Grundfos ALPHA2 Series Bedienungsanleitung

ALPHA2/ALPHA3

Installation and operating instructions

GRUNDFOS INSTRUCTIONS

English (GB)

English (GB) Installation and operating instructions

Original installation and operating instructions

CONTENTS

These installation and operating instructions describe ALPHAx.

Sections 1-6 give the information necessary to be able to unpack,

install and start up the product in a safe way.

Sections 6-17 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. General information 2

1.1 Target group 2

1.2 Symbols used in this document 3

1.3 Other important notes 3

2. Receiving the product 3

2.1 Inspecting the product 3

2.2 Scope of delivery 3

3. Installing the product 4

3.1 Mechanical installation 4

3.2 Control box positions 4

3.3 Control box positions, ALPHA SOLAR 5

3.4 Insulating the pump housing 6

4. Electrical installation 6

4.1 Assembling the plug 7

4.2 Disassembling the plug 8

4.3 Electrical installation, ALPHA SOLAR 8

4.4 Power supply connection, ALPHA SOLAR 8

4.5 Control signal connection, ALPHA SOLAR 8

5. Starting up the product 9

5.1 Before startup 9

5.2 Venting the pump 9

5.3 Venting the heating system 9

5.4 First startup 9

6. Product introduction 10

6.1 Product description 10

6.2 Applications 10

6.3 Pumped liquids 11

6.4 Identification 11

7. Control functions 13

7.1 Elements on the control panel 13

7.2 Display 13

7.3 Light fields indicating the pump setting 13

7.4 Light field indicating the status of automatic night

setback 13

7.5 Button for enabling or disabling of automatic night

setback 13

7.6 Button for selection of pump setting 14

7.7 Control modes 14

7.8 Pump performance 16

7.9 Bypass valve 17

8. Operating the product 17

8.1 Using automatic night setback 17

8.2 Function of automatic night setback 18

8.3 Setting manual summer mode 18

8.4 Dry-running protection 18

8.5 ALPHA Reader 18

8.6 High-torque start 18

9. Fault finding 19

10. Technical data and installation dimensions 20

10.1 Technical data 20

10.2 Dimensions, ALPHAx XX-40, XX-50, XX-60, XX-80 21

10.3 Dimensions, ALPHAx 25-40 A, 25-60 A 22

11. Performance curves 23

11.1 Guide to performance curves 23

11.2 Curve conditions 23

11.3 Performance curves, ALPHAx XX-40 (N) 24

11.4 Performance curves, ALPHAx XX-50 (N) 25

11.5 Performance curves, ALPHAx XX-60 (N) 26

11.6 Performance curves, ALPHAx 25-40 A 27

11.7 Performance curves, ALPHAx 25-60 A 28

11.8 Performance curves, ALPHAx XX-80 (N) 29

12. Accessories 30

12.1 Unions and valve kits 30

12.2 Insulating shells 30

12.3 ALPHA plugs 31

13. ALPHA SOLAR 31

13.1 Product introduction 31

13.2 Application 31

13.3 Product description 31

13.4 Operating the product 31

13.5 Setting by means of the control panel 31

13.6 Operating status 31

13.7 Alarm status 31

13.8 Operating status 32

13.9 Fault finding the product 32

14. External PWM control mode and signals 33

15. Digital solar-circuit controller 33

16. Technical data 33

17. Disposing of the product 35

Prior to installation, read this document and the quick

guide. 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.

English (GB)

1.2 Symbols used in this document

1.2.1 Warnings against hazards involving risk of death or

personal injury

The text accompanying the three hazard symbols DANGER,

WARNING and CAUTION will be structured in the following way:

1.3 Other important notes

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:

• ALPHAx pump

• ALPHA plug

• insulating shells

• two gaskets

• quick guide.

ALPHA SOLAR is delivered without insulating shells but with a

plug designed for ALPHA SOLAR.

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.

Notes or instructions that make the work easier and

ensure safe operation.

English (GB)

3. Installing the product

3.1 Mechanical installation

3.1.1 Mounting the product

Fig. 1 Mounting ALPHAx

The arrows on the pump housing indicate the flow direction

through the pump. See fig. 1, pos. A.

See section 10.2 Dimensions, ALPHAx XX-40, XX-50, XX-60,

XX-80 or section 10.3 Dimensions, ALPHAx 25-40 A, 25-60 A.

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

fig. 1, pos. B.

2. Install the pump with a horizontal motor shaft. See fig. 1, pos.

C. See also section 3.2 Control box positions.

3. Tighten the fittings.

3.2 Control box positions

Fig. 2 Control box positions

Always install the pump with a horizontal motor shaft.

• Pump installed correctly in a vertical pipe. See fig. 2, pos. A.

• Pump installed correctly in a horizontal pipe. See fig. 2, pos. B.

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

pos. C and D.

