Grundfos ALPHA1 L 25-60 N Installation And Operating Instructions Manual

Grundfos
Marca
Grundfos
Model
ALPHA1 L 25-60 N
Tip
Installation And Operating Instructions Manual
ALPHA1 L
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
ALPHA1 L.
Sections 1-4 give the information necessary to be able to unpack,
install and start up the product in a safe way.
Sections 5-12 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:
1.2 Notes
The symbols and notes below may appear in Grundfos
installation and operating instructions, safety instructions and
service instructions.
1. General information
2
1.1 Hazard statements
2
1.2 Notes
2
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 Electrical connection
5
3.5 Insulating the pump housing
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
9
5.5 Accessories
10
6. Control functions
12
6.1 Operating panel
12
6.2 Control modes
12
6.3 Control signal
13
6.4 Pump performance
15
7. Setting the product
16
7.1 Setting the PWM input signal
17
8. Servicing the product
17
8.1 Dismantling the product
17
8.2 Dismantling the plug
17
9. Fault finding the product
18
9.1 Deblocking the shaft
19
10. Technical data
20
10.1 Dimensions, ALPHA1 L XX-40, XX-60, 15-65
21
10.2 Dimensions, ALPHA1 L 25-65
22
11. Performance curves
22
11.1 Guide to performance curves
22
11.2 Curve conditions
22
11.3 Performance curves, ALPHA1 L XX-40 (N)
23
11.4 Performance curves, ALPHA1 L XX-60 (N)
24
11.5 Performance curves, ALPHA1 L XX-65 (N)
25
12. Disposal
25
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.
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.
English (GB)
3
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:
• ALPHA1 L 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 within ± 5 °. 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
CAUTION
Crushing of feet
Minor or moderate personal injury
- Wear safety shoes when opening the box and
handling the product.
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
Crushing of feet
Minor or moderate personal injury
- Wear safety shoes when opening the box and
handling the product.
Installation must be carried out by trained persons in
accordance with local regulations.
The pump must always be installed with a horizontal
motor shaft within ± 5 °.
The mechanical installation must be carried out by
trained persons in accordance with local regulations.
TM06 8535 0918TM06 8536 0918TM06 8537 0918
English (GB)
4
3.2 Pump positions
Always install the pump with a horizontal motor shaft within ± 5 °.
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
TM06 8538 0918
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.
TM06 8539 0918
2
Turn the pump
head to the
desired
position.
TM06 8540 0918
3
Refit the screws
on the pump
head.
TM06 8541 0918
English (GB)
5
3.4 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.
3.4.1 Assembling the installer plug
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.
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:
The pump is not a safety component and cannot be
used to ensure functional safety in the final
appliance.
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
0/Off
1/On
42 mm
32 mm
Ø 5.5 - 10 mm
0.5 - 1.5 mm
2
8 mm
L
PE
N
x 3
x 3
English (GB)
6
3.5 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.
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.
TM06 8553 0119
Step Action Illustration
B
A
TM06 8564 1317
Do not insulate the control box or cover the operating
panel.
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. See section 4.3 Venting the pump. 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 button on the operating
panel.
2. Let the pump run for minimum 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.
TM06 8554 0918
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.
TM06 8556 0918
0/Off
1/On
TM07 0153 0918
The pump must not run dry.
The pump is from factory set to radiator heating
mode.
Minimum 30 min
English (GB)
8
5. Product introduction
5.1 Product description
ALPHA1 L 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 ALPHA1 L.
The model type is stated on the packaging and nameplate.
5.2 Applications
The pump 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 ALPHA1 L, must not be speed-controlled by an external
speed controller varying or pulsing the supply voltage.
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.
In domestic hot-water systems, we recommend that
you keep the liquid temperature below 65 °C to
eliminate the risk of lime precipitation.
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.
English (GB)
9
5.4 Identification
5.4.1 Nameplate
Fig. 8 Nameplate
5.4.2 Type key
TM06 8664 1717
1
1
l1/1(A)
Grundfos Holding A/S
DK-8850 Bjerringbro
P1(W) MPa
Min.
Max.
