Grundfos VersaFlo UPS Bedienungsanleitung

VersaFlo®UPS

GRUNDFOS INSTRUCTIONS

Installation and operating instructions

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 24 months from date of installation, but not morethan 30 monthsfrom

date of manufacture. Grundfos' liability under this warranty shall be limited to repair-

ing 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 manu-

facturer 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 sup-

porting the warranty claim and/or a Return Material Authorization must be included

if so instructed.

GRUNDFOS WILL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUEN-

TIAL DAMAGES, LOSSES, OR EXPENSES ARISING FROM INSTALLATION,

USE, OR ANY OTHER CAUSES. THERE ARE NO EXPRESS OR IMPLIED WAR-

RANTIES, 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 conse-

quential 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.

VersaFlo®UPS

Installation and operating instructions 4

Notice d’installation et d’entretien 20

CONTENTS Page

1. Safety warning 4

1.1 Read this booklet 4

1.2 Electrical work 4

2. Pre-installation checklist 4

2.1 Confirm you have the correct pump 4

2.2 Check the condition of the pump 4

2.3 Verify electrical requirements 4

2.4 Pumped liquid requirements 5

3. Installation procedures 5

3.1 Electrical preparation 5

3.2 Piping considerations 6

3.3 Connect the pump 6

3.4 Electrical connection 6

4. Starting the pump 8

4.1 Vent the piping system 8

4.2 Check the direction of shaft rotation 9

4.3 Speed selection 9

5. Troubleshooting 11

5.1 Fault finding chart 11

5.2 Preliminary checks 12

5.3 Current measurement 13

5.4 Insulation resistance (lead-to-ground) 13

5.5 Winding resistance (line-to-line) 14

5.6 Winding resistance chart 16

6. Replacing components 18

6.1 Removing the pump head 18

6.2 Fitting the pump head 18

6.3 Replacing the terminal box or capacitor 19

7. Disposal 19

1. Safety warning

1.1 Read this booklet

This booklet is designed to help a certified installer

install, begin operation of and troubleshoot the

Grundfos VersaFlo UPS pumps. The booklet should

be left with the owner of the pump for future refer-

ence 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 regula-

tions.

2. Pre-installation checklist

2.1 Confirm you have the correct pump

• Read the pump nameplate to make sure it is the

one you ordered.

• Compare the pump's nameplate data and its per-

formance 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?

2.2 Check the condition of the pump

The shipping carton your pump came in is specially

designed around your 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.

2.3 Verify electrical requirements

Verification of the electrical supply should be made

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.

These motors are designed to run on ±10% of the

nameplate-rated voltage.

Wiring connection diagrams can be found inside the

terminal box cover and later in these Installation and

Operating Instructions. If voltage variations are

larger than ±10%, do not operate the pump.

WARNING!

A faulty motor or wiring can cause electri-

cal shock that could be fatal, whether

touched directly or conducted through

standing water. For this reason, proper

grounding of the pump to the power sup-

ply'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

Article 250-80 of the National Electrical

Code.

2.4 Pumped liquid requirements

CAUTION: The VersaFlo UPS pump is intended for

use with water only.

The pump can be used to circulate:

• Potable hot water

• Water for hydronic heating

• Cooling water

• In domestic hot-water systems it is advisable to

use bronze pumps (VersaFlo UPS model) only for

water with a degree of hardness lower than

14 grains per gallon of hardness. For water with a

higher degree of hardness, a direct-coupled

VersaFlo TP pump is recommended.

• 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 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 pre-

mature wear to the bearings and excessive motor

heat. The pumped liquid must also meet the follow-

ing requirements:

Minimum pump inlet pressure (during operation)

Liquid temperature range

Continuously:

14°F (–10°C) up to 230°F (110°C).

Intermittent:

< 284°F (140°C) for short periods of time.

Domestic hot water:

<140°F (60°C).

