Grundfos UPE 25-40, UPE 25-60, UPE 25-60 A, UPE 25-80, UPE 32-40 Installation And Operating Instructions Manual

UPE Series 2000

UPE 25-40, UPE 25-40 A, UPE 25-60, UPE 25-60 A, UPE 25-80,

UPE 32-40, UPE 32-60, UPE 32-80, UPE 40-80, UPE 50-80

GRUNDFOS INSTRUCTIONS

Installation and operating instructions

Declaration of Conformity

We Grundfos declare under our sole responsibility that the products
UPE Series 2000, to which this declaration relates, are in conformity with the

Council Directives on the approximation of the laws of the EC Member States
relating to
– Machinery (98/37/EC).

Standard used: EN ISO 12100.

– Electromagnetic compatibility (89/336/EEC).

Standards used: EN 61 000-6-2 and EN 61 000-6-3.

– Electrical equipment designed for use within certain voltage limits

(73/23/EEC) [95].
Standards used: EN 60 335-1: 1994 and EN 60 335-2-51: 1997.

Konformitätserklärung

Wir Grundfos erklären in alleiniger Verantwortung, dass die Produkte
UPE Serie 2000, auf die sich diese Erklärung bezieht, mit den folgenden

Richtlinien des Rates zur Angleichung der Rechtsvorschriften der EG­Mitgliedstaaten übereinstimmen
– Maschinen (98/37/EG).

Norm, die verwendet wurde: EN ISO 12100.

– Elektromagnetische Verträglichkeit (89/336/EWG).

Normen, die verwendet wurden: EN 61 000-6-2 und EN 61 000-6-3.

– Elektrische Betriebsmittel zur Verwendung innerhalb bestimmter

Spannungsgrenzen (73/23/EWG) [95].
Normen, die verwendet wurden: EN 60 335-1: 1994 und
EN 60 335-2-51: 1997.

Déclaration de Conformité

Nous Grundfos déclarons sous notre seule responsabilité que les produits
Série UPE 2000 auxquels se réfère cette déclaration sont conformes aux

Directives du Conseil concernant le rapprochement des législations des Etats
membres CE relatives à
– Machines (98/37/CE).

Standard utilisé: EN ISO 12100.

– Compatibilité électromagnétique (89/336/CEE).

Standards utilisés: EN 61 000-6-2 et EN 61 000-6-3.

– Matériel électrique destiné à employer dans certaines limites de tension

(73/23/CEE) [95].
Standards utilisés: EN 60 335-1: 1994 et EN 60 335-2-51: 1997.

Dichiarazione di Conformità

Noi Grundfos dichiariamo sotto la nostra esclusiva responsabilità che i pro­dotti UPE Serie 2000 ai quali questa dichiarazione se riferisce sono conformi
alle Direttive del Consiglio concernente il ravvicinamento delle legislazioni
degli Stati membri CE relative a
– Macchine (98/37/CE).

Standard usato: EN ISO 12100.

– Compatibilità elettromagnetica (89/336/CEE).

Standard usati: EN 61 000-6-2 e EN 61 000-6-3.

– Materiale elettrico destinato ad essere utilizzato entro certi limiti di ten-

sione (73/23/CEE) [95].
Standard usati: EN 60 335-1: 1994 e EN 60 335-2-51: 1997.

Declaración de Conformidad

Nosotros Grundfos declaramos bajo nuestra única responsabilidad que los
productos Serie UPE 2000 a los cuales se refiere esta declaración son confor­mes con las Directivas del Consejo relativas a la aproximación de las
legislaciones de los Estados Miembros de la CE sobre
– Máquinas (98/37/CE).

Norma aplicada: EN ISO 12100.

– Compatibilidad electromagnética (89/336/CEE).

Normas aplicadas: EN 61 000-6-2 y EN 61 000-6-3.

– Material eléctrico destinado a utilizarse con determinadas límites

de tensión (73/23/CEE) [95].
Normas aplicadas: EN 60 335-1: 1994 y EN 60 335-2-51: 1997.