X.XX
X.XX
XX
XXX X.X
((,;;3DUW;
XXXV ~ XX/XXHz IPXXX TFXXX
P/N:XXXXXXXX
S/N:XXXXXXXX
Made in XXXXXXX
PL.avg.<XXW
Denmark
2
3
4
5
6
8
7
9
10
23
22
21
20
19
18
17
16
14 1511 12 13
Min.XX°CModel:XXXXXX X
GFNXX
PC:P1XXXX
ALPHA1 L 25-65
ALPHA1 L XX-40/60/65
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]
7 Average compensated power input PL, avg [W]
8 Product type
9 Material number
10 Serial number
11 Country of origin
12 Frequency [Hz]
13 Part, according to EEI
14 Enclosure class
15 Manufacturer's name and address
16
Production code:
• 1st and 2nd figures: production site code
• 3rd and 4th figures: year
• 5th and 6th figures: week
17 Minimum liquid temperature
18 VDE code
19 TF class
20 Crossed-out wheeled bin according to EN 50419
21 Maximum system pressure
22 Maximum input power [W]
23 Minimum input power [W]
Example ALPHA1 L 25 -40 180
Pump type
Nominal diameter (DN) of inlet and outlet
ports [mm]
Maximum head [dm]
[ ]: Cast-iron pump housing
N: Stainless-steel pump housing
Port-to-port length [mm]
English (GB)
10
5.5 Accessories
5.5.1 Unions and valve kits
G-threads have a cylindrical form in accordance with the EN ISO
228-1 standard and are not sealing the thread. It requires a flat
gasket. You can only screw cylindrical male G-threads, into
female G-threads. The G-threads are standard thread on the
pump housing.
R-threads are tapered external threads in accordance with the
EN 10226-1 standard.
Rc- or Rp-threads are internal threads with either tapered or
cylindrical threads. You can screw conical male R-threads into
female Rc- or Rp-threads. See fig. 9.
Fig. 9 G-threads and R-threads
5.5.2 Insulating shells
The insulating shells, which are tailored to the individual pump
type, can be ordered as accessories. It is easy to fit the insulating
shells around the pump.
Product numbers, unions
ALPHAx
Connection
3/4 1 1 1/4 1 1 1/4 3/4 1 1 1/4 ∅22 ∅28 ∅15 ∅18 ∅22 ∅28 ∅42
25-xx
G 1 1/2
529921 529922 529821 529925 529924
25-xx N 529971 529972 519805 519806 519807 519808 519809 529977 529978 529979
32-xx G 2 509921 509922
Rp
R
mm
mm
TM06 7632 3616
R
Rp
Rc
G
Pump type Product number
ALPHA1 L XX-XX (N) 99270706
English (GB)
11
5.5.3 Cables and plugs
The pump has two electrical connections: the power supply and
the control signal connection.
Power supply connection
The installer plug is both supplied with the pump and available as
an accessory.
Power cable adapters are also available as accessories.
Control signal connection
The control signal cable connection has three conductors: the
signal input, the signal output and the signal reference. Connect
the cable to the control box by a mini superseal plug. See section
7.1 Setting the PWM input signal. The optional signal cable is
available as an accessory.
Fig. 10 Mini superseal plug
TM06 58210216
Product Product description
Length
[mm]
Product
number
Installer plug 99439948
Mini superseal signal cable (PWM input signal) 2000 99165309
Superseal power cable 2000 99198990
Power cable adapter: Superseal Molex cable
adapter, overmoulded
150 99165311
Power cable adapter: Superseal Volex cable
adapter, overmoulded
150 99165312
English (GB)
12
6. Control functions
6.1 Operating panel
Fig. 11 Operating panel
The operating panel shows the following:
• The control mode, after pressing the button
• Alarm status
6.1.1 Alarm or warning
If the pump has detected one or more alarms or warnings, the
first LED switches from green to red. When the fault has been
resolved the operating panel switches back to operating status.
See section 9. Fault finding the product.
6.2 Control modes
The pump has seven different control modes. Learn more about
them in the following sections.
6.2.1 Radiator heating mode (factory setting)
The radiator heating mode adjusts the pumps performance to the
actual heat demand in the system following a
proportional-pressure curve.
Fig. 12 Proportional-pressure curve
6.2.2 Underfloor heating mode
The underfloor heating mode adjusts the pump performance to
the actual heat demand in the system following a
constant-pressure curve.
Fig. 13 Constant-pressure curve
TM06 7286 4616
Symbol Description
Button
I, II, III
Constant curve or constant speed curve I, II and
III
Radiator heating mode (proportional pressure)
Underfloor heating mode (constant pressure)
TM06 8815 1217
System
type
Recommended
control mode
Alternative control mode
Two-pipe
system
Radiator heating
mode
Constant curve or constant
speed I, II, III, see section
6.2.3 Constant curve or
constant speed, I, II or III
TM06 8816 1217
System type
Recommended
control mode
Alternative
control mode
Underfloor heating
system
Underfloor heating
mode
No alternatives
Q
H
Q
H
English (GB)
13
6.2.3 Constant curve or constant speed, I, II or III
At constant-curve or constant-speed operation, the pump runs at
a constant curve. The pump performance follows the selected
performance curve, I, II or III. See fig. 14 where II has been
selected.
