Grundfos Alpha2 l Bedienungsanleitung

Grundfos ALPHA2

Installation and operating instructions

GRUNDFOS INSTRUCTIONS

English (GB)

English (GB) Installation and operating instructions

Original installation and operating instructions.

CONTENTS

Page

1. Symbols used in this document 3

1.1 Warning symbols used in the quick guide 3

2. General information 4

2.1 System specifications 4

2.2 Applications 4

2.3 Pumped liquids 4

3. Identification 5

3.1 Nameplate 5

3.2 Model type 5

3.3 Type key 5

4. Mechanical installation 6

4.1 Mounting 6

4.2 Control box positions 6

4.3 Positioning in heating and domestic hot-water systems 6

4.4 Positioning in air-conditioning and cold-water systems 7

4.5 Changing the control box position 7

4.6 Insulation of pump housing 7

4.7 Air-conditioning and cold-water systems 7

5. Electrical installation 8

5.1 Assembling the plug 8

5.2 Disassembling the plug 9

5.3 First startup 9

6. Control panel 10

6.1 Elements on the control panel 10

6.2 Display 10

6.3 Light fields indicating the pump setting 10

6.4 Light field indicating the status of automatic night

setback 11

6.5 Button for enabling or disabling of automatic night

setback 11

6.6 Button for selection of pump setting 11

7. Setting the pump 12

7.1 Pump setting for two-pipe heating systems 12

7.2 Pump setting for one-pipe heating systems 12

7.3 Pump setting for underfloor heating systems 13

7.4 Pump setting for domestic hot-water systems 13

7.5 Changing from recommended to alternative pump

setting 13

7.6 Pump control 14

8. Automatic night setback/summer mode 15

8.1 Use of automatic night setback 15

8.2 Function of automatic night setback 15

8.3 Setting summer mode 16

8.4 Purpose of bypass valve 16

8.5 Manually operated bypass valve 16

8.6 Automatic bypass valve (thermostatically controlled) 16

9. Startup 17

9.1 Before startup 17

9.2 Venting the pump 17

9.3 Venting of heating systems 17

10. Pump settings and pump performance 18

10.1 Relation between pump setting and pump performance 18

11. Fault finding 19

12. Technical data and installation dimensions 20

12.1 Technical data 20

12.2 Installation dimensions, Grundfos ALPHA2 XX-40,

XX-50, XX-60, XX-80 21

12.3 Installation dimensions, Grundfos ALPHA2 25-40 A,

25-60 A 22

13. Performance curves 23

13.1 Guide to performance curves 23

13.2 Curve conditions 23

13.3 Performance curves, ALPHA2 XX-40 (N) 24

13.4 Performance curves, ALPHA2 XX-50 (N) 25

13.5 Performance curves, ALPHA2 XX-60 (N) 26

13.6 Performance curves, ALPHA2 25-40 A 27

13.7 Performance curves, ALPHA2 25-60 A 28

13.8 Performance curves, ALPHA2 XX-80 (N) 29

14. Accessories 30

14.1 Insulating shells 31

14.2 ALPHA plugs 31

15. Disposal 31

Warning

Prior to installation, read these

installation and operating

instructions. Installation and

operation must comply with

local regulations and accepted

codes of good practice.

Warning

The use of this product requires

experience with and knowledge

of the product.

Persons with reduced physical,

sensory or mental capabilities

must not use this product,

unless they are under

supervision or have been

instructed in the use of the

product by a person responsible

for their safety.

Children must not use or play

with this product.

Warning

This product can be used by

children of eight years and up

and persons with reduced

physical, sensory or mental

capabilities or lack of

experience and knowledge if

they are under supervision or

have been instructed in the safe

use of the product and

understand the hazards

involved.

Children must not play with the

product. Cleaning and

maintenance of the product

must not be made by children

without supervision.

English (GB)

1. Symbols used in this document 1.1 Warning symbols used in the quick guide

Warning

If these safety instructions are

not observed, it may result in

personal injury.

Warning

If these instructions are not

observed, it may lead to electric

shock with consequent risk of

serious personal injury or death.

Caution

If these safety instructions are not observed,

it may result in malfunction or damage to the

equipment.

Symbol Description

Warning

Do not use the pump for

flammable liquids, such as

diesel oil and petrol.

Warning

Do not use the pump for

aggressive liquids, such as

acids and seawater.

Warning

Drain the system or close

the isolating valves on either

side of the pump before you

remove the screws.

The pumped liquid may be

scalding hot and under high

pressure.

