Grundfos ALPHA User Manual

Grundfos ALPHA

Installation and operating instructions

GRUNDFOS 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 36 months from date of manufacture. Grun dfos' liability un der 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 condition s, accident, abuse, misuse, u nauthorized
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 togeth er
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
INST ALLATION, 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.

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Grundfos ALPHA

Installation and operating instructions 4

Notice d’installation et d’entretien 11

Instrucciones de instalación y funcionamiento 19

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CONTENTS

1. General 4

2. Shipment inspection 4

3. Pumped Liquids 4

4. Pump installation 4

5. Changing the control box position 5

6. Electrical installation 5

7. Name Plate 6

8. Control Display 6

9. Performance & operation modes 7

10. Fault finding 8

11. Disposal 8

12. Technical data 9

Warnin g

Prior to installation, read these
installation and operating instructions.
Installation and operation must comply
with national, state, and local
regulations and accepted codes of
good practice.

Page

1. General

Grundfos Alpha is suitable for systems with constant
or variable flows where it is desirable to optimize the
setting of the pump duty point .

2. Shipment inspection

Examine the components carefully to make sure no
damage has occurred to the pump during shipment.
Care should be taken to ensure the pump is NOT
dropped or mishandled.

• One Grundfos Alpha pump

• One line cord

• Two gaskets

• One installation and operating instructions

• One check valve

• One "Check Valve Installed" sticker

4. Pump installation

Warnin g

Do not energize pump until properly
installed.

Risk of electric shock — This pump has
not been investigated for use in
swimming pool or marine areas.

When making piping connections, be sure to
follow piping manufactures recommendations
and all code requirements for piping material.

• System should be properly flushed of debris
before pump installation.

• Insert check valve only if required; see fig. 1.

• Arrows on the pump housing indicate the liquid
flow direction through the pump.

• Install the pump with the motor shaft horizontal;
See fig. 2.

• Fit the two gaskets supplied to pump ends.

Fig. 1 Check valve installation

TM 3422 4408TM04 3417 4408

3. Pumped liquids

Warnin g

The pump must not be used for the
transfer of flammable liquids such as
diesel oil, gasoline, and similar liquids.

Pump not for pool or marine use.

Clean, thin, non-aggressive and non-explosive
liquids, not containing solid particles, fibers or
mineral oil.

For glycol usage see Section 10. Review Section 10
for additional liquid information.

4

Fig. 2 Installation positions

5. Changing the control box position

Insert line cord plug onto pump

To remove cord plug from pump:

1

2

3

(Side view)

(Bottom view)

Warnin g

Before starting any work on this
circulator, make sure electrical supply
has been switched off and that it cannot
be accidentally switched on.

The control box orientation change should be made
before filling the system with fluid.

Pump liquid may be scalding hot and under high
pressure.

The control box can be rotated in steps of 90°.
Review fig. 3 for possible/permissible positions.

Only use orientations C and D for CSA Encl os ur e
Type 2.

6. Electrical installation

Warnin g

Risk of electrical shock - This pump is
supplied with a grounding conductor
and grounding-type attachment plug.
To reduce the risk of electric shock, be
certain that it is connected only to a
properly grounded, grounding -type
receptacle in accordance with the
National Electric Code and any state,
local governing codes and regulations.

All electrical work should be performed by a qualified
electrician in accordance with the latest edition of the
National Electric Code and state, local codes and
regulations.

• The motor of Grundfos Alpha is protected by the
electronics in the control box and requires no
external motor protection.

• Check that the supply voltage and frequency
correspond to the values stated on the pump.

• Only connect the pump to the mains with the cord
set supplied; see fig. 4.

• Lights on the control panel indicate that the
electrical supply has been switched on.

• Do not modify and only use cord set supplied.

Fig. 3 Changing the control box position

Procedure:

1. If fluid is present, drain system fluid from pump or
isolate system fluid from pump.

2. Loosen 4mm screws and turn the pump head to
desired position; see fig. 3.

3. Insert and cross-tighten the screws to 7 ft-lbs
torque.

TM04 3418 4408

TM04 3420 4408

Fig. 4 Connecting and removing power plug

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7. Name Plate

Fig. 5 Nameplate

8. Control Display

TM04 3419 4408

Pos. Description

1 Product Number
2 Production Code:

• 1st and 2nd figures = year

• 3rd and 4th figures = week
3 Voltage (V):
4 Rated current (A):

• Min.: Minimum Current (A)

• Max.: Maximum Current (A)
5 Input power (W):

• Min.: Minimum Power (W)

• Max.: Maximum Power (W)
6 Max. fluid temperature (F)

TM04 3421 4408

Fig. 6 Control display

Pos. Description

1 LED showing Watt or flow indicator
2 LED indicating fixed speed
3 LED indicating constant pressure
4 LED AutoADAPT
5 Push-button for selection of pump setting

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9. Performance* and operation mode s election

*Hydraulic performance without check valve

Pos. Description

• Push -button for selection of pump setting

• Ever y time the push-button is pressed, the circulator setting is changed

High Fixed Speed

• Runs at a constant speed and consequently on a constant curve. In Speed III, the pump is set

III

on the maximum curve under all operating conditions. Quick Vent of the pump can be obtained
by setting the pump to Speed III for a short period.

