Grundfos SuperBrute XL Bedienungsanleitung

Grundfos SuperBrute XL

Maintenance-free Circulators

GRUNDFOS INSTRUCTIONS

Installation and operating instructions

3191277 Conforms to UL STD 514C

Certified to CSA STD C22.2 No. 18.2

LIMITED WARRANTY

Products manufactured by GRUNDFOS PUMPS CORPORATION (Grundfos)

are warranted to the original user only to be free of defects in material and

workmanship for a period of 36 months from date of manufacture. Grundfos'

liability under this warranty shall be limited to repairing or replacing at

Grundfos' option, without charge, F.O.B. Grundfos' factory or authorized

service station, any product of Grundfos' manufacture. Grundfos will not be

liable for any costs of removal, installation, transportation, or any other

charges which may arise in connection with a warranty claim. Products which

are sold but not manufactured by Grundfos are subject to the warranty

provided by the manufacturer of said products and not by Grundfos' warranty.

Grundfos will not be liable for damage or wear to products caused by

abnormal operating conditions, accident, abuse, misuse, unauthorized

alteration or repair, or if the product was not installed in accordance with

Grundfos' printed installation and operating instructions.

To obtain service under this warranty, the defective product must be returned

to the distributor or dealer of Grundfos' products from which it was purchased

together with proof of purchase and installation date, failure date, and

supporting installation data. Unless otherwise provided, the distributor or

dealer will contact Grundfos or an authorized service station for instructions.

Any defective product to be returned to Grundfos or a service station must be

sent freight prepaid; documentation supporting the warranty claim and/or a

Return Material Authorization must be included if so instructed.

GRUNDFOS WILL NOT BE LIABLE FOR ANY INCIDENTAL OR

CONSEQUENTIAL DAMAGES, LOSSES, OR EXPENSES ARISING FROM

INSTALLATION, USE, OR ANY OTHER CAUSES. THERE ARE NO

EXPRESS OR IMPLIED WARRANTIES, INCLUDING MERCHANTABILITY

OR FITNESS FOR A PARTICULAR PURPOSE, WHICH EXTEND BEYOND

THOSE WARRANTIES DESCRIBED OR REFERRED TO ABOVE.

Some jurisdictions do not allow the exclusion or limitation of incidental or

consequential damages and some jurisdictions do not allow limit actions on

how long implied warranties may last. Therefore, the above limitations or

exclusions may not apply to you. This warranty gives you specific legal rights

and you may also have other rights which vary from jurisdiction to jurisdiction.

Grundfos SuperBrute XL

Maintenance-free Circulators

Installation and operating instructions 4

Notice d’installation et d’entretien 18

Instrucciones de instalación y funcionamiento 32

CONTENTS Page

1. Safety warning 5

1.1 Read this booklet 5

1 2 Electrical work 5

2. Pre-installation checklist 5

2.1 Confirm you have the correct pump 5

2 2 Check the condition of the pump 6

2 3 Verify electrical requirements 6

2.4 Pumped liquid requirements 6

3. Installation procedures 7

3.1 Piping considerations 7

3 2 Changing the terminal box position 7

3 3 Electrical connection 9

4. Starting the pump 10

4.1 Vent the piping system 10

4 2 Speed selection 10

5. Troubleshooting 11

5.1 Fault finding chart 11

5 2 Preliminary checks 12

5 3 Current measurement 12

5.4 Insulation resistance

(lead-to-ground) 13

5.5 Winding resistance (line-to-line) 13

5 6 Resistance charts 14

6. Replacing components 15

6.1 Removing the pump head 15

6 2 Fitting the pump head 15

6 3 Replacing the terminal

box or capacitor 16

7. Additional technical data 17

8. Disposal 17

1. Safety warning

1.1 Read this booklet

This booklet is designed to help a certified

installer to install, begin operation of, and

troubleshoot the Grundfos SuperBrute XL,

UP and UPS pumps.

Following the instructions will ensure safe,

trouble-free operation.

This booklet should be left with the owner of

the pump for future reference and information

regarding its operation. Should the owner

experience any problems with the pump, a

certified professional should be contacted.