Declaração de Conformidade

Nós Grundfos declaramos sob nossa única responsabilidade que os produtos
Série 2000 da UPE aos quais se refere esta declaração estão em conformi-

dade com as Directivas do Conselho das Comunidades Europeias relativas à
aproximação das legislações dos Estados Membros respeitantes à
– Máquinas (98/37/CE).

Norma utilizada: EN ISO 12100.

– Compatibilidade electromagnética (89/336/CEE).

Normas utilizadas: EN 61 000-6-2 e EN 61 000-6-3.

– Material eléctrico destinado a ser utilizado dentro de certos limites de ten-

são (73/23/CEE) [95].
Normas utilizadas: EN 60 335-1: 1994 e EN 60 335-2-51: 1997.

∆ήλωση Συµµόρφωσης

Εµείς η Grundfos δηλώνουµε µε αποκλειστικά δική µας ευθύνη ότι τα προιόντα
Σειρά UPE 2000 συµµορφώνονται µε την Οδηγία του Συµβουλίου επί της
σύγκλισης των νόµων των Κρατών Mελών της Ευρωπαικής Ενωσης σε σχέση

µε τα
– Μηχανήµατα (98/37/EC).

Πρότυπο που χρησιµοποιήθηκε: EN ISO 12100.

– Ηλεκτροµαγνητική συµβατότητα (89/336/EEC).

Πρότυπα που χρησιµοποιήθηκαν: EN 61 000-6-2 και EN 61 000-6-3.

– Ηλεκτρικές συσκευές σχεδιασµένες γιά χρήση εντός ορισµένων ορίων

ηλεκτρικής τάσης (73/23/EEC) [95].
Πρότυπα που χρησιµοποιήθηκαν: EN 60 335-1: 1994 και

EN 60 335-2-51: 1997.

Overeenkomstigheidsverklaring

Wij Grundfos verklaren geheel onder eigen verantwoordelijkheid dat de pro­dukten UPE Serie 2000 waarop deze verklaring betrekking heeft in
overeenstemming zijn met de Richtlijnen van de Raad inzake de onderlinge
aanpassing van de wetgevingen van de Lid-Staten betreffende
– Machines (98/37/EG).

Norm: EN ISO 12100.

– Elektromagnetische compatibiliteit (89/336/EEG).

Normen: EN 61 000-6-2 en EN 61 000-6-3.

– Elektrisch materiaal bestemd voor gebruik binnen bepaalde spannings-

grenzen (73/23/EEG) [95].
Normen: EN 60 335-1: 1994 en EN 60 335-2-51: 1997.

Försäkran om överensstämmelse

Vi Grundfos försäkrar under ansvar, att produkterna UPE Serie 2000, som
omfattas av denna försäkran, är i överensstämmelse med Rådets Direktiv om
inbördes närmande till EU-medlemsstaternas lagstiftning, avseende
– Maskinell utrustning (98/37/EC).

Använd standard: EN ISO 12100.

– Elektromagnetisk kompatibilitet (89/336/EC).

Använda standarder: EN 61 000-6-2 och EN 61 000-6-3.

– Elektrisk material avsedd för användning inom vissa spänningsgränser

(73/23/EC) [95].
Använda standarder: EN 60 335-1: 1994 och EN 60 335-2-51: 1997.

Vastaavuusvakuutus

Me Grundfos vakuutamme yksin vastuullisesti, että tuotteet UPE Sarja 2000,
jota tämä vakuutus koskee, noudattavat direktiivejä jotka käsittelevät EY:n
jäsenvaltioiden koneellisia laitteita koskevien lakien yhdenmukaisuutta seur.:
– Koneet (98/37/EY).

Käytetty standardi: EN ISO 12100.

– Elektromagneettinen vastaavuus (89/336/EY).

Käytetyt standardit: EN 61 000-6-2 ja EN 61 000-6-3.

– Määrättyjen jänniterajoitusten puitteissa käytettävät sähköiset laitteet

(73/23/EY) [95].
Käytetyt standardit: EN 60 335-1: 1994 ja EN 60 335-2-51: 1997.