3. Installation procedures

3.1 Electrical preparation

Terminal box position

At the bottom of the stator, closest to the pump hous-

ing, there are eight drain holes to allow condensed

water to escape. The drain holes shall not be

blocked. The drain holes must point downwards.

The terminal box must therefore point upwards in

one of the positions shown in fig. 1. The following

terminal box positions apply whether the piping is

mounted vertically or horizontally.

Fig. 1 Possible terminal box positions

Rotating the terminal box

To change the position of the terminal box, follow

these steps:

1. Remove the four allen-head screws holding the

pump head onto the pump housing.

2. Carefully lift the pump head and rotate it so the

terminal box is in the desired position.

DO NOT locate the terminal box beneath the

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

the pump housing.

3. Replace the pump head onto the pump housing.

4. Tighten the allen-head screws evenly.

Torque to:

8 mm............15 ft lbs

10 mm..........25 ft lbs.

UPS

model

At these liquid temperatures

167°F/

75°C 194°F/

90°C 230°F/

110°C

[psi] hf [psi] hf [psi] hf

32-40/4 0.7 1.6 2.2 5.1 21.0 48.5

32-80/2 0.7 1.6 5.1 11.8 23.9 55.2

32-160/2 11.6 26.8 16.0 37.0 34.1 78.8

40-40/4 0.7 1.6 4.4 10.2 23.2 53.6

40-80/4 0.7 1.6 1.5 3.5 18.1 41.8

40-80/2 6.5 15.0 10.9 25.2 29.0 67.0

40-160/2 5.1 11.8 9.4 21.7 27.6 63.8

40-240/2 11.6 26.8 16.0 37.0 34.1 78.8

50-40/4 0.7 1.6 2.9 6.7 21.8 50.4

50-80/4 0.7 1.6 4.4 10.2 23.2 53.6

50-80/2 4.4 10.2 8.7 20.1 26.8 61.9

50-160/2 11.6 26.8 16.0 37.0 34.1 78.8

50-240/2 10.2 23.6 14.5 33.5 32.6 75.3

53-55/57 4.4 10.2 8.7 20.1 26.8 61.9

75-69 11.6 26.8 16 37 34.1 78.8

80-40/4 11.6 26.8 16.0 37.0 34.1 78.8

80-80/4 14.5 33.5 18.9 43.7 37.0 85.5

80-160/2 21.8 50.4 26.1 60.3 43.5 100.5

100-40/4 27.6 63.8 31.9 73.7 50.0 115.5

WARNING!

Never make any connections in the pump

terminal box unless the electrical supply

has been switched off.

TM03 7296 4706

WARNING!

If the pump is already installed in the sys-

tem, the system must be drained or the

isolation valves on both sides of the pump

must be closed before the allen-head

screws are removed as the pumped liquid

may be scalding hot and/or under pres-

sure.

Do not start the pump until the system has

been filled with liquid and vented.

5. Check to make sure 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 to 4 above.

6. 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.

7. Refer to pages 18 and 19 for additional instruc-

tions.

3.2 Piping considerations

Thoroughly clean and flush all dirt and sediment from

the system before attempting to install the pump.

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.

Mounting positions

The arrows on the flanges of the pump indicate the

direction of water flow. Although the VersaFlo UPS

may be installed in either vertical or horizontal pip-

ing, the motor shaft must always remain horizontal,

as shown in figures 1 and 2.

Fig. 2 Direction of water flow through the pump

NOTE: Pumps installed outdoors must be protected

by a ventilated, watertight cover to keep out moisture

and dirt.

3.3 Connect the pump

Install the pump into the piping system.

Grundfos recommends that pressure gauges be

installed in the inlet and discharge flanges or pipes

to check pump and system performance.

3.4 Electrical connection

The electrical connection and protection should be

carried out in accordance with the latest edition of

the National Electrical Code, local codes and regula-

tions by a qualified electrician.

The operating voltage and frequency are marked on

the pump nameplate. Make sure that the motor is

suitable for the electrical supply it is being installed

to.