1.2 Electrical work

All electrical work should be performed by a

qualified electrician in accordance with the

latest edition of the National Electrical Code,

local codes and regulations.

2. Pre-installation checklist

2.1 Confirm you have the correct

pump

• Read the pump nameplate to ensure it is

the one you ordered.

• Compare the pump's nameplate data and its

performance curve (for head, gpm, etc.)

with the application in which you plan to

install it.

• Will the pump do what you expect it to do?

2.1.1 Pump to system type

recommendations

•Open systems (i.e. potable water):

Stainless steel or bronze volute (pump

housing) only.

•Closed systems (i.e. airless, non-potable

water): Cast iron, stainless steel, or bronze

volute (pump housing).

Other considerations regarding Grundfos

SuperBrute XL, UP and UPS pumps:

• These pumps are intended for indoor use

only.

• If installed outdoors the pump must be

protected by an appropriate, well ventilated,

water-tight enclosure to keep out moisture

and dirt.

• Minimum ambient temperatures must be no

lower than 33 °F (1 °C).

• For ambient and fluid temperature see

sections 2.4 Pumped liquid requirements

and 7. Additional technical data.

Warning!

A faulty motor or wiring can

cause electrical shock that could

be fatal, whether touched directly

or conducted through standing

water. For this reason, proper

grounding of the pump to the

power supply's grounding

terminal is required for safe

installation and operation.

In all installations, the above-

ground metal plumbing should

be connected to the power

supply ground as described in

the National Electrical Code. All

wiring must comply with the

National Electrical Code, state,

and local regulations.

2.2 Check the condition of the pump

The pump’s shipping carton is specially

designed around the pump during production

to prevent damage.

As a precaution, it should remain in the carton

until you are ready to install it. At that point,

look at the pump and examine it for any

damage that may have occurred during

shipping.

Examine any other parts of the shipment as

well for any visible damage. Once the pump

has been removed from the box, care should

be taken NOT to drop or mishandle the pump.

Box contents:

• one pump

• two gaskets (flanged units only)

• one Installation and Operation Instruction

(I&O).

2.3 Verify electrical requirements

Verify the electrical supply to be certain the

voltage, phase and frequency match that of

the pump motor. The proper operating voltage

and other electrical information can be found

on the pump nameplate.

This pump’s motor is designed to run on

+ / - 10 % of the nameplate-rated voltage.

2.4 Pumped liquid requirements

The pump can be used to circulate:

• Potable hot water.

• Water containing glycol for hydronic heating

(see section 7. Additional technical data for

additional limitations).

• Cooling water.

In domestic hot-water systems it is advisable

to use stainless steel pump housing versions

of this pump.

All pump types (stainless, bronze or cast iron

pump housing) should not be used in water

with a degree of hardness lower than 14 grains

per gallon of hardness.

Fluids should be clean and should not contain

solid particles, fibers, or mineral oils.

If the pump is installed in a heating system, the

water should meet the requirements of

accepted standards on water quality in heating

systems. The fluid should not contain solid

particles, fibers, or mineral oils.

The pump is lubricated and cooled by the

liquid being pumped. Therefore, the pumped

liquid must always be allowed to circulate

through the pump.

Extended periods without circulation will cause

premature wear to the bearings and excessive

motor heat.

The pumped liquid must meet the temperature

requirements listed in the following charts.

Note: Fluid must never be allowed to freeze

during non-operational periods.

The Grundfos SuperBrute XL,

UP/UPS pump is intended for

use with water only. The pump

must not be used for the transfer

of flammable liquids such as

diesel oil, gasoline, and similar

liquids.

The pump is not for pool or

marine use.

Open systems

(domestic, potable hot water)

Fluid Ambient

Min. 36 °F (2 °C) 33 °F (1 °C)

Max. < 149 °F(65 °C) 100 °F (38°C)

In domestic hot-water systems,

it is recommended to keep the

liquid temperature below 149 °F

(65 °C) to eliminate the risk of lime

precipitation.

Closed systems

(non-potable heating or cooling airless fluid)

XL pump

models Fluid Ambient

Min. All 36 °F

(2 °C) 33 °F

(1 °C)

Max.

