Grundfos ALPHA3 Series Bedienungsanleitung

ALPHA3

Model B

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

ALPHA3 model B.

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 4

3.2 Pump positions 4

3.3 Control box positions 4

3.4 Insulating the pump housing 5

3.5 Electrical installation 6

4. Starting up the product 7

4.1 Before startup 7

4.2 First startup 7

4.3 Venting the pump 7

5. Product introduction 8

5.1 Product description 8

5.2 Intended use 8

5.3 Pumped liquids 8

5.4 Identification 8

5.5 Accessories 10

6. Control functions 12

6.1 Operating modes 12

6.2 Control modes 12

6.3 Guide to control mode selection 14

7. Setting the product 15

7.1 Light fields indicating the pump setting 15

7.2 Connecting the pump to Grundfos GO Remote 15

7.3 Grundfos GO Remote menu overview 16

7.4 Setup wizard 16

7.5 Scheduling 17

7.6 Activating and deactivating "Automatic night setback" 17

7.7 Hydronic balancing 18

7.8 Firmware update 18

7.9 Resetting to factory settings 18

7.10 Setting the operating mode using the operating panel 19

8. Servicing the product 19

8.1 Dismantling the product 19

8.2 Dismantling the plug 19

9. Fault finding the product 20

9.1 Fault indication on the pump operating panel 20

9.2 Resetting an alarm or warning 20

9.3 Alarm and warning code logs 20

9.4 Automatic deblocking 20

9.5 Fault finding tables 21

10. Technical data 22

10.1 Dimensions, ALPHA3, XX-40, XX-60, XX-80 23

11. Performance curves 24

11.1 Guide to performance curves 24

11.2 Curve conditions 24

11.3 ALPHA3, XX-40 25

11.4 ALPHA3, XX-60 26

11.5 ALPHA3, XX-80 27

12. Disposing of the product 27

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

5.4.2 Nameplate.

2.2 Scope of delivery

The box contains the following items:

• ALPHA3 pump

• ALPHA plug

• insulating shells

• two gaskets

• quick guide.

3. Installing the product

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.

WARNING

Electric shock

Death or serious personal injury

- A damaged product must be repaired or replaced

by Grundfos or a service workshop authorised by

Grundfos.

WARNING

Steam

Death or serious personal injury

- The pumped liquid may be scalding hot and under

high pressure. A damaged product must be

repaired or replaced by Grundfos or a service

workshop authorised by Grundfos.

CAUTION

Crushing of feet

Minor or moderate personal injury

- Wear safety shoes when opening the box and

handling the product.

The pump must always be installed with a horizontal

motor shaft within ± 5 °.

English (GB)

3.1 Mechanical installation

3.1.1 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 supplied with the pump when you mount

the pump in the pipe. See fig. 1(B).

2. Install the pump with a horizontal motor shaft within ± 5 °. See

fig. 1(C). See also section 3.2 Pump positions.

3. Tighten the fittings.

Fig. 1 Mounting ALPHA3

3.2 Pump positions

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

• 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).

Fig. 2 Control box positions

3.3 Control box positions

3.3.1 Positioning of the control box in heating systems

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

See fig. 3.

Fig. 3 Control box positions, heating systems

TM07 1193 1118

TM07 1116 0218TM07 1121 0218

A B

English (GB)

3.3.2 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

3.3.3 Changing the control box position

To change the position of the control box, do as follows:

3.4 Insulating the pump housing

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

pump housing with the insulating shells supplied with the pump.

See fig. 5.

Fig. 5 Insulating the pump housing

TM07 1127 0218

Step Action Illustration

1Remove the four

screws.

TM05 5538 3812

Turn the pump

head to the

desired position.

You can turn the

control box in

steps of 90 °.

TM05 5539 3812

Insert and

cross-tighten the

screws.

TM05 5540 3812

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.

TM05 3058 0912

Do not insulate the control box or cover the operating

panel.

English (GB)

3.5 Electrical installation

• The pump requires no external motor protection.

• Check that the supply voltage and frequency correspond to

the values stated on the nameplate. See section

5.4.2 Nameplate.

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

with the pump. See steps 1 to 7 below.

3.5.1 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.

WARNING

Electric shock

Death or serious personal injury

- If national legislation requires a Residual Current

Device (RCD) or equivalent in the electrical

installation, or if the pump is connected to an

electric installation where an RCD is used as an

additional protection, this must be type A or better,

due to the nature of the pulsating DC leakage

current. The RCD must be marked with the symbol

shown below;

WARNING

Electric shock

Death or serious personal injury

- All electrical connections must be carried out by a

qualified electrician in accordance with local

regulations.