The pump should be grounded to protect against

indirect contact and a ground fault interrupter can be

used as extra protection.

Multi-speed pump (single-phase)

All single-phase pumps are equipped with built-in,

automatic resetting, thermal overload protection.

The pump is protected at all three speeds.

Multi-speed pump (three-phase)

The pump must be connected to the electrical supply

via an external contactor. The contactor must be

connected to the built-in thermal overload switch ter-

minals T1 and T2 (3 x 208-230 V) or P1 and P2

(3 x 460 V and 575 V) to protect the pump against

overloading at all three speeds.

OR: If the pump is protected by means of a motor

starter, the starter must be set to the current con-

sumption of the pump at the selected speed. The

motor starter setting must be changed every time the

pump speed is changed. The current consumption at

the individual speeds is stated on the pump name-

plate.

Figures 4, 6, 7, 9, and 10 on the next pages show the

possible connections.

TM03 7290 4706

WARNING!

The pump must be positioned so that

someone cannot accidentally come into

contact with the hot surfaces of the pump.

WARNING!

Never make any connections in the pump

terminal box unless the electrical supply

has been switched off.

The pump must be grounded.

The pump must be connected to an exter-

nal main power switch.

3.4.1 VersaFlo UPS 1 x 115 V and 1 x 230 V

terminal box

Fig. 3 VersaFlo UPS 1 x 115 V and 1 x 230 V

terminal box

All VersaFlo UPS single-phase pumps come with a

protection module and a speed switch as shown in

fig. 3. All pumps are equipped with built-in, automatic

resetting, thermal overload protection. The pump is

protected at all three speeds.

Wiring diagrams

Figure 4 shows the electrical connections for

a single-phase pump with protection module.

Fig. 4 1 x 115 V and 1 x 230 V supply

NOTE: Provide electrical disconnect and current

protection as per local electrical codes.

K = External contactor sized to FL and LR pump

current.

3.4.2 VersaFlo UPS 3 x 208-230 V terminal box

Fig. 5 VersaFlo UPS 3 x 208-230 V terminal box

All VersaFlo UPS pumps with three-phase x

208-230 V come with a standard module and a

speed switch as shown in fig. 5. All pumps are

equipped with an internal thermal overload switch

(terminals T1 and T2, to be connected to an external

contactor) to protect the pump at all three speeds.

Wiring diagrams

Figure 6 shows the electrical connections when

using an external changeover contact (safety circuit)

for start/stop push button station.

Fig. 6 External changeover contact

Auxiliary contacts rated for supply voltage.

Figure 7 shows the electrical connections when

using external impulse contacts (momentary con-

tacts) for start/stop push button station.

Fig. 7 External impulse contacts

TM03 7744 4806TM03 7743 4806

Protection

module

Speed

switch

L1 L2

1 x 115 V supply

1 x 230 V supply

TM03 7742 4806TM03 7892 5106TM03 7740 4806

Standard

module

Speed

switch

Stop/Start

L1L2L3T2T1

L1L2L3

Stop

Start

L1L2L3T2T1

L1L2L3

3.4.3 VersaFlo UPS 3 x 460 V and 575 V

terminal box

Fig. 8 VersaFlo UPS 3 x 460 V and 575 V

terminal box

All VersaFlo UPS pumps with three-phase x 460 V

and 575 V terminal boxes (fig. 8) come with a special

two-speed terminal box. The speed is changed by

the orientation of the jumpers as shown on page 10.

All pumps are equipped with an internal thermal

overload switch (terminals P1 and P2) to be con-

nected to external contactor.

Wiring diagrams

Figure 9 shows the electrical connections when

using an external changeover contact (safety circuit)

for start/stop push button station.

Fig. 9 External changeover contact

Auxiliary contacts rated for supply voltage.

Figure 10 shows the electrical connections when

using external impulse contacts (momentary con-

tacts) for start/stop push button station.

Fig. 10 External impulse contacts

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.