Overensstemmelseserklæring

Vi Grundfos erklærer under ansvar, at produkterne UPE Serie 2000, som
denne erklæring omhandler, er i overensstemmelse med Rådets direktiver om
indbyrdes tilnærmelse til EF medlemsstaternes lovgivning om
– Maskiner (98/37/EF).

Anvendt standard: EN ISO 12100.

– Elektromagnetisk kompatibilitet (89/336/EØF).

Anvendte standarder: EN 61 000-6-2 og EN 61 000-6-3.

– Elektrisk materiel bestemt til anvendelse inden for visse spændings-

grænser (73/23/EØF) [95].
Anvendte standarder: EN 60 335-1: 1994 og EN 60 335-2-51: 1997.

Deklaracja zgodności

My, Grundfos, oświadczamy z pełną odpowiedzialnością, że nasze wyroby
UPE seria 2000 których deklaracja niniejsza dotyczy, są zgodne z

następującymi wytycznymi Rady d/s ujednolicenia przepisów prawnych krajów
członkowskich EG:
– maszyny (98/37/EG),

zastosowana norma: EN ISO 12100.

– zgodność elektromagnetyczna (89/336/EWG),

zastosowane normy: EN 61 000-6-2 i EN 61 000-6-3.

– wyposażenie elektryczne do stosowania w określonym zakresie napięć

(73/23/EWG) [95],
zastosowane normy: EN 60 335-1: 1994 i EN 60 335-2-51: 1997.

Bjerringbro, 15th June 2005

Svend Aage Kaae
Technical Director

2

3

UPE Series 2000

UPE 25-40, UPE 25-40 A, UPE 25-60, UPE 25-60 A, UPE 25-80,

UPE 32-40, UPE 32-60, UPE 32-80, UPE 40-80, UPE 50-80

Installation and operating instructions 4

Montage- und Betriebsanleitung 27

Notice d’installation et d’entretien 52

Istruzioni di installazione e funzionamento 77

Instrucciones de instalación y funcionamiento 102

Instruções de instalação e funcionamento 126

Οδηγίες εγκατάστασης και λειτουργίας 151

Installatie- en bedieningsinstructies 176

Monterings- och driftsinstruktion 201

Asennus- ja käyttöohjeet 223

Monterings- og driftsinstruktion 245

Instrukcja montażu i eksploatacji 267

4

CONTENTS

Page

1. General description 4

2. Applications 5

2.1 Pumped liquids 5

3. Installation 5

3.1 Terminal box positions 5

3.2 Changing the terminal box position 6

3.3 Non-return valve 6

3.4 Air separator pump 6

3.5 Frost protection 6

4. Electrical connection 7

5. Start-up 7

6. Functions 8

6.1 Control modes 8

6.2 Selection of control mode 9

6.3 Max. or min. curve duty 10

6.4 Constant curve duty 10

6.5 Temperature influence 10

6.6 Indicator lights 11

6.7 Expansion modules 11

6.8 External analog 0-10 V controller 15

6.9 Deactivating the control panel 15

6.10 Wireless remote control 15

7. Setting the pump 16

7.1 Factory settings 16

7.2 Control panel 16

7.3 Setting of pump head 17

7.4 R100 19

7.5 Menu OPERATION 20

7.6 Menu STATUS 20

7.7 Menu INSTALLATION 21

7.8 Priority of settings 22

8. Fault finding chart 23

9. Megging 24

10. Technical data 25

11. Disposal 26

1. General description

The UPE Series 2000 is a complete range of circula­tor pumps with integrated differential pressure con­trol enabling adjustment of pump performance to the
actual system requirements. In many systems, this
will mean a considerable reduction in power con­sumption, prevent noise from thermostatic valves
and similar fittings, and improve the control of the
system.

The desired head can be set on the pump control
panel.

These instructions apply to the pump types
UPE 25-40, UPE 25-40 A, UPE 25-60, UPE 25-60 A,
UPE 25-80, UPE 32-40, UPE 32-60, UPE 3 2-80,
UPE 40-80 and UPE 50-80.

The pump offers the following functions:

• Proportional pressure control (factory setting).
The head is changed in accordance with the flow
demand. The desired head can be set on the
pump control panel.