UPS 26-150 230 °F

(110 °C) 100 °F

(38°C)

UPS 43-100 230 °F

(110 °C) 100 °F

(38°C)

UPS 50-60 212 °F

(100 °C) 100 °F

(38°C)

Water and glycol mix

Max. 50 % glycol @ 15 °F (-9.5 °C) fluid

(Hydraulic performance change can be expected.)

Caution

3. Installation procedures

3.1 Piping considerations

When making piping connections, be sure

to follow the piping manufacturer’s

recommendations and all code requirements

for piping material.

Thoroughly clean and flush all dirt and

sediment from the system before attempting to

install the pump.

3.1.1 Location in the piping line

The pump should never be located at the

lowest point of the piping system (where dirt

and sediment collect), nor should it be located

at the highest point of the piping system

(where air accumulates).

When installing the pump into the piping

system, Grundfos recommends that pressure

gauges be installed in the inlet and discharge

flanges or pipes. This will allow the pump and

system performance to be checked.

Do not block the pipe plugs in the pump

housing flanges by locating the terminal box

over these plugs.

3.1.2 Mounting positions

The arrows on the pump housing indicate the

direction of water flow. The XL UP/UPS pump

may be installed in vertical or horizontal

piping, but the motor shaft must always

remain horizontal, as shown in fig. 1.

Fig. 1 Installation positions

3.1.3 Terminal box position

At the bottom of the stator, closest to the pump

housing, there are three drain holes to allow

condensed water to escape. The drain holes

shall not be blocked for any reason and one

drain hole must always point downward.

There is not a drain hole directly below the

terminal box; therefore the terminal box must

be positioned in one of the positions shown in

fig. 1 or fig. 2.

3.2 Changing the terminal box

position

If the pump is already installed in the system,

the system must be drained or the isolation

valves on both sides of the pump must be

closed and the pressure released/relieved by

removing the vent plug.

Only after the pressure has been relieved and

the pump drained should you proceed with the

next steps.

Warning!

Never make any connections in

the pump terminal box unless the

electrical supply has been

switched off.

The pump should not be

connected to the electrical

system until it has been properly

installed in the piping system.

Risk of electrical shock — this

pump has not been investigated

for use in swimming pool or

marine areas.

Warning!

The pump must be positioned

so that someone cannot

accidentally come into contact

with the hot surfaces of the pump.

Caution

TM04 5646 3609

Warning!

Before starting any work on this

circulator, be sure electrical

supply has been switched off

and it cannot be accidentally

switched on.

Exercise caution when draining

the system or removing the vent

plug as the fluid in the system

may be scalding hot and under

pressure.

Caution

3.2.1 Rotating the terminal box

To change the position of the terminal box,

follow these steps:

1. Remove the four (5 mm) allen-head screws

holding the pump head onto the pump

housing.

2. Carefully lift/slide the pump head out and

away from the pump housing. Next rotate

the pump head and locate the terminal box

in the desired position. The terminal box

can be rotated in steps of 90 °. Review

fig. 1 and fig. 2 for possible/permissible

positions. DO NOT locate the terminal box

beneath the pump.

3. Make sure the O-ring is properly seated in

the pump housing.

4. Replace the pump head onto the pump

housing.

5. Diagonally tighten the 5mm allen-head

screws evenly.

Torque to: 7 ft lbs. / 9.5 Nm.

6. Check to ensure the rotor turns freely. Do

this by removing the vent plug in the

middle of the pump nameplate. Insert a

medium-size, flat-blade screwdriver into

the slot at the exposed end of the shaft.

Gently turn the shaft. If it does not turn

easily, repeat steps 1 through 5 above.

If the rotor spins freely, proceed to step 7.

Do not put the vent plug back into the

pump until the end of step 9.

7. The position of the nameplate can be

changed by easing the outer edge of the

plate at the cutout with a screwdriver.

Turn the nameplate to the required position

and push into place.

8. Follow electrical instructions in section 3.3.

9. Refill the system, open the isolation valves

and vent the system. Also allow air to vent

out of the pump; once water flows out the

vent hole, replace the vent plug removed in

step 6. See additional instructions in

section 4.1.