Warning

Position the pump so that

persons cannot accidentally

come into contact with hot

surfaces.

Warning

Switch off the power supply

before making connections.

Make sure that the power

supply cannot be

accidentally switched on.

The pump must be

connected to earth.

The pump must be

connected to an external

mains switch with a

minimum contact gap of

3 mm in all poles.

English (GB)

2. General information

2.1 System specifications

Fig. 1 Pumped liquids, warnings and operating conditions

2.2 Applications

The Grundfos 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.

Grundfos ALPHA2 is the best choice for the following systems:

• underfloor heating systems

• one-pipe systems

• two-pipe systems.

Grundfos ALPHA2 is suitable for the following:

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

optimise the setting of the pump duty point.

• Systems with variable flow-pipe temperature.

• Systems where automatic night setback is desired.

2.3 Pumped liquids

Fig. 1, pos. 1.

In heating systems, the water should 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, max. 14 °dH, max. 65 °C, peak max.

70 °C.

For water with a higher degree of hardness, we recommend 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 in anyway can/will disturb the

functionality of the pump.

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

into consideration.

TM05 3055 0912TM05 3056 0912

3Max. 95 %RH

IPX4D

Min./Max.

+2 C / +110

Max. 1.0 MPa

(10 bar)

°°

Min./Max.

0 C / +40

< 43 db(A)

°°

Warning

Do not use the pump for

flammable liquids, such as

diesel oil and petrol.

Warning

Do not use the pump for

aggressive liquids, such as

acids and seawater.

Warning

In domestic hot-water systems,

the temperature of the pumped

liquid must always be above

50 °C due to the risk of

legionella.

Recommended boiler

temperature: 60 °C.

Warning

In domestic hot-water systems,

the pump is permanently

connected to the mains water

and therefore not allowed to be

connected by a hose set

English (GB)

3. Identification

3.1 Nameplate

Fig. 2 Nameplate

3.2 Model type

These installation and operating instructions cover model B and

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

See figs. 3and 4.

Fig. 3 Model type on packaging

Fig. 4 Model type on nameplate

The table below shows the ALPHA2 models with built-in functions

and features.

3.3 Type key

TM05 3079 0912

Pos. Description

1 Pump type

Rated current [A]:

• Min.: Minimum current [A]

• Max.: Maximum current [A]

3 CE mark and approvals

EEI: Energy Efficiency Index

Part 1: Indicating whether the pump is tested in

accordance with the following:

Part 2 - Stand-alone product

Part 3 - Integrated product according to

EN 16297-1:2012 and EN 16297-2:2012.

5 Voltage [V]

6 Product number

7 Serial number

8 Model

9 Country of origin

Input power P1 [W]:

• Min.: Minimum input power P1 [W]

• Max.: Maximum input power P1 [W]

11 Maximum system pressure [MPa]

12 Enclosure class

13 Temperature class

Production code:

• 1st and 2nd figures = year

• 3rd and 4th figures = week

15 Frequency [Hz]

16 QR code

210

AUTO

ADAPT

ALPHA 2 25-40 180

TM061840 3214TM06 1716 2614

Functions/features Model B

2012

Model C

2014

AUTOADAPT ●●

Proportional pressure ●●

Constant pressure ●●

Constant curve ●●

Automatic night setback ●●

Summer mode ●

ALPHA2 XX-40 ●●

ALPHA2 XX-50 ●●

ALPHA2 XX-60 ●●

ALPHA2 XX-80 ●

Example ALPHA2 25 -40 N 180

Pump type

: Standard version

L: Limited version

Nominal diameter (DN) of suction and

discharge 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]

English (GB)

4. Mechanical installation

4.1 Mounting

Fig. 5 Mounting the Grundfos ALPHA2

Arrows on the pump housing indicate the liquid flow direction

through the pump. See fig. 5, pos. A.

See section 12.2 Installation dimensions, Grundfos ALPHA2

XX-40, XX-50, XX-60, XX-80 or 12.3 Installation dimensions,

Grundfos ALPHA2 25-40 A, 25-60 A.

1. Fit the two gaskets supplied when you mount the pump in the

pipe. See fig. 5, pos. B.

2. Install the pump with horizontal motor shaft. See fig. 5, pos. C.

See also section 4.2 Control box positions.

3. Tighten the fittings.

4.2 Control box positions

Fig. 6 Control box positions

Always install the pump with horizontal motor shaft.

• Pump installed correctly in a vertical pipe. See fig. 6, pos. A.