• Constant pressure control. A constant head is
maintained, irrespective of flow demand. The de­sired head can be set on the pump control panel.

• Constant curve duty. The pump runs at a con­stant speed on or between the max. and min.
curves.

• Temperature influence. The head varies depend­ing on the liquid temperature.

• External fault signal via a potential-free output.
(Requires an MC 40/60 or MC 80 expansion

module.)

• External analog control of head or speed from
an external 0-10 V signal transmitter.

(Requires an MC 40/60 or MC 80 expansion
module.)

• External forced control via inputs for:

-Start/stop,

- Max. curve,

- Min. curve (night-time duty).

(Requires an MC xx or MB xx expansion mod ule.)

• Bus communication. As the UPE Series 2000 in­corporates an input for bus communication, the
pump can be controlled and monitored by a
Grundfos Pump Management System 2000, a
building management system or another type of
external control system.

(Requires an MB 40/60 or MB 80 expansion
module.)

• Remote control . The pump can be operated by
means of the Grundfos wireless remote control
R100.

Before beginning installation procedures,
these installation and operating instruc­tions should be studied carefully. The in­stallation and operation should also be in
accordance with local regulations and ac­cepted codes of good practice.

5

2. Applications

The UPE Series 2000 is designed for circulating liq­uids in heating systems. The pumps can also be
used in domestic hot-water systems.

UPE Series 2000 is suitable for:

• systems w ith a constant flow where it is desira­ble to optimize the setting of the pump duty point
and

• systems w ith variable flow-pipe temperatures.

2.1 Pumped liquids

Thin, clean, non-aggressive and non-explosive liq­uids, not containing solid particles, fibres or mineral
oils.

In heating systems, the water should meet the re­quirements of accepted standards on water quality in
heating systems, e.g. the German standard
VDI 2035.

In domestic hot-water systems, it is advisable to
use UPE pumps only for water with a degree of hard­ness lower than approx. 14°dH.
For water with a higher degree of hardness a direct­coupled TPE pump is recommended.

3. Installation

When installing pumps, types UPE 32-80 F,
UPE 40-80 F and UPE 50-80 F, with oval bolt holes
in the pump flange, washers must be used as shown
in fig. 1.

Fig. 1

See mounting dimensions at the end of these in­structions.

The pump must be installed with the motor shaft hor­izontal, fig. 2.

Fig. 2

Arrows on the pump housing indicate the liquid flow
direction through the pump, fig. 3.

Fig. 3

3.1 Terminal box positions

The terminal box can be turned to the positions
shown in figure 4. However, these positions must be
checked with the “x” markings indicated in the tables
below:

The pump must not be used for the trans­fer of inflammable liquids such as diesel
oil, petrol or similar liquids.

Care should be taken to ensure that per­sons cannot accidentally come into con­tact with hot surfaces of the pump.

Installation

Pump

Washer

TM01 0683 1997

TM00 4551 3394TM00 4452 3394

Pumps without insulation kit

Fig. 4 A B C D (E) (F)

UPE 25-40 x x x x (x) (x)
UPE 25-40 A* x x (x)
UPE 25-60 x x x x (x) (x)
UPE 25-60 A* x x (x)
UPE 25-80 x x (x)
UPE 32-40 x x x x (x) (x)
UPE 32-60 x x x x (x) (x)
UPE 32-80 x x (x)
UPE 40-80 x x (x)
UPE 50-80 x x (x)

6

* UPE 25-40 A and UPE 25-60 A pumps, which have

a socket for an automatic air vent, must be
mounted in pipes with upward liquid flow.

Fig. 4

Note:
Pos. E and F: This terminal box position is not re-

commended.
Pos. G and H: This terminal box position is not

allowed.

3.2 Changing the terminal box position

Change the terminal box position as follows:

1. Remove the four screws holding the pump head.

2. Turn the pump head to the required position.

3. Replace the four screws and tighten securely.

3.3 Non-return valve

If a non-return valve is fitted in the pipe system, see
fig. 5, it must be ensured that the minimum discharge
pressure is always higher than the closing pressure
of the valve. This is especially important in propor­tional-pressure control mode (reduced head at low
flows).

