ALPHA1
Variable-speed circulators
Installation and operating instructions
GRUNDFOS INSTRUCTIONS
Listed
3191277
Conforms to ANSI/UL Std. 778
Certified to CAN/CSA Std. C22.2 No. 108
Table of contents
ALPHA1
English (US)
Installation and operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Français (CA)
Notice d'installation et de fonctionnement . . . . . . . . . . . . . . . . . . . . . . . 17
Español (MX)
Instrucciones de instalación y operación . . . . . . . . . . . . . . . . . . . . . . . . 31
2
English (US) Installation and operating instructions
Original installation and operating
instructions
These installation and operating instructions
describe Grundfos ALPHA1.
Sections 1-5 give the information necessary to
be able to unpack, install and start up the
product in a safe way.
Sections 6-11 give important information about
the product, as well as information on service,
fault finding and disposal of the product.
CONTENTS
Page
1. Limited warranty
2. General information
2.1 Symbols used in this document
3. Receiving the product
3.1 Inspecting the product
3.2 Scope of delivery
4. Installing the product
4.1 Quick installation tips
4.2 Mechanical installation
4.3 Changing the power head position
4.4 Electrical connection
5. Starting up the product
5.1 Venting the pump
5.2 First startup
6. Product introduction
6.1 Product description
6.2 Applications
6.3 Pumped liquids
7. Identification
7.1 Nameplate
7.2 Type key
7.3 Approvals
8. Control functions
8.1 Elements on the control panel
8.2 Display
8.3 Setting the pump
8.4 Pump control
8.5 Pump performance and operating
mode selection
9. Fault finding the product
10. Technical data
10.1 Operating conditions
11. Disposing of the product
Prior to installation, read this
document. Installation and operation
must comply with local regulations
and accepted code
s 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 the use of the
appliance in a safe way and
understand the hazards involved.
Children must not use or play with the
appliance. Cleaning and user
maintenance shall not be made by
children without supervision.
3
4
4
4
4
1. Limited warranty
4
Products manufactured by Grundfos Pumps
5
Corporation (Grundfos) are warranted to the
original user only to be free of defects in
5
material and workmanship for a period of 30
5
months from date of installation, but not more
6
than 36 months from date of manufacture.
7
Grundfos' liability under this warranty shall be
9
limited to repairing or replacing at Grundfos'
option, without charge, F.O.B. Grundfos' factory
9
or authorized service station, any product of
9
Grundfos manufacture. Grundfos will not be
9
liable for any costs of removal, installation,
9
transportation, or any other charges that may
9
arise in connection with a warranty claim.
10
Products which are sold, but not manufactured
by Grundfos, are subject to the warranty
11
provided by the manufacturer of said products
11
and not by Grundfos' warranty.
11
Grundfos will not be liable for damage or wear to
11
products caused by abnormal operating
12
conditions, accident, abuse, misuse,
12
unauthorized alteration or repair, or if the
product was not installed in accordance with
12
Grundfos' printed installation and operating
12
instructions and accepted codes of good
12
practice. The warranty does not cover normal
wear and tear.
13
To obtain service under this warranty, the
14
defective product must be returned to the
distributor or dealer of Grundfos' products from
16
which it was purchased together with proof of
16
purchase and installation date, failure date and
16
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.
Successful operation depends on
careful attention to the procedures
described in this manual. Keep this
manual for future use.
English (US)
3
English (US)
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
limitations 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.
Products which are repaired or replaced by
Grundfos or authorized service center under the
provisions of these limited warranty terms will
continue to be covered by Grundfos warranty
only through the remainder of the original
warranty period set forth by the original
purchase date.
2. General information
2.1 Symbols used in this document
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.
The text accompanying the three hazard
symbols DANGER, WARNING and CAUTION
will be structured in the following way:
SIGNAL WORD
Description of hazard
Consequence of ignoring the warning.
- Action to avoid the hazard.
Example
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.
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.
3. Receiving the product
3.1 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 7. Identification for
information on the nameplate.
3.2 Scope of delivery
The box contains the following items:
• one Grundfos ALPHA1 pump
• one line cord or terminal box
• two gaskets
• installation and operating instructions
• one check valve
• one "Check Valve Installed" sticker.
