Grundfos MixiMizer Installation And Operation Manual

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Grundfos MixiMizer
Installation and Operation
1
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2
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3
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5
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6
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7
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8
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Settings
Sensor Installation
Pump Installation
General MixiMizer Features
Shipment Inspection
Start Up
Error Messages & Trouble Shooting
MixiMizer Technical Data
GRUNDFOS INSTRUCTIONS
Pumps Incorporating the (MR) Mixing Reset Control with Date Code 0718 or higher
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MixiMizer™
The hot water heating system can now be accurately and comfortably controlled by modulating the hot water supply. As the outdoor temperature changes, the MixiMizer will automatically calculate the pump speed required, to ensure proper water temperature for your heating system.
For maximum performance and proper installation, please follow the simple instructions in this manual.
1. Shipment Inspection
Check the contents of this package. Care should be taken to ensure the pump is NOT dropped or mishan­dled; dropping will damage the pump.
Grundfos MixiMizer Injection Pump Package Includes:
One Grundfos UP15-42 MixiMizer pump with integral control.
Two Water Temperature Sensors (Supply & Re­turn) – Pre-wired into control box with 8’ of wire.
One 6’ line cord with 115 V plug, pre-wired into control box.
One Outdoor Air Temperature Sensor (OATS)
Two flange gaskets
Installation and Operating Instructions.
Four sensor (Supply & Return) cable ties.
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When installing and using this electrical equipment, basic safety precautions and local code requirements should always be followed, including the following:
CAUTION: The installer must ensure that this control and its wiring are isolated and/or shielded from strong sources of electromagnetic noise. Conversely, this
Class B digital apparatus complies with Part 15 of the FCC Rules and meets all requirements of the Canadian Interference-Causing Equipment Regulations. However, if this control does cause harm­ful interference to radio or television reception, which can be determined by turning the control off and on, the user is encouraged to try to correct the interference by reorienting or relocating the receiving antenna, relocat­ing the receiver with respect to this control, and/or connecting the control to a different circuit from that to which the receiver is connected.
CAUTION: The non-metallic Outdoor Air Temperature Sensor (OATS) and Pump Control Box enclosures do not provide grounding between conduit connections. Use grounding type bushings and jumper wires.
CAUTION: Improper installation and operation of this control could result in damage to the equipment and possibly even personal injury. It is your responsibility to ensure that this control is safely installed according to all applicable codes and standards. This electronic control is not intended for use as a primary limit control. Other controls that are intended and certified as safety limits must be placed into the control circuit.
WARNING: All field wiring to be low voltage. Power for control is provided through the power cord supply­ing power to the pump. Use copper conductors only. Disconnect all power sources prior to servicing.
Risk of electric 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.
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2.
General MixiMizer Features
All minimum and maximum settings are operating, not safety limits. Necessary auxiliary equipment
and safety devices must be added.
The boiler return minimum temperature is fixed at 135°F. This function can be disabled by a DIP switch.
The system supply maximum temperature is fixed at 140°F. This function can be disabled by a DIP switch.
Heating curve parallel shift: The heating curve can be shifted 5°F parallel to the default curve. This function can be enabled by the DIP switch.
Pump Exercising: After every three days of no operation, the control will exercise the pump for 10 seconds. The % of Pump Performance LED will be on during exercising.
Post Purge: A 20 second post purge is available once the heat demand is removed or control
enters WWSD. The purging holds the last speed
used.
As variable speed output modulates, the control flashes the % of Pump Performance LED on for ¼ second and off for ¼ to 2 1/2 seconds.
A 2 second delay from demand to actually starting the pump is used to prevent issues with a noisy demand relay signal.
Optional Boiler On/Off Output: is activated when the pump speed is raised to the boiler enable percentage (30% pump speed) and is de­activated when the pump speed falls to 50% of the boiler enable percentage (15% pump speed). The boiler enable relay has a minimum activation time of 3 minutes and a minimum de-activation time of 20 seconds.
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Optional Zone Control Input: The unit can accept external “Call For Heat” input signal. This must be a powered signal (20 to 30 V AC .1 VA). This function can be enabled by a DIP switch.
Warm Weather Shut Down (WWSD): When the
outdoor air temperature is warmer than 70°F (with
±1°F hysteresis), the unit shuts down until the temperature drops below 70°F.