• Pump installed correctly in a horizontal pipe. See fig. 6, pos. B.

• Do not install the pump with vertical motor shaft.

See fig. 6, pos. C and D.

4.3 Positioning in heating and domestic hot-water

systems

You can position the control box in position 3, 6 and 9 o'clock.

See fig. 8.

Fig. 7 Control box positions, heating and domestic hot-water

systems

TM05 3057 0612

TM05 2919 0912TM05 3146 0912

English (GB)

4.4 Positioning in air-conditioning and cold-water

systems

Position the control box with the plug pointing downwards.

See fig. 8.

Fig. 8 Control box positions, air-conditioning and cold-water

systems

4.5 Changing the control box position

Fig. 9 Changing the control box position

The control box can be turned in steps of 90 °.

Procedure:

1. Slacken and remove the four hexagon socket head screws

while holding the pump head with a tee key (M4).

2. Turn the pump head to the desired position.

3. Insert and cross-tighten the screws.

4.6 Insulation of pump housing

Fig. 10 Insulation of pump housing

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

insulating the pump housing and the pipe with the insulating

shells supplied with the pump. See fig. 10.

4.7 Air-conditioning and cold-water systems

Use the insulating shells for pumps in air-conditioning and

cold-water systems as well.

Polystyrene insulating shells can be ordered from Grundfos.

See section 14. Accessories.

TM05 3151 1212TM05 3151 1212

Warning

Drain the system or close the

isolating valves on either side of

the pump before you remove the

screws. The pumped liquid may

be scalding hot and under high

pressure.

Caution

When the position of the control box has been

changed, fill the system with the liquid to be

pumped or open the isolating valves.

TM05 3058 0912

Note

Limit the heat loss from the pump housing and

pipework.

Caution

Do not insulate the control box or cover the

control panel.

English (GB)

5. Electrical installation

Fig. 11 Electrical connection

The electrical connections and protection must be carried out 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

3.1 Nameplate.

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

with the pump. See steps 1 to 7.

5.1 Assembling the plug

Warning

The pump must be connected to

earth .

The pump must be connected to

an external mains switch with a

minimum contact gap of 3 mm in

all poles.

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

Max. 1.5 mm2

12 mm

∅5.5 - 10 mm

7 mm

17 mm

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.

TM05 3058 0912

English (GB)

5.2 Disassembling the plug

5.3 First startup

• The light in the control panel shows that the power supply has

been switched on. See fig. 12.

• Factory setting: AUTOADAPT.

Fig. 12 Switching on 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

TM05 3058 0912

1 x 230 V ± 10 % ∽50/60 Hz

English (GB)

6. Control panel

6.1 Elements on the control panel

Fig. 13 Control panel

The control panel on the pump comprises the following:

6.2 Display

The display (pos. 1) is on when the power supply has been

switched on.

The display shows the actual pump power consumption in watt

(integer) or the actual flow in m3/h (in steps of 0.1 m3/h) during

operation.

If a fault is indicated, correct the fault and reset the pump by

switching the power supply off and on.

6.3 Light fields indicating the pump setting

The pump has ten optional performance settings which can be

selected with the button. See fig. 13, pos. 5.

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

See fig. 14.

Fig. 14 Nine light fields

See section 10. Pump settings and pump performance for

information about the function of the settings.

TM05 3060 0912

Pos. Description

1Display showing the actual pump power

consumption in watt or the actual flow in m3/h.

Nine light fields indicating the pump setting.

See section 6.3 Light fields indicating the pump

setting.

3Light field indicating the status of automatic night

setback.

4Button for enabling or disabling of automatic night

setback/summer mode.

5 Button for selection of pump setting.

Button for selection of parameter to be shown in the

display, i.e. actual power consumption in watt or

actual flow in m3/h.

Note

Faults preventing the pump from operating

properly (for example blocked rotor) are

indicated in the display by fault codes.

See section 11. Fault finding.

Note

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.

TM05 3061 0912

Button

presses Active light fields Description

0AUTOADAPT

(factory setting) AUTOADAPT

Lowest

proportional-pressure

curve, referred to as PP1

Intermediate

proportional-pressure

curve, referred to as PP2

Highest

proportional-pressure

curve, referred to as PP3

Lowest

constant-pressure curve,

referred to as CP1

Intermediate

constant-pressure curve,

referred to as CP2

Highest

constant-pressure curve,

referred to as CP3

Constant curve/constant

speed III

Constant curve/constant

speed II

Constant curve/constant

speed I

AUTOADAPT

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