UPS3
Installation and operating instructions
GRUNDFOS INSTRUCTIONS
English (GB)
2
English (GB) Installation and operating instructions
Original installation and operating instructions
These installation and operating instructions describe Grundfos
UPS3.
Sections 1-4 give the information necessary to be able to unpack,
install and start up the product in a safe way.
Sections 5-11 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 Hazard statements
The symbols and hazard statements below may appear in
Grundfos installation and operating instructions, safety
instructions and service instructions.
The text accompanying the three hazard symbols DANGER,
WARNING and CAUTION is structured in the following way:
The hazard statements are structured in the following way:
1. General information
2
1.1 Hazard statements
2
1.2 Notes
3
2. Receiving the product
3
2.1 Inspecting the product
3
2.2 Scope of delivery
3
3. Installing the product
3
3.1 Mechanical installation
3
3.2 Pump positions
4
3.3 Control box positions
4
3.4 Insulating the pump housing
4
3.5 Electrical connection
5
3.6 Assembling the installer plug
6
4. Starting up the product
7
4.1 Before startup
7
4.2 Starting up the pump
7
4.3 Venting the pump
7
5. Product introduction
8
5.1 Product description
8
5.2 Applications
8
5.3 Pumped liquids
8
5.4 Identification
8
5.5 Accessories
9
5.6 Power supply
10
6. Control functions
11
6.1 Operating panel
11
6.2 Control modes
11
6.3 Pump performance
13
7. Setting the product
14
7.1 Constant curve I, II, III
14
7.2 Proportional pressure I, II and constant pressure mode
I, II
14
7.3 Setting the PWM input signal
14
8. Servicing the product
15
8.1 Dismantling the product
15
8.2 Dismantling the plug
15
9. Fault finding the product
16
9.1 Deblocking the shaft
17
10. Technical data
18
10.1 Dimensions, UPS3 15-50/65
19
10.2 Curve conditions
20
10.3 Performance curve, UPS3 15-50/65
20
11. Disposing of the product
21
Read this document and the quick guide before you
install the product. 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.
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.
SIGNAL WORD
Description of hazard
Consequence of ignoring the warning.
- Action to avoid the hazard.
English (GB)
3
1.2 Notes
The symbols and notes below may appear in Grundfos
installation and operating instructions, safety instructions and
service instructions.
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
5.4.1 Nameplate.
2.2 Scope of delivery
The box contains the following items:
• UPS3 pump
• installer plug
• two gaskets
• quick guide.
3. Installing the product
3.1 Mechanical installation
3.1.1 Mounting the product
1. The arrows on the pump housing indicate the flow direction
through the pump. See fig. 1.
2. Fit the two gaskets supplied with the pump when you mount
the pump in the pipe. Install the pump with a horizontal motor
shaft. See fig. 2. See also section 3.3 Control box positions.
3. Tighten the fittings. See fig. 3.
Fig. 1 Flow direction
Fig. 2 Pump installation
Fig. 3 Tightening the fittings
Observe these instructions for explosion-proof
products.
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.
TM07 0368 1518TM07 0369 1518TM07 0370 1518
English (GB)
4
3.2 Pump positions
Always install the pump with a horizontal motor shaft. Do not
install the pump with a vertical motor shaft. See fig. 4, bottom row.
• Pump installed correctly in a vertical pipe. See fig. 4, top row,
left.
• Pump installed correctly in a horizontal pipe. See fig. 4, top
row, right.
Fig. 4 Pump positions
3.3 Control box positions
The control box can be mounted in all positions. See fig. 5.
Fig. 5 Possible control box positions
3.3.1 Changing the control box position
3.4 Insulating the pump housing
Fig. 6 Insulating the pump housing
You can reduce the heat loss from the pump and pipe by
insulating the pump housing and the pipe with insulating shells,
which can be ordered as an accessory. See section
5.5.2 Insulating shells.
TM07 0371 1518
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.
CAUTION
Hot surface
Minor or moderate personal injury
- The pump housing may be hot due to the pumped
liquid being scalding hot. Close the isolating valves
on both sides of the pump and wait for the pump
housing to cool down.
CAUTION
Pressurised system
Minor or moderate personal injury
- Before dismantling the pump, drain the system or
close the isolating valves on both sides of the
pump. The pumped liquid may be scalding hot
and under high pressure.
TM06 7297 0918
Step Action Illustration
1
Make sure that
the inlet and
outlet valves are
closed.
Unscrew the
screws on the
pump head.
TM07 0372 1518
2
Turn the pump
head to the
desired position.
TM07 0373 1518
3
Refit the screws
on the pump
head.
TM07 0374 1518
TM07 0375 1518
Do not insulate the control box or cover the operating
panel.
English (GB)
5
3.5 Electrical connection
• The motor requires no external motor protection.
• Check that the supply voltage and frequency correspond to
the values stated on the nameplate. See section
5.4.1 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
- All electrical connections must be carried out by a
qualified electrician in accordance with local
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 be accidentally switched on.
DANGER
Electric shock
Death or serious personal injury
- Connect the pump to earth.
- Connect the pump to an external main switch with
a minimum contact gap of 3 mm in all poles.
DANGER
Electric shock
Death or serious personal injury
- If national legislation requires a Residual-Current
Device (RCD) or equivalent in the electrical
installation, or if the pump is connected to an
electric installation where an RCD is used as an
additional protection, this must be type A or better,
due to the nature of the pulsating DC leakage
current. The RCD must be marked with the symbol
shown below:
English (GB)
6
3.6 Assembling the installer plug
Step Action Illustration
1
Loosen the cable
gland and unscrew
the union nut in the
centre of the terminal
cover.
