plug

cover while pressing

on both sides.

TM05 5546 3812

Add the conductor

guide plate to loosen

all three cable

conductors at the

same time.

If the guide plate is

missing, then loosen

the cable conductors

one by one by

pressing a

screwdriver gently

into the terminal clip.

TM05 5547 3812

The plug has now

been removed from

the power supply

plug.

TM05 5548 3812

TM07 7700 4520

English (GB)

5.3 Venting the pump

Fig. 8 Venting the pump

The pump is self-venting through the system. You do not have to

vent the pump before startup.

Air in the pump may cause noise. This noise ceases when the

pump has run for a few minutes.

You obtain quick venting of the pump by setting the pump to

speed III. 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 7. Control functions.

You cannot vent the system through the pump. See section

6. Product introduction.

6. Product introduction

6.1 Product description

Fig. 9 Pumped liquids, warnings and operating conditions

ALPHA1 pumps are a complete range of circulator pumps.

6.1.1 Model type

These installation and operating instructions cover ALPHA2 L.

The model type is stated on the packaging and nameplate. See

figs 10.

Fig. 10 Model type on the packaging

TM06 9104 4317

The pump must not run dry.

TM07 7701 4520TM07 7789 4520

English (GB)

6.2 Applications

The pump is designed for the circulation of water in heating

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 flow rates where you want

to optimise the setting of the pump duty point.

• Systems with variable flow-pipe temperature.

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 the following liquids:

• Thin, clean, non-aggressive and non-explosive liquids, not

containing solid particles or fibres.

• Cooling liquids, not containing mineral oil.

• Domestic hot water

Maximum: 14 °dH

Maximum: 65 °C

Maximum peak: 70 °C.

For water with a higher degree of hardness, we recommend

that you use a direct-coupled TPE pump.

• Softened water.

The kinematic viscosity of water is 1 mm2/s (1 cSt) at 20 °C. If the

pump is used for a liquid with a higher viscosity, the hydraulic

performance of the pump will be reduced.

Example: 50 % glycol at 20 °C means a viscosity of approx. 10

mm2/s (10 cSt) and a reduction of the pump performance by

approx. 15 %.

Do not use additives that can or will disturb the functionality of the

pump.

When selecting a pump, take the viscosity of the pumped liquid

into consideration.

For more information about the pumped liquids, warnings and

operating conditions, see fig. 9.

6.4 Identification

6.4.1 Nameplate

Fig. 11 Nameplate

6.4.2 Type key

Example: ALPHA2 L 25 - 60 180

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 according to

local legislation.

CAUTION

Corrosive substance

Minor or moderate personal injury

- Do not use the pump for aggressive liquids, such

as acids and seawater.

TM05 3079 0912

Pos. Description

1 Minimum rated current [A]

2 Maximum rated current [A]

3 CE mark and approvals

4 EEI: Energy Efficiency Index

5 Voltage [V]

6 Product number

7 Serial number

8 Pump model

9 Country of origin

10 Data matrix code

11 Frequency [Hz]

Production code:

• 1st and 2nd figures: year

• 3rd and 4th figures: week

13 Temperature class

14 Enclosure class

15 Crossed-out wheeled bin according to EN 50419

16 Maximum system pressure [MPa]

17 Minimum input power P1 [W]

18 Maximum input power P1 [W]

Code Explanation

ALPHA2 L Pump type

25 Nominal diameter (DN) of inlet and outlet ports

[mm]

60 Maximum head [MPa]

-[ ]: Cast-iron pump housing

N: Stainless-steel pump housing

180 Port-to-port length [mm]

P1(W) MPa

I1/1 (A)

Min.

Max.

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English (GB)

7. Control functions

7.1 Elements on the operating panel

Fig. 12 Operating panel

7.2 Display

The display (1) is on when you have switched on the power

supply.

If the pump impeller is rotated, for example when filling the pump

with water, sufficient energy can be generated to light up the

display even if the power supply has been switched off.

7.3 Light fields indicating the pump setting

The pump has different performance settings which you can

select between with the button. See fig. 12 (2).

Every time you press the button , the pump setting is changed.

The pump setting is indicated by light fields in the display. See fig.

13.

Fig. 13 Nine light fields

For information about the function of the settings, see section

7.4 Control modes.

TM07 7703 4520

Pos. Description

1Light fields indicating the pump setting.

See section 7.3 Light fields indicating the pump setting.

2 Button for selection of pump setting.

TM077702 4520

Active light

fields Description

Factory setting

Lowest proportional-pressure curve, PP1

Highest proportional-pressure curve, PP2

Lowest constant-pressure curve, CP1

Highest constant-pressure curve, CP2

Constant curve/constant speed III

Constant curve/constant speed II

Constant curve/constant speed I

English (GB)

7.4 Control modes

7.4.1 Pump setting for two-pipe heating systems

Fig. 14 Selection of pump setting for system type

Recommended and alternative pump settings according to fig.

14:

* See section 10.1 Guide to performance curves.

Proportional-pressure curve, PP1 or PP2

Proportional-pressure control adjusts the pump performance to

the actual heat demand in the system. The pump performance

follows the selected performance curve, PP1 or PP2. See fig. 15

where PP1 has been selected. For further information, see

section 10.1 Guide to performance curves.

Fig. 15 The proportional-pressure curves and settings

The selection of the proportional-pressure setting depends on the

characteristics of the heating system and the actual heat

demand.

7.4.2 Pump setting for one-pipe heating systems

Fig. 16 Selection of pump setting for system type

Recommended and alternative pump settings according to fig.

16:

* See section 10.1 Guide to performance curves.

Constant-pressure curve, CP1 or CP2

The constant-pressure control adjusts the flow rate to the actual

heat demand in the system keeping a constant pressure at the

same time. The pump performance follows the selected

performance curve, CP1 or CP2. See fig. 17 where CP1 has been

selected. For further information, see section 10.1 Guide to

performance curves.

Fig. 17 The constant-pressure curves and settings

The selection of the constant-pressure setting depends on the

characteristics of the heating system and the actual heat

demand.

TM07 7705

Heating

system

Pump setting

Recommended Alternative

Two-pipe

system

Proportional-pressure

curve, PP1 or PP2 *

Constant-pressure

curve, CP1 or CP2 *

TM07 7706 4520

PP2

PP1

TM07 7704 4520

Heating

system

Pump setting

Recommended Alternative

One-pipe

system

Constant-pressure

curve, CP1 or CP2 *

Constant curve/constant

speed, I, II or III*

TM07 7707 4520

CP2

CP1

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