Summer Service Instructions
When the outdoor temperature is greater than 70oF and the warm weather shutdown (WWSD) feature is active, the pump will normally not be in operation. To allow the pump to be tested, disconnect one of the wires from the air temperature sensor in the control box. This will simulate an open circuit in the outdoor sensor and the control assumes an outdoor temperature of 30oF. This will allow the pump to operate for testing and/or service. Remember to re-connect the outdoor temperature sensor wire when finished.
3. Pump Installation
Warning: Consult piping manufactures for material selection before installing this pump. Absence of pumping fluid may damage some piping materials.
Caution: Thoroughly clean and flush the system prior to pump installation
Pump: For Indoor Use Only
Variable speed injection systems require complete isolation between the boiler loop and system loop. For example, when the injection pump is turned off, there must be no heat transfer from the boiler loop to the system loop. In order to avoid this unwanted heat transfer, review standard primary-secondary piping techniques described below. See figure 1.
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Note 1: The injection piping (Supply and Return) must
be at least one pipe diameter smaller than the piping of the boiler and system loops.
Note 2: There must be a maximum of 4 pipe
diameters between the tees in the boiler and system loops in order to prevent ghosts flow when the variable speed injection pump is off and either the boiler pump or system pump is on.
Note 3: There must be at least 6 pipe diameters
of straight pipe on either side of the tees in order to prevent momentum of water in the boiler and system loops from pushing flow through the injection loop.
Note 4: To prevent convective heat transfer through
the injection loop, there should be a minimum of 1 foot drop to create a thermal trap.
System
Loop
Grundfos
Note 3
Note 4
MixiMizer Pump
Boiler
Loop
Balancing
Valve
{
Note 1
{
Note 3
{
{
Note 2
{
Figure 1 - Injection loop without thermal trap.
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Design Injection Nominal Injection MixiMizer Flow Rate (GPM) Pipe Diameter Pump Model
0-8 3/4"
UP15-42BUC5/MR
UP15-42BUC7/MR*
Warning:
*Can produce flow velocity
greater than 8 ft/sec in this size.
0-5 1/2"
UP15-42BUC5/MR*
UP15-42FC/MR*
UP15-42FC/MR
0-16 1"
UP15-42BUC7/MR
Arrows on the side or bottom of the pump chamber indicate direction of flow through the pump. Grundfos Miximizer pumps can be installed in both vertical and horizontal lines. Flow direction should be from the boiler loop into the system loop.
The pump must be installed with the motor shaft posi­tioned horizontally. Under no circumstances should the pump be installed with the shaft vertical or where the shaft falls below the horizontal plane (Fig.2).
Table 1
Recommended
Optional
DO NOT
Mount Motor Shaft in Vertical Position
Figure 2
Preferred installation of the pump will have the terminal box located to one side of the pump or the other, with the conduit entry down.
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4.
Sensor Installation
Warning: 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.
CAUTION: Power must not be applied to any of the wires during the rough-in wiring stage.
CAUTION: All field wiring must pass through a suitable listed conduit fitting, to ensure proper strain relief.
CAUTION: All field installed wiring should meet or exceed requirements for class 2 wiring per article 725 of the National Electrical Code rated at 30VAC 250VA. Ensure that enough wiring is in the control box to reach the terminal strip.
NOTE: All field wiring shall have insulation stripped exposing 6.0mm of conductor before placement into control box terminal strip.
If the terminal box position needs to be changed, ensure that the electrical supply is turned off and close the isolation valves before removing the Allen screws. To change control box position:
Remove the four (4) Allen screws (4 or 5mm wrench) while supporting the stator (motor).
Carefully separate the stator from the pump chamber and rotate it to the correct terminal box orientation.
Replace the Allen screws and tighten diagonally and evenly (7 ft. –lb. torque).
Check that the motor shaft turns freely. Remove the large screw in the middle of the nameplate, insert a small flat blade screwdriver into the end of the shaft, and turn gently.
If the shaft does not turn easily, repeat the disas­sembly/reassembly process.
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Outdoor Air Temperature Sensor (OATS):
The Outdoor Air Temperature Sensor includes a built in 10 kW (ohm) thermistor which provides an accurate measurement of the outdoor temperature. The OATS sensor is protected by a white U.V. resistant PVC plastic enclosure (Fig. 3A & 3B).
Remove the screw and pull the front cover off the sensor enclosure.
The OATS can either be mounted directly onto a wall or in a 2” x 4” electrical box. When the OATS is wall mounted, the wiring should enter through the back or bottom of the enclosure. Do not
mount the OATS with the conduit knockout fac­ing upwards as rain could enter the enclosure and damage the sensor (Fig. 4).