CAUTION: Never operate the pump dry - the system

must first be filled with liquid and 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.

TM03 7739 4806TM03 7738 5106

T5 T1

Jumpers

Start/stop

T3 T2 T1

TM03 7737 4806

WARNING!

If the vent screw is to be loosened, care

should be taken to ensure that the escap-

ing scalding hot liquid does not cause

personal injury or damage to components

(see fig. 12).

Start K

Stop

T3 T2 T1

4.2 Check the direction of shaft rotation

Applies to 460 V and 575 V two-speed models

only

(The direction of rotation of three-speed pumps is

checked by means of the fault finding chart, pages

11 and 12).

1. Make sure that the power is OFF.

2. Unscrew and remove the vent plug located at the

center of the nameplate.

3. Insert a small, flat-blade screwdriver into the slot

in the end of the motor shaft (see fig. 12). Rotate

the shaft with the screwdriver to make sure it

does so freely.

4. Bump the pump and watch to see which direction

the shaft rotates. The shaft must rotate in the

counterclockwise direction as shown on the

nameplate (see fig. 11).

5. If the pump shaft is rotating incorrectly, discon-

nect the power and interchange any two power

leads in the terminal box.

6. Check once again for proper counterclockwise

rotation. When it is rotating correctly, replace the

vent plug.

Fig. 11 Vent plug and direction of rotation

Fig. 12 Removing the vent plug

4.3 Speed selection

4.3.1 Three-speed pumps, all models except

3 x 460 V and 575 V

The speed switch in the terminal box can be turned

to three positions. The speed in the three positions

appears in the table below (also see fig. 13).

Changing to lower speeds offers considerable reduc-

tion in energy consumption and less noise in the sys-

tem.

Fig. 13 Pump performance at speed settings

Change the pump performance as follows:

1. Switch off the electrical supply to the pump at the

main circuit breaker. The green indicator light in

the terminal box must be off.

2. Remove the terminal box cover by loosening the

four screws in the cover.

3. Pull out the speed switch module and re-insert it

so that the desired speed is visible through the

window in the terminal box (see fig. 14).

Fig. 14 Speed switch module

TM03 7750 4806TM03 7277 4706

Vent plug Directionof

rotation

Inspection screw

Inspection screw/

vent plug

Switch

position

Speed in % of maximum speed

Single-phase

pumps Three-phase

pumps

1 approx. 60% approx. 70%

2 approx. 80% approx. 85%

3 100% 100%

TM03 7736 4806

WARNING!

Never make any connections in the pump

terminal box unless the electrical supply

has been switched off.

TM03 7735 4806

H = head and Q = flow

SPEED

1SPEED

2SPEED

NOTE: When changing to and from speed 1, the

cover of the speed switch module must be removed

and fitted on the other side of the switch.

4. Fit the terminal box cover back onto the terminal

box and tighten the four screws in the cover.

5. Switch on the electrical supply.

Check that the green indicator light is perma-

nently on or flashing.

NOTE: The speed switch module must never be

used as an on/off switch.

4.3.2 Two-speed pumps, 3 x 460 V and 575 V

The speed setting in the terminal box can be

changed to two positions. The speed in the two posi-

tions appears in the table below (also see fig. 13 on

page 9).

Change the pump performance as follows:

The speed is changed by the position of the jumpers

in the terminals. The jumpers are fitted according to:

• figure 15 for speed 1 - low speed

• figure 16 for speed 2 - high speed.

Fig. 15 Speed 1 (low speed)

Fig. 16 Speed 2 (high speed)

Fig. 17 Terminal box

Speed step Speed in % of maximum speed

1 approx. 75%

2 100%

WARNING!

Never make any connections in the pump

terminal box unless the electrical supply

has been switched off.

TM03 7734 4806TM03 7733 4806

P2 T5 T4 T6

T3 T2 T1

Jumper wire

P2 T5 T4 T6

T3 T2 T1

Jumper wire

TM03 7739 4806

T5 T1

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