Grundfos ALPHA2 25-40 130, ALPHA2 25-40 N 130, ALPHA2 25-50 130, ALPHA2 25-50 N 130, ALPHA2 25-60 N 130 Installation And Operating Instructions Manual
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ALPHA2/ALPHA3
Installation and operating instructions
GRUNDFOS INSTRUCTIONS
English (GB) Installation and operating instructions
English (GB)
Original installation and operating instructions
CONTENTS
These installation and operating instructions describe ALPHAx.
Sections 1-6 give the information necessary to be able to unpack,
install and start up the product in a safe way.
Sections 6-17 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 Symbols used in this document
1.3 Other important notes
2. Receiving the product
2.1 Inspecting the product
2.2 Scope of delivery
3. Installing the product
3.1 Mechanical installation
3.2 Control box positions
3.3 Control box positions, ALPHA SOLAR
3.4 Insulating the pump housing
4. Electrical installation
4.1 Assembling the plug
4.2 Disassembling the plug
4.3 Electrical installation, ALPHA SOLAR
4.4 Power supply connection, ALPHA SOLAR
4.5 Control signal connection, ALPHA SOLAR
5. Starting up the product
5.1 Before startup
5.2 Venting the pump
5.3 Venting the heating system
5.4 First startup
6. Product introduction
6.1 Product description
6.2 Applications
6.3 Pumped liquids
6.4 Identification
7. Control functions
7.1 Elements on the control panel
7.2 Display
7.3 Light fields indicating the pump setting
7.4 Light field indicating the status of automatic night
setback
7.5 Button for enabling or disabling of automatic night
setback
7.6 Button for selection of pump setting
7.7 Control modes
7.8 Pump performance
7.9 Bypass valve
8. Operating the product
8.1 Using automatic night setback
8.2 Function of automatic night setback
8.3 Setting manual summer mode
8.4 Dry-running protection
8.5 ALPHA Reader
8.6 High-torque start
9. Fault finding
10. Technical data and installation dimensions
10.1 Technical data
10.2 Dimensions, ALPHAx XX-40, XX-50, XX-60, XX-80
10.3 Dimensions, ALPHAx 25-40 A, 25-60 A
11. Performance curves
11.1 Guide to performance curves
11.2 Curve conditions
11.3 Performance curves, ALPHAx XX-40 (N)
11.4 Performance curves, ALPHAx XX-50 (N)
10
10
10
11
11
13
13
13
13
13
13
14
14
16
17
17
17
18
18
18
18
18
19
20
20
21
22
23
23
23
24
25
11.5 Performance curves, ALPHAx XX-60 (N)
11.6 Performance curves, ALPHAx 25-40 A
11.7 Performance curves, ALPHAx 25-60 A
11.8 Performance curves, ALPHAx XX-80 (N)
12. Accessories
12.1 Unions and valve kits
12.2 Insulating shells
12.3 ALPHA plugs
13. ALPHA SOLAR
13.1 Product introduction
13.2 Application
13.3 Product description
13.4 Operating the product
2
2
3
3
3
3
3
4
4
4
5
6
6
7
8
8
8
8
9
9
9
9
9
13.5 Setting by means of the control panel
13.6 Operating status
13.7 Alarm status
13.8 Operating status
13.9 Fault finding the product
14. External PWM control mode and signals
15. Digital solar-circuit controller
16. Technical data
17. Disposing of the product
1. General information
1.1 Target group
Prior to installation, read this document and the quick
guide. 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.
26
27
28
29
30
30
30
31
31
31
31
31
31
31
31
31
32
32
33
33
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35
2
1.2 Symbols used in this document
1.2.1 Warnings against hazards involving risk of death or personal injury
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.
1.3 Other important notes
A blue or grey circle with a white graphical symbol
indicates that an action must be taken.
English (GB)
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.
Notes or instructions that make the work easier and
ensure safe operation.
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
voltage and frequency of the installation site. See section
6.4.1 Nameplate.
2.2 Scope of delivery
The box contains the following items:
• ALPHAx pump
• ALPHA plug
• insulating shells
• two gaskets
• quick guide.
ALPHA SOLAR is delivered without insulating shells but with a
plug designed for ALPHA SOLAR.
3
3. Installing the product
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, pos. A.
See section 10.2 Dimensions, ALPHAx XX-40, XX-50, XX-60,
XX-80 or section 10.3 Dimensions, ALPHAx 25-40 A, 25-60 A.
1. Fit the two gaskets when you mount the pump in the pipe. See
fig. 1, pos. B.
2. Install the pump with a horizontal motor shaft. See fig. 1, pos.
C. See also section 3.2 Control box positions.
3. Tighten the fittings.
3.2 Control box positions
TM05 2919 0912TM05 3146 0912
Fig. 2 Control box positions
Always install the pump with a horizontal motor shaft.
• Pump installed correctly in a vertical pipe. See fig. 2, pos. A.
• Pump installed correctly in a horizontal pipe. See fig. 2, pos. B.
• Do not install the pump with a vertical motor shaft. See fig. 2,
pos. C and D.