In order to prevent heat transmitted through the wall from affecting the sensor reading, it may be necessary to install an insulating barrier behind the OATS enclosure.
The OATS should be mounted on a wall which best represents the heat load on the building (a northern wall for most buildings or a southern fac­ing wall for buildings with large south facing glass areas). The OATS should not be exposed to heat sources such as ventilation or window openings.
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Figure 3A - Closed Outdoor Air Temperature Sensor (OATS)
Sensor
Figure 3B - Open Outdoor Air Temperature Sensor (OATS)
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The OATS should be installed at an elevation above the ground that will prevent accidental dam­age or tampering.
Install field wiring from the OATS mounting loca­tion to the control box for the control wiring. Do not run field wires parallel to telephone or power cables. If the sensor wires are located in an area with strong sources of electromagnetic interfer­ence (EMI), shielded cable or twisted pair should be used. If using shielded cable, the shield wire should be connected to the Com (–) terminal on the control and not to earth ground.
Connect the two field wires from the OATS directly to the control box “Com (-)” and “Os/V” (not polar sensitive) terminals (Fig. 8).
Water Temperature Sensors (Supply & Return):
The Water Temperature Sensor has a zinc sleeve for fast response and a wide operating range (Fig
5). Factory Pre-wired
Note: Sensors are designed to mount on a pipe or in a temperature immersion well.
The sensor can be strapped directly to the pipe using the cable tie provided. Insulation should be placed around the sensor to reduce the effect of air currents on the sensor measurement (Fig. 6).
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Figure 5 - Sensor
Sensor with rear entry wiring
Sensor with bottom entry wiring
Sensor mounted onto 2" x 4" electrical box.
Figure 4 - Mounting the Outdoor Air Temperature Sensor (OATS)
Figure 6 - Mounted Sensor
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The sensor should be placed downstream of a pump or after an elbow or similar fitting. This is especially important if large diameter pipes are used as the thermal stratification within the pipe can result in erroneous sensor readings. Proper sensor location requires that the fluid is thoroughly mixed within the pipe before it reaches the sensor.
Locate the labels attached to each sensor. One sensor will be identified as the Return Sensor and one will be identified as the Supply Sensor. (Fig. 7A & 7B) Mount the Return Sensor to the return piping of the boiler loop. Mount the Supply Sensor to supply piping of the system loop.
Figure 7A - Return Sensor Label Figure 7B - Supply Sensor Label
Optional Boiler On/Off Output:
The boiler terminals are used to activate a boiler when the pump is ramped to the boiler enable percentage 30% and is shut off when the pump is ramped to 50% of the boiler enable percentage. The boiler enable includes a minimum "ON" time of 3 minutes and a mini­mum "OFF" time of 20 seconds. Connect field wiring to control box terminals Boil & Boil (not polar sensitive) (Fig. 8).
Optional Zone Control Input:
Connect field wiring 24 V (ac) power supply or heat demand to control box terminals “DEM” and “DEM” (not polar sensitive) (Fig. 8).
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Sup
Com
Ret / I
Com(-)
Os / V
Boil
Boil
Dem
Dem
tN4
Signal wires must
be min. 300V rating
Class 2
Only
Optional
Boiler On/Off
Output
Return
Sensor
Optional Zone
Control Input
Use copper
conductors only
Outside
Temp
Sensor
Supply
Sensor
Fig. 8
Figure 9 - Dip Switches
ON
5.
Settings
Dip switch settings:
POSITION
SWITCH ON OFF DEFAULT
A
Permanent External ON position
Demand Demand Permanent Demand
Max system Max system ON position B supply set supply feature supply set at at 140
o
F is off 140oF
Boiler return Boiler return ON position C minimum set minimum feature minimum set at at 135oF is off 135oF
D Heating curve Heating Curve 5oF On position No shift Parallel shift No shift
ON position
Max supply set at
140°F
ON position
Boiler minimum
set at 135°F
Starting Temp.
70°F
Starting Temp.
75°F
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Heating Curve - Dial Set Point:
Before adjusting the dial settings, read through the sequence of operation to ensure that you understand how this control operates.
The Heating Curve setting deter­mines the number of degrees the supply water temperature is raised for each one degree drop in outdoor temperature. The Heating Curve dial position can be calculated from the following formula.