4
4. Installing the product
WARNING
Pressurized system
Death or serious personal injury
- Before dismantling the pump, drain
the system or close the isolating
valve on either side of the pump
before you remove the screws. The
pumped liquid may be scalding hot
and under high pressure.
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
- This pump has not been
investigated for use in swimming
pool or marine areas.
4.1 Quick installation tips
1. To ensure proper venting of your system,
place the pump in "Constant Pressure III"
mode until all air has been removed.
Isolating zones during this process will
ensure proper air removal.
2. For balancing manifold zone(s) applications,
utilizing modes "Constant Pressure I" or
"Constant Pressure II" and only one zone at
a time during balancing will ensure proper
flow rate to each zone.
3. Always review your boiler minimum flow rate
requirements if utilizing the pump as a
primary pump. Select one of the constant
pressure modes for boiler primary pump
applications. You may change hydraulic
selection while pumping. No permanent
damage will occur. In fact, Grundfos
encourages testing the various hydraulic
modes with your hydronic system to ensure
maximum energy savings and comfort level.
4. With zone panel control applications, when
there is a call for heat and power has been
sent to the pump, the pump will remember
and restart from the last duty point and
hydraulic mode.
4.2 Mechanical installation
When making pipe connections, follow the
piping manufacturer's recommendations and all
code requirements for the piping material.
• Flush the system of debris before
installation.
• Insert the check valve if required. See fig. 1.
• Refer to the arrows on the pump housing
indicating the direction of the liquid flow
through the pump.
• Install the pump with horizontal motor shaft.
See fig. 2.
• Fit the two gaskets supplied to the pump
ends.
Fig. 1 Check valve installation
Fig. 2 Installation positions
English (US)
TM04 3422 4408
TM06 8959 1417
5
English (US)
Power head
orientation A
Power head
orientation B
Power head
orientation C
Power head
orientation D
4.3 Changing the power head position
CAUTION
Hot surface
Minor or moderate personal injury
- Position the pump so that persons
cannot accidentally come into
contact with hot surfaces.
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
Pressurized system
Death or serious personal injury
- Before dismantling the pump, drain
the system or close the isolating
valve on either side of the pump
before you remove the screws. The
pumped liquid may be scalding hot
and under high pressure.
If you change the position of the
power head, fill the system with the
liquid to be pumped or open the
isolating valves.
• Make any change to the power head
orientation before filling the system with
liquid. You can turn the power head in steps
of 90 °.
• See fig. 3 for permissible positions.
• Only use orientations C and D for CSA,
enclosure type 2.
Proceed as follows:
1. If liquid is present, drain the liquid from the
pump or isolate the liquid from the pump.
2. Remove the four socket head cap screws.
3. Turn the pump head to the desired position.
See fig. 3.
4. Cross-tighten the screws to: 7 ft-lbs torque.
Fig. 3 Changing the power head position
TM06 8887 1417
6
Fig. 4 Remove the four socket head cap
screws on the power head to
change the power head position
TM06 8885 1417
4.4 Electrical connection
1
2
3
How to remove the cord plug from the
pump (bottom view):
How to insert the line cord plug onto the
pump (side view):
1. Insert a 1/8 in. flat blade
screwdriver into the slot.
2. Twist the screwdriver.
3. Pull the cord to remove it.
DANGER
Electric shock
Death or serious personal injury
- All electrical work must be carried
out by a qualified electrician in
accordance with the latest edition
of the National Electric Code and
state, local codes and regulations.
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 accidentally switched on.
4.4.1 For pump models with line cord
Follow the procedure as shown in fig. 5.
English (US)
DANGER
Electric shock
Death or serious personal injury
- This pump has not been
investigated for use in swimming
pool or marine areas.
DANGER
Electric shock
Death or serious personal injury
- This pump is supplied with a
grounding conductor and
grounding-type attachment plug. T o
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.
• The motor 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 power supply
with the line cord or through the terminal box
supplied with the pump; see sections
4.4.1 For pump models with line cord and
4.4.2 For pump models with terminal box.
• Do not modify and only use the line cord
supplied.
• The lights on the control panel indicate that
the electrical supply has been switched on.
Fig. 5 Connecting and removing the power
plug for line cord models
TM04 3420 1010
7
English (US)
0.4 in.
(10 mm)
Cable conductor
from the pump
Cable conductor
from the power
supply
4.4.2 For pump models with terminal box
1. Loosen the terminal box screw from the
terminal box cover.