3.2.1 Positioning of the control box in heating and domestic
hot-water systems
You can position the control box in position 3, 6 and 9 o'clock.
See fig. 4.
Fig. 1 Mounting ALPHAx
4
Fig. 3 Control box positions, heating and domestic hot-water
TM05 3057 0612
systems
3.2.2 Positioning the control box in air-conditioning and cold-water systems
Position the control box with the plug pointing downwards. See
fig. 4.
CAUTION
Hot surface
Minor or moderate personal injury.
- Position the pump so that persons cannot
accidentally come into contact with hot surfaces.
Fig. 4 Control box position, air-conditioning and cold-water
systems
3.2.3 Changing the control box position
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 3151 1212TM05 3147 1212
1. Remove the four screws.
2. Turn the pump head to the desired position.
3. Insert and cross-tighten the screws.
3.3 Control box positions, ALPHA SOLAR
English (GB)
Fig. 5 Changing the control box position
You can turn the control box in steps of 90 °.
TM06 5636 5115TM06 5831 0616
Fig. 6 Control box positions, ALPHA SOLAR
Always install the pump with horizontal motor shaft. Position the
control box in position 9 o'clock. See fig. 7.
Fig. 7 Position of the ALPHA SOLAR control box
You can turn the control box in steps of 90 °.
5
3.4 Insulating the pump housing
English (GB)
4. Electrical installation
Fig. 9 Electrical connection
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.
Fig. 8 Insulating the pump housing
You can reduce the heat loss from the pump and pipe by
insulating the pump housing and the pipe with the insulating
shells supplied with the pump. See fig. 8.
Do not insulate the control box or cover the control
panel.
3.4.1 Air-conditioning and cold-water systems
Use the insulating shells in air-conditioning and cold-water
systems as well.
The insulating shells for air-conditioning and cooling systems are
available as accessories. You can order the insulating shells
separately. See section 12. Accessories.
TM05 3058 0912
Carry out the electrical connection and protection in accordance
with local regulations.
• The motor requires no external motor protection.
• Check that the supply voltage and frequency correspond to
the values stated on the nameplate. See section
6.4.1 Nameplate.
• Connect the pump to the power supply with the plug supplied
with the pump. See steps 1 to 7.
DANGER
Electric shock
Death or serious personal injury
- Connect the pump to earth.
Connect the pump to an external mains switch with
a minimum contact gap of 3 mm in all poles.
6
4.1 Assembling the plug
Max. 1.5 mm
2
12 mm
∅5.5 - 10 mm
7 mm
17 mm
Step Action Illustration
Fit the cable gland
and plug cover to
the cable. Strip
1
the cable
conductors as
illustrated.
Connect the cable
conductors to the
2
power supply
plug.
Step Action Illustration
Screw the cable
gland onto the
6
power supply
plug.
TM05 5538 3812
Insert the power
supply plug into
the male plug in
7
the pump control
box.
English (GB)
TM05 5543 3812
Bend the cable
with the cable
3
conductors
pointing upwards.
Pull out the
conductor guide
4
plate and throw it
away.
TM05 5539 3812
TM05 5540 3812
TM05 5541 3812
TM05 3058 0912
5
Click the plug
cover onto the
power supply
plug.
TM05 5542 3812
7
4.2 Disassembling the plug
0
1
1 x 230 V ± 10 % ∽ 50/60 Hz
PWM =
Power =
English (GB)
Step Action Illustration
Loosen the cable
1
gland and remove
it from the plug.
Pull off the plug
cover while
2
pressing on both
sides.
Add the conductor
guide plate to
loosen all three
cable conductors
at the same time.
If the guide plate
is missing, then
3
loosen the cable
conductors one by
one by pressing a
screwdriver gently
into the terminal
clip.
4.3 Electrical installation, ALPHA SOLAR
TM05 5545 3812
Fig. 11 Control box connections
4.4 Power supply connection, ALPHA SOLAR
Connect the pump to the power supply with the TE Superseal
power plug.
DANGER
Electric shock
TM05 5546 3812
Death or serious personal injury
- Connect the pump to earth.
Connect the pump to an external mains switch with
a minimum contact gap of 3 mm in all poles.
4.5 Control signal connection, ALPHA SOLAR
If you do not need the signal connection, cover it with a blanking
plug. See fig. 11.
You can control the pump with a low-voltage PWM (pulse-width
modulation) signal.
The PWM signal is a method for generating an analog signal
using a digital source.
The control signal connection has three conductors: signal input,
signal output and signal reference. Connect the cable to the
TM05 5547 3812
control box with a TE Mini Superseal plug. The signal cable can
be supplied with the pump as an accessory.
TM06 5819 0216
The plug has now
been removed
4
from the power
supply plug.
Fig. 10 Starting up the pump
TM05 5548 3812
TM05 3058 0912
8
5. Starting up the product
10 Min.
1
2
40 180
A
40440
18
10 Min.
2
1
3
5.1 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 sections 3. Installing the product and 10. Technical data and
installation dimensions.
5.2 Venting the pump
5.3 Venting the heating system
English (GB)
Fig. 12 Venting the pump
The pump is self-venting. You do not have to vent the pump
before startup.