Fig. 5

3.4 Air separator pump

Fig. 6

Do not start the pump until the system has been
filled with liquid and vented. Furthermore, the re­quired minimum inlet pressure must be available at
the pump inlet, see section 10. Technical data.

3.5 Frost protection

If the pump is not being used during periods of frost,
the necessary steps must be taken to avoid frost
bursts.

Pumps with insulation kit

Fig. 4 A B C D (E) (F)

UPE 25-40 x x (x)
UPE 25-40 A* x (x)
UPE 25-60 x x (x)
UPE 25-60 A* x (x)
UPE 25-80 x x (x)
UPE 32-40 x x (x)
UPE 32-60 x x (x)
UPE 32-80 x x (x)
UPE 40-80 x x (x)
UPE 50-80 x x (x)

TM00 4453 1599

Before any dismantling of the pump, the
system must be drained or the isolating
valves on either side of the pump must be
closed as the pumped liquid may be scald­ing hot and under high pressure.

A

B

E

H

C

F

G

D

TM02 0640 0301

UPE 25-40 A and UPE 25-60 A pumps
must be fitted with an automatic air vent.
This must be fitted to the pump housing
before priming, fig. 6.

TM00 4454 3394

7

4. Electrical connection

The electrical connection and protection should be
carried out in accordance with local regulations.

• The pump requires no external motor protection.

• The operating voltage and frequency are marked
on the pump nameplate. Please make sure that
the motor is suitable for the electricity supply on
which it will be used.

• Supply voltage:
1 x 230-240 V –10%/+6%, 50 Hz, PE.

• Mains connection is to be carried out as shown in
figs. 7 and 8.

Fig. 7

UPE 25-40, 25-40 A, 25-60, 25-60 A, 32-40 and
32-60

Mains connection of UPE xx-40 and UPE xx-60 is
shown in page 293.

Fig. 8

UPE 25-80, 32-80, 40-80 and 50-80

Mains connection of UPE xx-80 is shown in page

294.

5. Start-up

Do not start the pump until the system has been
filled with liquid and vented. Furthermore, the re­quired minimum inlet pressure must be available at
the pump inlet, see section 10. Technical data.
The system cannot be vented through the pump.

To vent the pump, remove the vent screw, fig. 9,
switch on the electricity supply and ensure maximum
flow in the system.

When any remaining air has escaped, replace and
tighten the vent screw.

Fig. 9

The pump may be noisy, when first switched on, due
to air remaining in the chamber. The noise should
cease after a few minutes running.

After start-up, the desired operating mode and possi­bly pump head are set.

Never make any connections in the pump
terminal box unless the electricity supply
has been switched off for at least 5 min­utes.

The earth terminal of the pump must be
connected to earth.

The pump must be connected to an exter­nal mains switch with a minimum contact
gap of 3 mm in all poles.

Megging must be carried out as described
in section 9. Megging.

TM00 4449 3301TM01 0462 3399

NL

LN

When the vent screw is removed, scalding
hot liquid under high pressure may es­cape. Care should be taken to ensure that
the escaping liquid does not cause per­sonal injury or damage to other compo­nents.

TM00 4466 3394

8

6. Functions

Some functions can only be selected by means of
the remote control R100. Where and how the differ­ent settings are made will appear from section

7. Setting the pump.

6.1 Control modes

UPE Series 2000 pumps can be set to the control
mode which is most suitable for the individual sys­tem.

Two control modes are available:

• Proportional pressure (factory setting).

• Constant pressure.

Proportional pressure control:

Can be set by means of the control panel or the
R100.

The pump head is reduced at falling water demand
and increased at rising water demand, see fig. 10.

Constant pressure control:

Can be set by means of the control panel or the
R100.

The pump maintains a constant pressure, irrespec­tive of water demand, see fig. 10.