TM06 8542 0918
2
Detach the terminal
cover.
TM06 8543 0918
3
Pull the power cable
through the cable
gland and terminal
cover.
TM06 8544 0918
4
Strip the cable
conductors as
illustrated.
TM06 8545 0918
5
Loosen the screws
on the power supply
plug and connect the
cable conductors.
TM06 8546 0918 - TM06 8547 0918
6
Tighten the screws
on the power supply
plug.
TM06 8548 0918
L
PE
N
42 mm
32 mm
Ø 5.5 - 10 mm
0.5 - 1.5 mm
2
x 3
x 3
7
Refit the terminal
cover. See A.
Note: It is possible to
turn the power
supply plug on the
side for a 90 ° cable
entry. See B.
TM06 8549 0918 - TM06 8550 0918
8
Tighten the union
nut.
TM06 8551 0918
9
Tighten the cable
gland onto the power
supply plug.
TM06 8552 0918
10
Insert the power
supply plug into the
male plug on the
pump.
TM07 0376 1518
Step Action Illustration
B
A
English (GB)
7
4. Starting up the product
4.1 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 section 10. Technical data.
When using the pump for the first time, the system must be
vented at the highest point. The pump is self-venting through the
system.
4.2 Starting up the pump
4.3 Venting the pump
Fig. 7 Venting the pump
Small air pockets trapped inside the pump may cause noise when
starting up the pump. However, because the pump is self-venting
through the system, the noise ceases over a period of time.
To speed up the venting process, do as follows:
1. Set the pump to speed III using the push-button on the
operating panel.
2. Let the pump run for approximately 30 minutes. 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 6. Control functions.
Step Action Illustration
1
Open the inlet and
outlet valves.
TM07 0377 1518
2
Switch on the power
supply.
TM06 8555 1317
3
The lights in the
operating panel
indicates that the
power supply has
been switched on
and the pump is
running.
TM07 0378 1518
0/Off
1/On
TM07 1416 1618
The pump must not run dry.
The pump is from factory set to constant curve III.
Hold 3 sec.
=
30 min.
English (GB)
8
5. Product introduction
5.1 Product description
UPS3 can be used as stand-alone or integrated circulator pump
in existing systems as replacement or in new systems with either
variable or constant flow rate.
5.1.1 Model type
These installation and operating instructions cover UPS3. The
model type is stated on the packaging and nameplate.
5.2 Applications
UPS3 is designed for circulating liquids in all kinds of heating
applications. The pumps are suitable for the following systems:
• Systems with constant or variable flows where it is desirable to
optimise the pump duty point.
• Installation in existing systems where the differential pressure
of the pump is too high during periods of reduced flow
demand.
• Installation in new systems for automatic adjustment of the
performance to flow demands without the use of bypass
valves or similar expensive components.
The speed can be controlled by a low-voltage PWM (Pulse Width
Modulation) signal.
High-efficiency ECM (Electronically Commutated Motor) pumps,
such as UPS3, must not be speed-controlled by an external
speed controller varying or pulsing the supply voltage.
The speed can be controlled by a low-voltage PWM (Pulse Width
Modulation) signal.
5.3 Pumped liquids
In heating systems, the water must meet the requirements of
accepted standards on water quality in heating systems, for
example the German guideline VDI 2035.
The pump is suitable for clean, thin, non-aggressive and
non-explosive liquids, not containing solid particles, fibres or
mineral oil.
• Maximum water/propylene glycol mixture is 50 %
• Maximum 10 mm
2
/s viscosity
Note: The water/propylene glycol mixture reduces the
performance due to higher viscosity.
See section 10. Technical data for further information.
5.4 Identification
5.4.1 Nameplate
Fig. 8 Nameplate
CAUTION
Flammable material
Minor or moderate personal injury
- Do not use the pump for flammable liquids, such
as diesel oil and petrol.
CAUTION
Corrosive substance
Minor or moderate personal injury
- Do not use the pump for aggressive liquids, such
as acids and seawater.
TM07 0791 1618
Pos. Description
1 Pump name
2 Minimum current [A]
3 Maximum current [A]
4 CE mark and approvals
5 Energy Efficiency Index, EEI
6 Voltage [V]
7Product type
8 Material number
9 Serial number
10 Country of manufacture
11 Frequency [Hz]
12 Part, according to EEI
13 Enclosure class
14 Manufacturer’s name and address
15 Production code, year and week
16 Minimum liquid temperature
17 VDE code
18 TF class
19 Average compensated power input PL, avg [W]
20 Maximum system pressure
21 Maximum input power [W]
22 Minimum input power [W]
1
l1/1(A)
Grundfos Holding A/S
DK-8850 Bjerringbro
P1(W) MPa
Min.
Max.
X.XX
X.XXXXXXX X.X
((,0.XX - Part X
XXXV ~ XX/XXHz IPXXX TFXXX
P/N:XXXXXXXX PC:XXXXXXX
S/N:XXXXXXXX
Made in XXXXXXX
PL.avg.<XXW
Denmark
2
3
4
5
6
7
8
9
22
21
20
19
18
17
16
15
13 1410 11 12
Min.XX°CModel:XXXXXX X
GFNXX
UPS3
Hold 3 sec.
Loading...