2. Utilize either conduit port for the wiring
entrance.
3. Wire the plug connector as illustrated in the
section Wiring procedure below, steps 3a3d. Then complete steps 4-7.
Be sure to connect the ground cable
conductor (green) of the pump to the
ground cable conductor of the power
supply.
Wiring procedure
Step Action Illustration
Strip the ends of the cable conductors as
3a
illustrated.
Align the end of each of the pump's cable
conductors, including any frayed strands,
with the end of the corresponding cable
conductor from the power supply.
3b
Green conductor: ground
Black conductor: line
White conductor: neutral
TM06 8250 4816
TM06 8253 4816
Insert the ends of the cable conductors
into the connector.
3c
Push the cable conductors fully into the
connector.
Twist the connector until you see two
3d
twists in the cable conductors.
4. Slide the terminal box cover over the
terminal box body.
5. Tighten the cross-head screw on the terminal
box to 5 in-lbs.
6. Switch on the power supply.
7. The lights on the control panel will then
indicate that the power supply has been
switched on.
8
TM06 8251 4816
TM06 8252 4816
5. Starting up the product
6.2 Applications
Do not start the pump until the system
has been filled with liquid and vented.
The required minimum inlet pressure must be
available at the pump inlet.
5.1 Venting the pump
The pump is self-venting. It needs not to be
vented before startup.
The pump must not run dry.
Air in the pump may cause noise. This noise
ceases after a few minutes running.
You obtain quick venting of the pump by setting
the pump to "Constant Pressure III" for a short
period. How fast the pump is vented depends on
the system size and design.
When you have vented the pump, that is when
the noise has ceased, set the pump according to
the recommendations. See section 8.3 Setting
the pump.
You cannot vent the system through the pump.
5.2 First startup
• The light in the control panel shows that the
power supply has been switched on. See fig.
7.
• Factory setting: Constant Pressure III.
6. Product introduction
DANGER
Explosion hazard
Death or serious personal injury
- Do not use the pump for transfer of
flammable liquids such as diesel
oil, gasoline, and similar liquids.
DANGER
Electric shock
Death or serious personal injury
- This pump has not been
investigated for use in swimming
pool or marine areas.
The ALPHA1 circulator 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.
The pump is the best choice for the following
systems:
• underfloor heating systems
• one-pipe systems
• two-pipe systems.
The pump is suitable for the following:
• systems with constant or variable flows
where you want to optimize the setting of the
pump duty point
• systems with variable flow-pipe temperature
• balancing of domestic heating systems.
English (US)
6.1 Product description
The ALPHA1 circulator incorporates a
permanent-magnet motor and differentialpressure control enabling continuous
adjustment of the pump performance to the
actual system requirements.
The pump has a user-friendly front-mounted
control panel. See sections 7. Identification and
8. Control functions.
When you install an ALPHA1, it means:
• Easy installation and startup.
– The pump is easy to install.
You can start the pump, in most cases,
without making any settings.
• High degree of comfort.
• Mini mum noise from valves, etc.
• Low energy consumption.
– Low energy consumption compared to
conventional circulator pumps.
9
English (US)
6.3 Pumped liquids
For information about pressures and
temperatures, see section 10. Technical data.
CAUTION
Flammable material
Minor or moderate personal injury
- Do not use the pump for flammable
liquids, such as diesel oil and
petrol.
WARNING
Biological hazard
Death or serious personal injury
- In domestic hot-water systems, the
temperature of the pumped liquid
must always be above 122 °F (50
°C) due to the risk of legionella.
WARNING
Biological hazard
Death or serious personal injury
- In domestic hot-water systems, the
pump is permanently connected to
the mains water. Therefore, do not
connect the pump by a hose.
CAUTION
Corrosive substance
Minor or moderate personal injury
- Do not use the pump for aggressive
liquids, such as acids and
seawater.
In heating systems, the water must meet the
requirements of accepted standards on water
quality in heating systems.
The pump is suitable for the following liquids:
• Thin, clean, non-aggressive and nonexplosive liquids, not containing solid
particles or fibers.
• Cooling liquids, not containing mineral oil.
• Domestic hot water
Maximum: 14 °dH
Maximum: 149 °F (65 °C)
Maximum peak: 158 °F (70 °C).