Medium Fixed Speed

II

• Runs at a constant speed and consequently on a constant curve. In Speed II, the pump is set on
the medium curve under all operating conditions.

Low Fixed Speed

I

• Runs at a constant speed and consequently on a constant curve. In Speed I, the pump is set on
the minimum curve under all operating conditions.

Constant Pressure I

• The duty point of the pump will move left and right along the lowest constant-pressure curve
depending on water demand in the system. The pump head (pressure) is kept constant,
irrespective of the water demand.

Constant Pressure II

• The duty point of the pump will move left and right along the middle constant-pressure curve
depending on water demand in the system. The pump head (pressure) is kept constant,
irrespective of the water demand.

Constant Pressure III

• The duty point of the pump will move left and right along the highest constant-pressure curve
depending on water demand in the system. The pump head (pressure) is kept constant,
irrespective of the water demand.

AutoADAPT (Factory Setting)

• This function controls the pump performance a utomatica lly w ithin the define d perfor mance
range (shaded area). AutoADAPT will adjust the pump performance to system demands over
time.

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10. Fault finding

Warning

Before starting any work on this circulator, make sure electrical supply has been
switched off and that it cannot be accidentally switched on.

Pump liquid may be scalding hot and under high pressure.

Fault Control panel Remedy

1. The pump does not run LED off Check power supply (voltage) and

LED on Check that the electricity supply falls

___ ___"

"

2. Noise in the system LED on Install air eliminator.

3. Noise in the pump LED on Let the circulator run, will vent over time.

4. Insufficient heat LED on Increase circulator speed or constant

circuit breaker.
Check zone control; voltage, control

options, and thermostat.
Check all power connections.
Damaged circulator / replace.

within the specified range.
Impeller blocked by impurities.
Requires turning power OFF and back

On to pump.

Reduce the pump speed.
Fluid velocities to high; reduce pump

speed.
Emitter or piping expanding.

Increase the inlet pressure or check the
air volume in the expansion tank, if
installed.

No fluid (dry running).
Damaged circulator / replace.

pressure.
Circulator in proper operating mode.
Check for air; piping, zone(s) and

emitter(s).
Check thermostat(s).
Check all valving.
Heat emitter large enough.
Check direction of flow.
Check water temperature from boiler

and boiler functions.
Check proper sizing of circulator.
Check ΔT calculation.

11. Disposal

This product or parts of it must be disposed of in an
environmentally sound way; please use the public or
private waste collection service.

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12. Technical data

Caution

Supply voltage:

1x115V +/-10 %, 60Hz.

Motor protection:

The pump requires no external motor protection.

Enclosure class:

Indoor use only, IP42.
CSA Enclosure Type 2.

Insulation class:

F.

Relative air humidity:

Maximum 95 %.

Maximum discharge pressure:

150 psi (10.34 bar).

Inlet pressure:

Liquid temperature Min. inlet pressure

167 °F (75 °C) 0.75 psi (0.05 bar)
194 °F (90 °C) 4.06 psi (0.28 bar)

230 °F (110 °C) 15.7 psi (1.08 bar)

Sound pressure level:

43 dB (A).

Ambient temperature:

+32 °F (0 °C) to +104 °F (+40 °C) .

Liquid temperature:

+36 °F (+2 °C) to +230 °F (+110 °C).

To avoid condensation in the control box and stator,
the liquid temperature must always be higher than
the ambient temperature.

Ambient

temperature

[°F (°C) ]

+32 °F

(0 °C)

+50 °F

(+10 °C)

+68 °F

(+20 °C)

+86 °F

(+30 °C)

+95 °F

(+35 °C)

+104 °F

(+40 °C)

Liquid temperature

Min. [°F (°C)] Max. [°F (°C)]

+36 °F

(+2 °C)

+50 °F

(+10 °C)

+68 °F

(+20 °C)

+86 °F

(+30 °C)

+95 °F

(+35 °C)

+104 °F

(+40 °C)

+230 °F

(+110 °C)

+230 °F

(+110 °C)

+230 °F

(+110 °C)

+230 °F

(+110 °C)

+194 °F

(+90 °C)

+158 °F

(+70 °C)

In domestic hot-water system, it is
recommended to keep the liquid
temperature below +149 °F (+65 °C) to
eliminate the risk of lime precipitation.

Maximum glycol concentrations:

50 % glycol @ 36 °F (2 °C).

Hydraulic performance change can be expected.

Watt readings:

Accuracy +/-1 Watt.

Flow indicator:

Provides a relative indication of flow — should not
be used in lieu of a flow meter.

Check valve:

Use of check valve may reduce pump hydraulic
performance (up to -10%).

Use check valve in parallel pumping applications.

Curve conditions:

Test liquid: Airless water.
Curves apply to a density of 983.2 kg/m

3

and a

liquid temperature of +140 °F (+60 °C).
All curves show average values and should not be

used as guarantee curves. If a specific minimum
performance is required, individual measurements
must be made.

Curves apply to a kinematic viscosity of 0.474 cSt.

Approximate power usage:

Speed setting Min. Max.

High fixed speed III 39W 45W

Medium fixed speed II 15W 30W

Low fixed speed I 5W 8W

Constant pressure 8W 45W

Constant pressure 14W 45W

Constant pressure 22W 45W

AutoADAPT 5W 45W

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