Grundfos UP XL
3191277
Maintenance-free circulators
with insulating shell (if equipped)
Installation and operating instructions
GRUNDFOS INSTRUCTIONS
Conforms to UL STD 514C
Certified to CSA STD C22.2 No. 18.2
English (US)
Note
Caution
English (US) Installation and operating instructions
Original installation and operating
instructions.
CONTENTS
1. Symbols used in this document
2. Limited warranty
3. Safety warning
3.1 Read this booklet
3.2 Electrical work
4. Pre-installation checklist
4.1 Confirm you have the correct pump
4.2 Check the condition of the pump
4.3 Verify electrical requirements
4.4 Pumped liquid requirements
5. Installation procedures
5.1 Piping considerations
5.2 Changing the terminal box position
5.3 Electrical connection
5.4 Insulating shells (if equipped)
6. Starting the pump
6.1 Vent the piping system
6.2 Speed selection
7. Fault finding
7.1 Fault finding chart
7.2 Preliminary checks
7.3 Current measurement
7.4 Insulation resistance (lead-to-ground)
7.5 Winding resistance (line-to-line)
7.6 Resistance tables
8. Replacing components
8.1 Removing the pump head
8.2 Fitting the pump head
8.3 Replacing the terminal box or
capacitor
9. Additional technical data
10. Disposal
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1. Symbols used in this document
Warning
If these safety instructions are not
observed, it may result in personal
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injury.
Warning
If these instructions are not
observed, it may lead to electric
shock with consequent risk of
serious personal injury or death.
Warning
The surface of the product may be
so hot that it may cause burns or
personal injury.
Notes or instructions that
make the job easier and
ensure safe operation.
If these safety instructions are
not observed, it may result in
malfunction or damage to the
equipment.
Warning
Prior to installation, read these
installation and operating
instructions. Installation and
operation must comply with local
regulations and accepted codes of
good practice.
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2. Limited warranty
Products manufactured by GRUNDFOS PUMPS
CORPORATION (Grundfos) are warranted to
the original user only to be free of defects in
material and workmanship for a period of 36
months from date of manufacture. 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,
transportation, or any other charges which may
arise in connection with a warranty claim.
Products which are sold but not manufactured
by Grundfos are subject to the warranty
provided by the manufacturer of said products
and not by Grundfos' warranty. Grundfos will not
be liable for damage or wear to products caused
by abnormal operating conditions, accident,
abuse, misuse, unauthorized alteration or repair,
or if the product was not installed in accordance
with Grundfos' printed installation and operating
instructions.
To obtain service under this warranty, the
defective product must be returned to the
distributor or dealer of Grundfos' products from
which it was purchased together with proof of
purchase and installation date, failure date, and
supporting installation data. Unless otherwise
provided, the distributor or dealer will contact
Grundfos or an authorized service station for
instructions. Any defective product to be
returned to Grundfos or a service station must
be sent freight prepaid; documentation
supporting the warranty claim and/or a Return
Material Authorization must be included if so
instructed.
GRUNDFOS WILL NOT BE LIABLE FOR ANY
INCIDENTAL OR CONSEQUENTIAL
DAMAGES, LOSSES, OR EXPENSES ARISING
FROM 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
limit actions on how long implied warranties may
last. Therefore, the above limitations or
exclusions may not apply to you. This warranty
gives you specific legal rights and you may also
have other rights which vary from jurisdiction to
jurisdiction.
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English (US)
3. Safety warning
4. Pre-installation checklist
3.1 Read this booklet
This booklet is designed to help a certified
installer to install, begin operation of, and
troubleshoot the Grundfos Small UP and UPS
pumps.
Following the instructions will ensure safe,
trouble-free operation.
This booklet should be left with the owner of the
pump for future reference and information
regarding its operation. Should the owner
experience any problems with the pump, a
certified professional should be contacted.
3.2 Electrical work
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.
Warning
A faulty motor or wiring can cause
electrical shock that could be fatal,
whether touched directly or
conducted through standing water.
For this reason, proper grounding
of the pump to the power supply's
grounding terminal is required for
safe installation and operation.
In all installations, the
above-ground metal plumbing
should be connected to the power
supply ground as described in the
National Electrical Code. All wiring
must comply with the National
Electrical Code, state, and local
regulations.
4.1 Confirm you have the correct pump
• Read the pump nameplate to ensure it is the
one you ordered.
• Compare the pump's nameplate data and its
performance curve (for head, gpm, etc.) with
the application in which you plan to install it.
• Will the pump do what you expect it to do?
4.1.1 Pump to system type recommendations
• Open systems (i.e. potable water): Stainless
steel or bronze volute (pump housing) only.
• Closed systems (i.e. airless, non-potable
water): Cast iron, stainless steel, or bronze
volute (pump housing).
Other considerations regarding Grundfos small
UP and UPS pumps:
• These pumps are intended for indoor use
only.