3.2.1 Positioning of the control box in heating and domestic

hot-water systems

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

See fig. 4.

Fig. 3 Control box positions, heating and domestic hot-water

systems

TM05 3057 0612

TM05 2919 0912TM05 3146 0912

English (GB)

3.2.2 Positioning the control box in air-conditioning and

cold-water systems

Position the control box with the plug pointing downwards. See

fig. 4.

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

systems

3.2.3 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.

3.3 Control box positions, ALPHA SOLAR

Fig. 6 Control box positions, ALPHA SOLAR

Always install the pump with horizontal motor shaft. Position the

control box in position 9 o'clock. See fig. 7.

Fig. 7 Position of the ALPHA SOLAR control box

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

TM05 3151 1212TM05 3147 1212

CAUTION

Hot surface

Minor or moderate personal injury.

- Position the pump so that persons cannot

accidentally come into contact with hot surfaces.

CAUTION

Pressurised system

Minor or moderate personal injury.

- Before dismantling the pump, drain the system or

close the isolating valve on either side of the

pump. The pumped liquid may be scalding hot and

under high pressure.

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

system with the liquid to be pumped or open the

isolating valves.

TM06 5636 5115TM06 5831 0616

English (GB)

3.4 Insulating the pump housing

Fig. 8 Insulating the pump housing

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

insulating the pump housing and the pipe with the insulating

shells supplied with the pump. See fig. 8.

3.4.1 Air-conditioning and cold-water systems

Use the insulating shells in air-conditioning and cold-water

systems as well.

The insulating shells for air-conditioning and cooling systems are

available as accessories. You can order the insulating shells

separately. See section 12. Accessories.

4. Electrical installation

Fig. 9 Electrical connection

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.

TM05 3058 0912

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 mains switch with

a minimum contact gap of 3 mm in all poles.

English (GB)

4.1 Assembling the plug

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

Max. 1.5 mm2

12 mm

∅5.5 - 10 mm

7 mm

17 mm

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

Step Action Illustration

English (GB)

4.2 Disassembling the plug

Fig. 10 Starting up the pump

4.3 Electrical installation, ALPHA SOLAR

Fig. 11 Control box connections

4.4 Power supply connection, ALPHA SOLAR

Connect the pump to the power supply with the TE Superseal

power plug.

4.5 Control signal connection, ALPHA SOLAR

If you do not need the signal connection, cover it with a blanking

plug. See fig. 11.

You can control the pump with a low-voltage PWM (pulse-width

modulation) signal.

The PWM signal is a method for generating an analog signal

using a digital source.

The control signal connection has three conductors: signal input,

signal output and signal reference. Connect the cable to the

control box with a TE Mini Superseal plug. The signal cable can

be supplied with the pump as an accessory.

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

TM06 5819 0216

DANGER

Electric shock

Death or serious personal injury

- Connect the pump to earth.

Connect the pump to an external mains switch with

a minimum contact gap of 3 mm in all poles.

PWM =

Power =

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 sections 3. Installing the product and 10. Technical data and

installation dimensions.

5.2 Venting the pump

Fig. 12 Venting the pump

The pump is self-venting. 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 for a short period. 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

5.3 Venting the heating system.

5.3 Venting the heating system

Fig. 13 Venting of the heating system

Vent the heating system as follows:

• via an air vent valve installed above the pump (1)

• via a pump housing with air separator (2).

In heating systems that often contain much air, we recommend

that you install pumps with pump housing with air separator, i.e.

ALPHAx XX-XX A.

When the heating system has been filled with liquid, do as

follows:

1. Open the air vent valve.

2. Set the pump to speed III.

3. Let the pump run for a short period

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

7. Control functions.

Repeat the procedure, if necessary.

5.4 First startup

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

been switched on. See fig. 10.

• Factory setting: AUTOADAPT.

TM05 3075 0912

The pump must not run dry.

10 Min.

TM03 8931 2707

The pump must not run dry.

40 180

10 Min.

English (GB)

6. Product introduction

6.1 Product description

Fig. 14 Pumped liquids, warnings and operating conditions

ALPHA2/ALPHA3, referred to as ALPHAx in the following, is a

complete range of circulator pumps.

6.1.1 Model type

These installation and operating instructions cover ALPHA2

model B, C and D, and ALPHA3. The model type is stated on the

packaging and nameplate. See figures 15 and 16.

Fig. 15 Model type on the packaging

Fig. 16 Model type on the nameplate

6.2 Applications

The ALPHAx 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.

ALPHAx is the best choice for the following systems:

• underfloor heating systems

• one-pipe systems

• two-pipe systems.

ALPHAx is suitable for the following:

• Systems with constant or variable flows where you want to

optimise the setting of the pump duty point.

• Systems with variable flow-pipe temperature.

• Systems where you want automatic night setback.

• Balancing of domestic heating systems.

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)

°°

TM06 45820 2515TM06 1716 2614

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