Heating Curve - Dial Set Point Example:
System Design Temperature = 120°F
Outdoor Design Temperature = 10°F
Warm Weather Shutdown (WWSD) = 70°F
Dial Set Point = 120 – 70°F = 0.8
70 – 10°F (Table 2)
Figure 10 - Heating Curve Dial
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-20-1001020304050607080
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.6
3.6
3.0
Heating Curve
System
Design
Tempera
ture,
Heating Curve Dial
S
et Point
Outd
oor Design Temperat
ure °F
°F
WWSD
>
>
>
Heating Curve Table - Dial Set Point
(Warm Weather Shut Down = 70°F)
Table 2
Table 3
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Performance Indicator LEDs (Fig. 11):
• Power ON: (Green) indicates power is applied.
• % of pump performance: (Yellow) indicates the
speed of the pump by flashing at different rates.
• Call For Heat: (Green) External devise requesting
heat from system
• Pump Perf. Reduced: (Yellow) Indicates the pump
speed is limited due to protection limits.
• Boiler: (Green) Boiler activated for operation
Call for Heat
% Of Pump Perf.
Power On
Pump Perf. Reduced
Boiler
Figure 11 - Performance indicator LEDs
6.
Start Up
DO NOT START THE PUMP UNTIL THE SYSTEM
HAS BEEN FILLED, FLUSHED, PROPERLY VENTED, AND CHECKED FOR LEAKS.
Ensure that water does not enter the terminal box
during the installation process.
Do not use the pump to vent the system. Install
additional ventilation for system purging.
Never operate the pump dry. The bearings require
water lubrication and will be damaged otherwise.
Fill system with water. This will result in immediate
lubrication of the bearings.
Operate the pump for 5 minutes, when control in-
stallation is complete, to purge remaining air from the bearing chamber. This is especially important when installing the pump during the off-season.
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Whenever a fault is detected in any of the sensors, the control LEDs will flash in a specific way, to indicate the lo­cation of the problem, and the control will assume a specific operating condition.
Call For Heat LED is flashing (Fig. 12):
There is a short or open circuit to OATS Sensor And the control assumes an outdoor
temperature of 30°F
Pump Performance Reduced LED is flashing
(Fig. 13): There is a short or open circuit to the Supply
Sensor
And the control runs pump at 10% and
does boiler protection if enabled.
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Figure 13 - Control Lights (Pump Performance Reduced)
Call for Heat
% Of Pump Perf.
Power On
Pump Perf. Reduced
Boiler
Figure 12 - Control Lights (Call For heat)
7. Error Messages and
Trouble Shooting
Call for Heat
% Of Pump Perf.
Power On
Pump Perf. Reduced
Boiler
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Testing Sensors:
Warning: No wires connected to control box
during testing
Outdoor Air Temperature Sensor (OATS):
First measure the ambient air temperature next to the OATS sensor.
Disconnect all field wiring from the OATS sensor.
Measure (ohms) resistance directly at the OATS sensor location, convert ohms reading to temperature (Table 4).
Compare ambient air temperature to the measured sensor resistance. Both temperatures should be close +/- 10% (Table 4).
Supply & Return Sensors:
Disconnect sensor wiring from control box.
Measure the resistance (ohms) of the Supply then the Return sensor (Wires have no polarity). See Table 4.
Compare fluid temperature to Resistance/ Temperature Chart (Table 4). Both temperatures should be close +/- 10%.
Possible reasons for short circuit:
Water in OATS sensor case
Nail or staple in field wiring
Possible reasons for open circuit:
Sensor wire jacket has been compromised
Sensor is disconnected
Sensor insulation is interfering with sensor at the pipe location
Faulty sensor
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Call For Heat and Pump Performance Reduced LEDs are flashing (Fig. 14):
There is a short or open circuit to Boiler Return
Sensor
Boiler protection is disabled
Figure 14 - Control Lights (PPR & CFH)
Call for Heat
% Of Pump Perf.
Power On
Pump Perf. Reduced
Boiler
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Test the Power Supply or Heat Demand.
Make sure exposed wires and bare terminals are not in contact with other wires or grounded surfaces. Turn on the power or provide a heat demand and measure the voltage across the leads. The voltmeter should read between plus and minus 4 volts of the supplied voltage.