Fig. 10

TM00 5546 4596

2

H

Q

H

Q

H

set

Proportional
pressure

Constant
pressure

Control modes

H

set

H

set

H

set

9

6.2 Selection of control mode

Systems with specified control mode:

If the control mode (proportional or constant pres­sure) and the pump head have been specified for the
system in which the pump is to be installed, the
pump should be set as specified. See section 7. Set-

ting the pump. If problems should arise, see section

8. Fault finding chart.

Systems with no specified control mode:

If the control mode and the pump head have not
been specified for the system (for instance, an un­controlled standard pump is replaced by the UPE
pump), it is advisable to use the settings in the fol­lowing table and in section 6.2.1 Settings in connec-
tion with pump replacement.

In systems
with

for instance

select this con­trol mode:

relatively great
head losses in
the boiler circuit
and the distribu­tion pipes

1. Two-pipe
heating sys­tems with
thermostatic
valves and
with:

• a dimensioned pump head higher than 4 metres,

Proportional

pressure

• very long distribution pipes,

• strongly throttled pipe balancing valves,

• differential pressure regulators,

• great head losses in those parts of the system
through which the total quant ity of water flows (e.g.
boiler, heat exchanger and distribution pipe up to
the first branching) or

• low differential temperature.

2. Underfloor heating systems and one-pipe heating systems with ther­mostatic valves and great head losses in the boiler circuit.

3. Primary circuit pumps in systems with great head losses in the pr imary
circuit.

relatively small
head losses in
the boiler circuit
and the distribu­tion pipes

1. Two-pipe
heating sys­tems with
thermostatic
valves and:

• with a dimensioned pump head lower than 2 me­tres,

Constant
pressure

• dimensioned for natural circulation,

• with small head losses in those parts of the system
through which the total quant ity of water flows (e.g.
boiler, heat exchanger and distribution pipe up to
the first branching) or

• modified to a high differential temperature (e.g. dis­trict heating).

2. Underfloor heating systems with thermostatic valves.

3. One-pipe heating systems with thermostatic valves or pipe balancing
valves.

4. Primary circuit pumps in systems with small head losses in the primary
circuit.

10

6.2.1 Settings in connection with pump
replacement

If an uncontrolled pump is to be replaced with a
UPE Series 2000, settings can be made according to
the tables below.

Read the tables as follows:

• If the maximum head of the existing pump is 5 me-

tres and the pump is running at maximum speed
under normal operating conditions, it is recom­mended to set the UPE pump to 2.5 metres and to
select proportional pressure.

• If, however, the existing pump is running at a re-

duced speed, it is recommended to set the pump
to 2 metres and to select constant pressure.

6.3 Max. or min. curve duty

Can be set by means of the control panel or the
R100.

The pump can be set to operate according to the
max. or min. curve, like an uncontrolled pump, see
fig. 11.

Fig. 11

The max. curve mode can be selected if an uncon­trolled pump is required. In this operating mode, the
pump will operate independently of an external con­troller, if installed.

The min. curve mode can be used in periods in
which a minimum flow is required. This operating
mode is suitable for night-time duty.

6.4 Constant curve duty

Can be set by means of the R100.

The pump can be set to operate according to a con­stant curve, like an uncontrolled pump. Select one of
19 curves between the max. and min. curves, see
fig. 12.

Fig. 12

6.5 Temperature influence

Can be set by means of the R100.

When this function is activated in proportional or
constant control mode, the setpoint for head will be
reduced according to the liquid temperature. It is
possible to set temperature influence to function at
liquid temperatures below 80°C or below 50°C.
These temperature limits are called T

max.

.
The setpoint is reduced in relation to the head set
(= 100%) according to the characteristics below.

Existing pump at maximum speed Existing pump at reduced speed

Existing pump UPE Series 2000 Existing pump UPE Series 2000

Maximum

head [m]

Setting of

head [m]

Setting of

control mode

Maximum

head [m]

Setting of

head [m]

Setting of

control mode

21.5

Constant pressure

21

Constant pressure

32

Constant pressure

31.5

Constant pressure

42

Proportional pressure

41.5

Constant pressure

52.5

Proportional pressure

52

Constant pressure

63

Proportional pressure

62

Proportional pressure

73.5

Proportional pressure

72.5

Proportional pressure

84

Proportional pressure

83

Proportional pressure

TM00 5547 4596

Q

H

Min.

Max.

TM00 5548 4596

Q

H

Max.

Min.