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

12 mm

17 mm

7 mm

Ø 5.5 -10 mm

0.5 - 1.5 mm2

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

Step Action Illustration

English (GB)

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.

4.2 First startup

After 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. 6.

Factory setting

The pump is factory set to radiator mode with AUTOADAPT.

Fig. 6 Starting up the pump

4.2.1 Dry-running protection

The dry-running protection protects the pump against dry running

during startup and normal operation. See section 9. Fault finding

the product.

During first startup and in case of dry-run, the pump will show a

warning. See section 9.5 Fault finding tables.

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. Still,

we recommend venting the pump in new installations or when the

pipes have been emptied and refilled with water.

Venting the pump at the first startup

When the pump is connected to Grundfos GO Remote, the app

takes you through a setup wizard. See section 7.4 Setup wizard.

When the setup is completed, a "Pump venting" dialogue box

appears after approximately two seconds, which guides you

through the pump venting process.

The venting process lasts 30 minutes.

Venting the pump via the "Assist" menu

You access the "Pump venting" menu in the "Assist" menu. Do as

follows:

1. Connect the pump to Grundfos GO Remote. See section

7.2 Connecting the pump to Grundfos GO Remote.

2. Go to the "Assist" menu and choose "Pump venting". Follow

the instructions given in Grundfos GO Remote. The venting

process lasts 30 minutes.

Fig. 8 Operating panel during venting process

TM07 1126 0218TM07 1192 1118

30 min

TM07 1210 1118

The pump automatically returns to its initial settings

after venting.

The pump must not run dry.

You cannot vent the system through the pump.

ALPHA3

English (GB)

5. Product introduction

5.1 Product description

The Grundfos ALPHA3 pump is designed for circulating liquids in

systems with variable flow rates where it is desirable to optimise

the setting of the pump duty point to reduce energy costs.

ALPHA3 is completely controlled with Grundfos GO Remote via

Bluetooth, which gives you step-by-step assistance to pump

configuration, maintenance and repair, including:

• operating and control modes

• scheduling for when the pump should operate and when not

• warning and alarm status with up to 20 entries.

Furthermore, ALPHA3 is able to connect to the Grundfos GO

Balance app, which allows you to hydronically balance two-pipe

radiators and underfloor heating systems in a fast and safe way.

5.2 Intended use

The pump is designed for circulating liquids in heating and air

conditioning systems with temperatures equal to or higher than 2

°C.

5.3 Pumped liquids

In heating systems, the water must meet the requirements of

accepted standards on water quality in heating systems, for

example the German guideline 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.

• 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

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

performance by approximately 15 %.

Do not use additives that can 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 section 10. Technical data.

5.4 Identification

5.4.1 Model type

These installation and operating instructions cover Grundfos

ALPHA3 model B. The model type is stated on the packaging and

nameplate. See figs 9and 10.

Fig. 9 Model type on the packaging

Fig. 10 Model type on the nameplate

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.

TM07 0356 1318TM07 1191 1118

English (GB)

5.4.2 Nameplate

Fig. 11 Nameplate

5.4.3 Type key

TM07 0628 1118

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 Frequency [Hz]

11 Data matrix code

12 Grundfos address

Production code:

• 1st and 2nd figures: production site code

• 3rd and 4th figures: year

• 5th and 6th figures: week

14 Temperature class

15 Enclosure class

16 Part, according to EEI

17 Crossed-out wheeled bin according to EN 50419

18 Maximum system pressure [MPa]

19 Maximum input power P1 [W]

20 Minimum input power P1 [W]

21 Product type

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Example ALPHA3 25 -40 N 180

Pump type

[ ]: Standard version

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

Note: The product numbers are always for one complete set, incl. gaskets.

* When ordering for UK 15-xx versions, use product numbers for 25-xx (G 1 1/2).

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 male G-threads (cylindrical) 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 (parallel) threads. You can screw male R-threads

(conical) into female Rc- or Rp-threads. See fig. 12.

Fig. 12 G-threads and R-threads

Product numbers, unions

Union nut with internal

threads

Union nut with

external

threads

Ball valve with internal

threads

Ball valve with

compression fitting Union nut with soldering fitting

ALPHA3

Connection

3/4 1 1 1/4 1 1 1/4 3/4 1 1 1/4 ∅22 ∅28 ∅18 ∅22 ∅28 ∅42

15-xx* G 1

25-xx G 1 1/2 529921 529922 529821 529925 529924 519805 519806 519807 519808 519809 529977 529978 529979

32-xx G 2 509921 509922 529995

TM07 0558 0218

RRp Rc

Rc Rp R

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