For water with a higher degree of hardness,
contact Grundfos.
• Softened water.
2
2
/s (10 cSt)
/s (1
The kinematic viscosity of water is 1 mm
cSt) at 68 °F (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 68 °F (20 °C) means a
viscosity of approximately 10 mm
and a reduction of the pump performance by
approximately 15 %.
Do not use additives that can or will disturb the
functionality of the pump.
When selecting a pump, take the viscosity of the
pumped liquid into consideration.
For technical data, see section 10. Technical
data.
6.3.1 Glycol
The pump is designed for pumping clean water,
or up to 50/50 mixtures by weight of glycol and
water.
For glycol usage as well as additional liquid
information, see section 10. Technical data.
To prevent the glycol mixture from degrading,
avoid temperatures exceeding the rated liquid
temperature and minimize the operating time at
high temperatures.
It is important to clean and flush the system
before adding the glycol mixture.
To prevent corrosion or precipitation, check the
glycol mixture and maintain it regularly. If further
dilution of the supplied glycol is required, follow
the glycol supplier's instructions.
10
7. Identification
3191277
Listed
7.1 Nameplate
Fig. 6 Nameplate
Pos. Description
1 Product number
2 Voltage [V]
Rated current [A]:
3
• Min.: Minimum current [A]
• Max.: Maximum current [A]
Input power [W]:
4
• Min.: Minimum power [W]
• Max.: Maximum power [W]
5 Maximum fluid temperature [°F]
7.2 Type key
Example ALPHA1 15 -55 F
Pump type
Nominal diameter (DN) of inlet and
outlet ports [mm]
Maximum head [dm]
Pipe connection
F: Flange
7.3 Approvals
TM06 8960 1417
FCC sections
Section 15.19 (a) 3
This device complies with Part 15 of the FCC
Rules. Operation is subject to the following two
conditions: (1) this device may not cause
harmful interference, and (2) this device must
accept any interference received, including
interference that may cause undesired
operation.
Section 15.21
Any changes or modifications to this equipment
not expressly approved by the party responsible
for compliance could void the user's authority to
operate this equipment void.
Section 15.105 (b)
These limits are designed to provide reasonable
protection against harmful interference in a
residential installation. This equipment
generates, uses and can radiate radio frequency
energy and, if not installed and used in
accordance with the instructions, may cause
harmful interference to radio communications.
However, there is no guarantee that interference
will not occur in a particular installation. If this
equipment does cause harmful interference to
radio or television reception, which can be
determined by turning the equipment off and on,
the user is encouraged to try to correct the
interference by one or more of the following
measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the
• Connect the equipment to an outlet on a
• Consult the dealer or an experienced radio/
Canadian EMC Standard: ICES-003
This class B digital apparatus complies with
Canadian ICES-003.
This equipment has been tested and
found to comply with the limits for a
class B digital device, pursuant to Part
15 of the FCC Rules.
equipment and receiver.
circuit different from that to which the
receiver is connected.
TV technician for help.
English (US)
11
English (US)
3
4
2
1
PC XXXX
8. Control functions
8.1 Elements on the control panel
Fig. 7 Control panel
Pos. Description
Display showing the power
consumption in watt or the flow
1
Light field indicating high and low flow
Production code:
2
• 1st and 2nd figures: year
• 3rd and 4th figures: week
Light field indicating constant pressure
3
setting
Push-button for selection of pump
4
setting
8.2 Display
The display (1) is on when you have switched on
the power supply.
The display shows the actual pump power
consumption in watt (integer) or the actual flow
during operation.
If a fault is indicated, correct the fault and reset
the pump by switching the power supply off and
on.
If the pump impeller is rotated, for example
when filling the pump with water, sufficient
energy can be generated to light up the display
even if the power supply has been switched off.
Light field indicating high and low flow
• The light field blinks for low flow
– If the flow is lower than 1 gpm, the light
field alternately flashes between "0" and
"1" randomly.
• The light field shows HI for high flow
– If the flow is higher than 12 gpm, the light
field shows "HI" on user interface.
8.2.1 Light fields indicating the pump setting
The pump has optional performance settings
which you can select with the push-button. See
fig. 7.
The pump setting is indicated by light fields in
the display. See fig. 8.
Fig. 8 Light fields
For more information about the function of the
TM06 8878 1417
settings, see section 9. Fault finding the product.