Temperature Resistance Temperature Resistance
o
F
o
C
o
F
o
C
-50 -46 490,813 90 32 46,218
-45 -43 405,710 95 35 7,334
-40 -40 336,606 100 38 5,828
-35 -37 280,279 105 41 5,210
-30 -34 234,196 110 43 4,665
-25 -32 196,358 115 46 4,184
-20 -29 165,180 120 49 3,760
-15 -26 139,402 125 52 3,383
-10 -23 118,018 130 54 3,050
-5 -21 100,221 135 57 2,754
0 -18 85,362 140 60 2,490
5 -15 72,918 145 63 2,255
10 -12 62,465 150 66 2,045
15 -9 53,658 155 68 1,857
20 -7 46,218 160 71 1,689
25 -4 39,913 165 74 1,538
30 -1 34,558 170 77 1,403
35 2 29,996 175 79 1,281
40 4 26,099 180 82 1,172
45 7 22,763 185 85 1,073
50 10 19,900 190 88 983
55 13 17,436 195 91 903
60 16 15,311 200 93 829
65 18 13,474 205 96 763
70 21 11,883 210 99 703
75 24 10,501 215 102 648
80 27 9,299 220 104 598
85 29 8,250 225 107 553
Table 4
OATS / Return / Supply Temperature Resistance Chart
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Maximum Ambient Temperature:
• 107°F (42°C) with Control Box vertical
• 105°F (41°C) with Control Box on top of pump and horizontal
Outdoor Air Temperature Sensor: Approvals: CSA, UL Terminals: Out/V & Com (-) 5V DC +/- 5% Max
0.166 mA DC +/- 5% Max Operating Range: -67 to 149°F (-55 to 65°C) Sensor: NTC thermistor, 10Ohms @ 77°F (25°C +/- 0.2°C), B=3892 Enclosure: White U.V. resistant, PVC, NEMA 1
Control Box: Input Voltage: 120V +/- 10%, 50/60Hz, 250vA Output Rating: 1.8A, 1/12Hp
Supply & Return Temperature Sensors: Approvals: CSA, UL Terminals: (Sup & Com) (Ret/I & Com) 5V DC +/- 5% Max
0.166 mA DC +/- 5% Max Operating Range: 14 to 266°F (-10 to 130°C) Sensor: NTC thermistor, 10Ohms @ 77°F (25°C +/- 0.2°C), B=3892 Wire: 8ft., 300V, UL2722, PVC insulation, 105°C
Optional Boiler On/Off Output: Terminals: Boil & Boil 30 VAC
2.5 Amp Pilot Duty
Optional Zone Control Input: Terminals: Dem & Dem 20 - 30 VAC
0.1 VA Max
8.
MixiMizer Technical Data
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UP15 Pump:
Max Working Pressure: 145 PSI Min. Inlet Pressure: 5 PSI Approvals: UL, cUL listed Integrated Check Valve: Yes
UP15-42FC/MR: Connection: GF 15/26 Flange - (2) 1/2” Diam. Bolt Holes Flow Range (GPM): 0 - 9 Head Range (ft.): 0 - 14 Motor: 2 Pole, Single Phase Amps: 0.74 Watts: 85 Hp: 1/25 Max Fluid Temp: 205°F (96°C) Volute Material: Cast Iron
UP15-42BUCX/MR: Motor: 2 Pole, Single Phase Amps: 0.74 Watts: 85 Hp: 1/25 Max Fluid Temp: 205°F (96°C) Volute Material: Silicon Bronze
BUC5: Flow Range (GPM): 0 - 8.5 Head Range (ft.): 0 - 14.5 Connection: 1/2” Sweat
BUC7: Flow Range (GPM): 0 - 16 Head Range (ft.): 0 - 15 Connection: 3/4” Sweat
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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 more than 30 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, transpor-tation, 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 altera-tion or repair, or if the product was not installed in accordance with GRUNDFOS' printed installation and operation 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 sup-porting installation data. Unless otherwise provided, the distributor or dealer will contact the GRUNDFOS factory or authorized service station for instructions. Any defective product to be returned to the factory or service station must be sent freight prepaid; documentation supporting the warranty claim and/or a Return Authorization must be included if so instructed.
GRUNDFOS WILL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, LOSSES, OR EXPENS-ES 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 consequential damages and some jurisdic-tions 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.
Grundfos Pumps Corporation 17100 W. 118th Terrace Olathe, Kansas 66061 Telephone: (913) 227-3400 Fax: (913) 227-3500
Grundfos Canada, Inc. 2941 Brighton Rd. Oakville, Ontario L6H 6C9 Telephone: (905) 829-9533 Fax: (905) 829-9512
Bombas Grundfos de Mexico, S.A. de C.V. Boulevard TLC #15, Parque Industrial Stiva Aeropuerto C.P. 66600 Apodaca, N.L. Mexico Telephone: 52-81-8144-4000 Fax: 52-81-8144-4010
L-UP-TL-035 3/07
PRINTED IN USA
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