Air in the pump may cause noise. This noise ceases when the
pump has run for a few minutes.
You obtain quick venting of the pump by setting the pump to
speed III for a short period. How fast the pump is vented depends
on the system size and design.
When you have vented the pump, i.e. when the noise has
ceased, set the pump according to the recommendations. See
section 7. Control functions.
You cannot vent the system through the pump. See section
5.3 Venting the heating system.
The pump must not run dry.
Fig. 13 Venting of the heating system
Vent the heating system as follows:
• via an air vent valve installed above the pump (1)
• via a pump housing with air separator (2).
In heating systems that often contain much air, we recommend
that you install pumps with pump housing with air separator, i.e.
ALPHAx XX-XX A.
TM05 3075 0912
When the heating system has been filled with liquid, do as
follows:
1. Open the air vent valve.
2. Set the pump to speed III.
3. Let the pump run for a short period
4. Set the pump according to the recommendations. See section
7. Control functions.
Repeat the procedure, if necessary.
The pump must not run dry.
5.4 First startup
• The light in the control panel shows that the power supply has
been switched on. See fig. 10.
• Factory setting: AUTO
ADAPT
.
TM03 8931 2707
9
6. Product introduction
1
2
3
Max. 95 %RH
IPX4D
Min./Max.
+2 C / +110
Max. 1.0 MPa
(10 bar)
4
5
6
7
°°
Min./Max.
0 C / +40
< 43 db(A)
°°
English (GB)
6.1 Product description
TM06 45820 2515TM06 1716 2614
Fig. 15 Model type on the packaging
TM05 3055 0912TM05 3056 0912
ALPHA2/ALPHA3, referred to as ALPHAx in the following, is a
complete range of circulator pumps.
6.1.1 Model type
These installation and operating instructions cover ALPHA2
model B, C and D, and ALPHA3. The model type is stated on the
packaging and nameplate. See figures 15 and 16.
Fig. 14 Pumped liquids, warnings and operating conditions
Fig. 16 Model type on the nameplate
6.2 Applications
The ALPHAx circulator pump 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.
ALPHAx is the best choice for the following systems:
• underfloor heating systems
• one-pipe systems
• two-pipe systems.
ALPHAx is suitable for the following:
• Systems with constant or variable flows where you want to
optimise the setting of the pump duty point.
• Systems with variable flow-pipe temperature.
• Systems where you want automatic night setback.
• Balancing of domestic heating systems.
10
6.3 Pumped liquids
1
8
9
7
6
5
4
3
2
10
15
16
14
13
12
11
AUTO
ADAPT
ALPHA 2 25-60 180
For more information about the pumped liquids, warnings and
operating conditions, see fig. 14.
In heating systems, the water must meet the requirements of
accepted standards on water quality in heating systems, for
example the German standard 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.
• Domestic hot water
Maximum: 14 °dH
Maximum: 65 °C
Maximum peak: 70 °C.
For water with a higher degree of hardness, we recommend
that you use a direct-coupled TPE pump.
• Softened water.
The kinematic viscosity of water is 1 mm
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 approx. 10
2
mm
/s (10 cSt) and a reduction of the pump performance by
approx. 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.
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 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.
2
/s (1 cSt) at 20 °C. If the
6.4 Identification
6.4.1 Nameplate
Fig. 17 Nameplate
Pos. Description
1 Pump type
Rated current [A]:
2
• Min.: Minimum current [A]
• Max.: Maximum current [A]
3 CE mark and approvals
EEI: Energy Efficiency Index
Part 1: Indicating whether the pump is tested in
accordance with the following:
4
Part 2: Stand-alone product
Part 3: Integrated product according to EN
16297-1:2012 and EN 16297-2:2012.
5 Voltage [V]
6 Product number
7 Serial number
8 Model
9 Country of origin
Input power P1 [W]:
10
• Min.: Minimum input power P1 [W]
• Max.: Maximum input power P1 [W]
11 Maximum system pressure [MPa]
12 Enclosure class
13 Temperature class
Production code:
14
• 1st and 2nd figures: year
• 3rd and 4th figures: week
15 Frequency [Hz]
16 QR code
English (GB)
TM05 3079 0912
11
The table below shows the ALPHAx models with built-in functions.
English (GB)
Functions/features
AUTO
ADAPT
Proportional pressure ●●●●
Constant pressure ●●●●
Constant curve ●●●●
Automatic night setback ●●●●
Manual summer mode ●●●
Dry-running protection ●●
ALPHA Reader ●
High-torque start ●●
ALPHAx XX-40 ●●●●
ALPHAx XX-50 ●●●●
ALPHAx XX-60 ●●●●
ALPHAx XX-80 ●●●
6.4.2 Type key
Example ALPHAx 25 -40 N 180
Pump type
Blank: Standard version
L: Limited version
Nominal diameter (DN) of inlet and outlet
ports [mm]
Maximum head [dm]
Blank: Cast-iron pump housing
A: Pump housing with air separator
N: Stainless-steel pump housing
Port-to-port length [mm]
Model B
2012
●●●●
Model C
2015
Model D
2015
ALPHA3 model A
2015
12
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