• If installed outdoors the pump must be
protected by an appropriate, well ventilated,
water-tight enclosure to keep out moisture
and dirt.
• Minimum ambient temperatures must be no
lower than 33 °F ( 1 ° C ).
• For ambient and fluid temperature see
sections 4.4 Pumped liquid requirements
and 9. Additional technical data.
4.2 Check the condition of the pump
The pump's shipping carton is specially
designed around the pump during production to
prevent damage.
As a precaution, it should remain in the carton
until you are ready to install it. At that point, look
at the pump and examine it for any damage that
may have occurred during shipping.
Examine any other parts of the shipment as well
for any visible damage. Once the pump has
been removed from the box, care should be
taken NOT to drop or mishandle the pump.
Box contents:
• one pump
• two gaskets (flanged units only)
• one Installation and Operation Instruction
(I&O).
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4.3 Verify electrical requirements
Note
Caution
Verify the electrical supply to be certain the
voltage, phase and frequency match that of the
pump motor. The proper operating voltage and
other electrical information can be found on the
pump nameplate.
This pump's motor is designed to run on ± 10 %
of the nameplate-rated voltage.
4.4 Pumped liquid requirements
Warning
The Grundfos Small UP/UPS pump
is intended for use with water only.
The pump must not be used for the
transfer of flammable liquids such
as diesel oil, gasoline, and similar
liquids.
The pump is not for pool or marine
use.
The pump can be used to circulate:
• Potable hot water.
• Water containing glycol for hydronic heating
(see section 9. Additional technical data for
additional limitations).
• Cooling water.
In domestic hot-water systems it is advisable to
use stainless steel pump housing versions of
this pump.
All pump types (stainless, bronze or cast iron
pump housing) should not be used in water with
a degree of hardness lower than 14 grains per
gallon of hardness.
Fluids should be clean and should not contain
solid particles, fibers, or mineral oils.
If the pump is installed in a heating system, the
water should meet the requirements of accepted
standards on water quality in heating systems.
The fluid should not contain solid particles,
fibers, or mineral oils.
The pump is lubricated and cooled by the liquid
being pumped. Therefore, the pumped liquid
must always be allowed to circulate through the
pump.
Extended periods without circulation will cause
premature wear to the bearings and excessive
motor heat.
The pumped liquid must meet the temperature
requirements listed in the following charts.
Fluid must never be allowed to
freeze during non-operational
periods.
Open systems
(domestic, potable hot water)
Fluid Ambient
Min. 36 °F (2 °C) 33 °F (1 °C)
Max. < 149 °F (65 °C) 100 °F (38 °C)
In domestic hot-water systems, it is
recommended to keep the liquid
temperature below 149 °F (65 °C) to
eliminate the risk of lime
precipitation.
(non-potable heating or cooling airless
Min. All
Max.
Max. 50 % glycol at 15 °F (-9.5 °C) liquid
(Hydraulic performance change can be
expected.)
Closed systems
fluid)
Pump
models
UPS 26-150
UPS 43-100
UPS 50-60
Water and glycol mix
Liquid Ambient
36 °F
(2 °C)
230 °F
(110 °C)
230 °F
(110 °C)
212 °F
(100 °C)
33 °F
(1 °C)
100 °F
(38 °C)
100 °F
(38 °C)
100 °F
(38 °C)
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English (US)
5. Installation procedures
Warning
Never make any connections in the
pump terminal box unless the
electrical supply has been
switched off.
The pump should not be connected
to the electrical system until it has
been properly installed in the
piping system.
Warning
Risk of electrical shock - this pump
has not been investigated for use
in swimming pool or marine areas.
5.1 Piping considerations
When making piping connections, be sure to
follow the piping manufacturer's
recommendations and all code requirements for
piping material.
Thoroughly clean and flush all dirt and sediment
from the system before attempting to install the
pump.
5.1.1 Location in the piping line
The pump should never be located at the lowest
point of the piping system (where dirt and
sediment collect), nor should it be located at the
highest point of the piping system (where air
accumulates).
Warning
The pump must be positioned so
that someone cannot accidentally
come into contact with the hot
surfaces of the pump.
When installing the pump into the piping system,
Grundfos recommends that pressure gauges be
installed in the inlet and discharge flanges or
pipes. This will allow the pump and system
performance to be checked.
Do not block the pipe plugs in the pump housing
flanges by locating the terminal box over these
plugs.
5.1.2 Mounting positions
The arrows on the pump housing indicate the
direction of water flow. The pump may be
installed in vertical or horizontal piping, but the
motor shaft must always remain horizontal,
as shown in fig. 1.
Fig. 1 Installation positions
5.1.3 Terminal box positions
At the bottom of the stator, closest to the pump
housing, there are three drain holes to allow
condensed water to escape. The drain holes
shall not be blocked for any reason and one
drain hole must always point downward.
There is not a drain hole directly below the
terminal box; therefore the terminal box must be
positioned in one of the positions shown in fig. 1
or fig. 2.
TM04 5646 3609
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