8.3 Setting the pump
You can change the pump setting by pressing
the push-button.
8.3.1 Factory default setting
The pump's factory default setting is the
Constant Pressure III setting.
8.3.2 Changing from recommended to alternative pump setting
Heating systems are "slow" systems that cannot
be set to the optimum operation within minutes
or hours.
However, if the recommended pump setting in
some applications does not give the desired
distribution of heat in the rooms of the house,
you can change to an alternative pump setting.
8.4 Pump control
See section 8.5 Pump performance and
operating mode selection.
Constant-pressure control
In this control mode, a constant differential
pressure across the pump is maintained,
irrespective of the flow.
See also sections 8. Control functions and
8.3 Setting the pump.
TM06 8893 1417
12
8.5 Pump performance and operating mode selection
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Q [US GPM]
0
2
4
6
8
10
12
14
16
18
20
[ft]
H
0
1
2
3
4
5
6
[m]
H
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0
Q [m³/h]
Constant Pressure III
Constant Pressure II
Constant Pressure I
17 18
The hydraulic performance shown is without check valve.
Pos. Description
• Push-button for selection of pump setting
• Every time you press the push-button, the circulator setting is changed.
Constant pressure III
III
• The duty point of the pump will move left and right along the highest constant-pressure
curve depending on the water demand in the system.
Constant pressure II
II
• The duty point of the pump will move left and right along the middle constant-pressure
curve depending on the water demand in the system.
Constant pressure I
I
• The duty point of the pump will move left and right along the lowest constant-pressure
curve depending on the water demand in the system.
English (US)
TM06 8910 1417
13
English (US)
9. Fault finding 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.
Fault Control panel Remedy
1. The pump
does not
run.
2. Noise in
the system
3. Noise in
the pump
The light field is
off.
The light field is
on.
___ ___" a) Supply voltage is too
"
The light field is
on.
The light field is
on.
a) The pump is not
connected to the
power supply.
b) The circuit breaker
has tripped.
c) The pump is
defective.
a) Supply voltage is too
high.
b) The rotor is blocked
by impurities.
low.
a) There is air in the
system.
b) The flow is too high. Reduce the pump speed.
c) Thermal expansion
of system
components.
a) There is air in the
pump.
b) The inlet pressure is
too low.
c) No liquid (dry
running).
d) The pump is
defective.
WARNING
Pressurized system
Death or serious personal injury
- Before dismantling the pump, drain
the system or close the isolating
valve on either side of the pump
before you remove the screws. The
pumped liquid may be scalding hot
and under high pressure.
Connect the pump to the power
supply.
Cut in the circuit breaker.
Replace the pump.
Check that the power supply falls
within the specified range.
Remove the impurities.
Switch the power off and on.
Check for air, locked rotor and/or
voltage.
Correct the power supply.
Install an air eliminator.
Check the mounting brackets for
the pipes.
Secure loose mounting brackets.
Let the pump run, as it will vent
over time.
Install an air eliminator.
Increase the inlet pressure.
Check the air volume in the
expansion tank, if this is installed.
(Pressure leaks in the system can
lead to cavitation.)
Ensure the system has been filled
with liquid and vented.
Open the isolating valves.
Replace the pump.
14
Fault Control panel Remedy
4. Insufficient
heat
The light field is
on.
a) The pump
performance is set
too low.
b) The thermostat is set
too low or is not
working.
c) Air or gas in the
system.
d) The valves are
sticking.
e) Wrong direction of
flow.
f) The boiler is not
working properly.
g) The pump
performance is not
adequate for the
application.
h) The pump
performance is not
adequate for the
application.
Increase the pump's constant
pressure setting.
Check to see if the circulator is in
the proper operating mode.
Check the thermostat to ensure
that it is set to the desired
temperature and is working.
Replace the batteries in the
thermostat.
Vent the air or gas from the system
by allowing the pump to run, as it
will vent over time.
Install an air eliminator.
If necessary rework the piping.
Make sure all valves are in good
working order, that is remove lime
deposits.
See the direction of flow arrow
marked on the pump.
Reinstall the pump to correct the
direction of flow.
Check the water temperature from
the boiler and check the boiler
functions.
Repair the boiler if required.
Check for proper sizing of the
circulator and other system
components.
Check the T calculation.
English (US)
15
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