10.Fig. 2 shows acceptable terminal box

positions along with recommended drip

loops (dashed lines) in the electrical wiring

harness based on entry point.

Fig. 2 Acceptable terminal box positions

Use caution as the rotor

assembly can fall out of the

pump head or pump housing if

the pump head is pulled too far

away from the pump housing.

Caution

TM04 5636 3609

Terminal box

position A

Terminal box

position B

Terminal box

position C

3.3 Electrical connection

Proper operating voltage and other electrical

information can be found on the pump name-

plate attached to the top of the motor.

• The motor is thermally protected on all three

speeds and no additional external

protection is needed.

• See fig. 3 for proper grounding and supply

power connection locations (115V and

208-230V).

• The terminal connections are toggle/lever

push design. Push the lever down and

insert the field wiring. Push the lever down

and pull to remove wires.

• Next, use care when installing the terminal

box cover with speed switch (rough

handling can damage the run light LED on

the printed circuit board (PCB)). Insert the

Phillips head screw through the cover and

tighten to a snug fit.

• An external "Drip Loop" is recommended in

the electrical wiring harness; see fig. 2.

• Where an external "Drip Loop" is not

possible, or if the wiring enters through the

upward facing (top) surface of the box, then

an internal "Drip Loop" is recommended;

see fig. 3.

Fig. 3 Examples of ground and power

supply connections (115V and

108-230 V) with internal drip loop

Warning!

Risk of electrical shock!

The electrical connection and

protection should be carried out in

accordance with the latest edition

of the National Electrical Code,

local codes and regulations by a

qualified electrician.

The safe operation of this pump

requires that it be grounded in

accordance with the National

Electrical Code and any state,

local governing codes and

regulations.

Ground wires should be copper

conductors of at least the size of

the circuit conductor supplying

power to the pump. Connect the

ground wire to the grounding

point in the terminal box and then

to an acceptable ground. Do not

ground to gas or water supply

line.

All wire sizes should be copper

and size-based on the ampacity

(current carrying properties of a

conductor) as required by the

National Electrical Code or local

regulations. Additionally UL

requires the following wire sizes

to be used: 18-12 Solid or 14-12

Stranded.

Both the power and grounding

wires must be suitable for at least

194 °F (90 °C).

TM04 5634 3609

CAPACITOR

Black

White

Green

SPEED

SWITCH

CAPACITOR

Black

White

Green

4. Starting the pump

4.1 Vent the piping system

After the pump has been installed and the

electrical connections made, the piping system

must be vented.

NOTE: Do not vent the piping system through

the pump. Instead, follow these steps:

1. Fill and pressurize the system with liquid,

and vent all trapped air from the piping by

suitable means.

2. If any isolation valves are used, make sure

they are OPEN.

3. Vent the pump by removing the vent plug.

When water exists through the port, the

pump is fully vented / primed.

4. Reinstall the vent plug.

Fig. 4 Vent screw/plug removal for pump

venting

4.2 Speed selection

UPS models

Speeds can be changed via the speed switch

on the terminal box cover. Power must be

turned off before changing speeds. The speed

in the three positions appears in the following

table; also see fig. 6.

UP models

Speed is fixed on Speed 3 (High) and cover

does not have a switch (cover is solid).

Fig. 5 Terminal box cover/lid with speed

switch in medium speed (Speed 2)

Changing to lower speeds offers considerable

reduction in energy consumption and less

noise in the system.

Fig. 6 Pump performance at speed

settings

Never operate the pump dry —

the system must first be filled

with liquid and vented.

Warning!

If the vent screw/plug is to be

loosened, care should be taken

to ensure that the escaping

scalding hot liquid does not cause

personal injury or damage to

components.

TM04 5644 3609

Caution

TM04 5641 3609

Switch position Speed in % of max. speed

Low (Speed 1) approx. 60 %

Medium (Speed 2) approx. 80 %

High (Speed 3) 100%

TM04 5640 3609

Low

HHH

Medium High

QQ Q

H = Head and Q = Flow

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