Fig. 14 Constant-curve/-speed curve
The selection of the constant-curve or constant-speed setting
depends on the characteristics of the heating system in question.
6.2.4 Pump setting for one-pipe heating systems
Recommended and alternative pump settings:
6.2.5 Pump setting for domestic hot-water systems
Recommended and alternative pump settings:
6.2.6 Changing from recommended to alternative pump
setting
Heating systems are relatively slow systems that cannot be set to
the optimum operation within minutes or hours.
If the recommended pump setting does not give the desired
distribution of heat in the rooms of the house, change the pump
setting to the shown alternative.
6.3 Control signal
The pump can be controlled via a digital low-voltage pulse-width
modulation (PWM) signal.
The square-wave PWM signal is designed for a 100 to 4,000 Hz
frequency range. The PWM signal is used to select the speed
(speed command) and as feedback signal. The PWM frequency
on the feedback signal is fixed at 75 Hz in the pump.
For instructions on how to set the connection, see section
7.1 Setting the PWM input signal.
Duty cycle
d % = 100 x t/T
Example
Fig. 15 PWM signal
6.3.1 Interface
The pump's interface consists of an electronic part connecting the
external control signal to the pump. The interface translates the
external signal into a signal type that the microprocessor can
understand.
In addition, the interface ensures that the user cannot get into
contact with dangerous voltage if touching the signal wires when
power is connected to the pump.
Note: "Signal ref." is a signal reference with no connection to
protective earth.
Fig. 16 Schematic drawing, interface
TM06 8822 1217
System
type
Recommended control
mode
Alternative control
mode
One-pipe
heating
system
Constant curve or
constant speed, I, II or III.
See section
6.2.3 Constant curve or
constant speed, I, II or III.
No alternatives
System
type
Recommended control
mode
Alternative control
mode
Domestic
hot-water
system
Constant curve or
constant speed, I, II or
III. See section
6.2.3 Constant curve or
constant speed, I, II or
III.
No alternatives
Q
H
Example Rating
T = 2 ms (500 Hz) U
iH
= 4-24 V
t = 0.6 ms U
iL
≤ 1 V
d % = 100 x 0.6 / 2 = 30 % I
iH
≤ 10 mA (depending on U
iH
)
TM04 9911 0211
Abbreviation Description
T Period of time [sec.]
d Duty cycle [t/T]
U
iH
High-level input voltage
U
iL
Low-level input voltage
I
iH
High-level input current
TM06 0787 0914
T
t
U
iH
U
iL
5
9
S
5
%&%
%&%
36
&1<)
N
N
PWM output
PWM input
Signal ref.
Galvanic isolation
Pump electronics
English (GB)
14
6.3.2 PWM input signal profile A (heating)
The pump runs on constant-speed curves depending on the PWM
input signal. The speed decreases when the PWM value
increases. If PWM equals 0, the pump runs at maximum speed.
Fig. 17 PWM input signal profile A (heating)
6.3.3 PWM feedback signal
The PWM feedback signal offers pump information like in bus
systems:
• current power consumption (accuracy ± 2 % of PWM signal)
• warning
•alarm.
Alarms
Alarm output signals are available because some PWM output
signals are dedicated to alarm information. If a supply voltage is
measured below the specified supply voltage range, the output
signal is set to 75 %. If the rotor is locked due to deposits in the
hydraulics, the output signal is set to 90 % because this alarm
has a higher priority. See fig. 18.
Fig. 18 PWM feedback signal - power consumption
Data
TM06 9136 1617
PWM input signal [%] Pump status
10 Maximum speed: max.
> 10 / ≤ 84 Variable speed: min. to max.
> 84 / ≤ 91 Minimum speed: IN
> 91/95 Hysteresis area: on/off
> 95 or ≤ 100 Standby mode: off
TM07 1313 1118
PWM input signal [%]
Max.
Speed
PWM input signal
Max.
Speed
25 50 100 150 200 250
10
20
30
40
50
60
70
80
90
100
Power [W]
Standby (stop)
Alarm stop: fault, blocked pump
Alarm stop: electrical fault
Warning Saturation at 70 Watt
S
l
o
p
e
:
1
W
/
%
P
W
M
Maximum rating Symbol Value
PWM frequency input with high-speed
optocoupler
f 100-4000 Hz
Guaranteed standby power
consumption
< 1 W
Rated input voltage - high level U
iH
4-24 V
Rated input voltage - low level U
iL
< 1 V
High-level input current I
iH
< 10 mA
Input duty cycle PWM 0-100 %
PWM frequency output, open collector f 75 Hz ± 5 %
Accuracy of output signal regarding
power consumption
-
± 2 % (of
PWM signal)
Output duty cycle PWM 0-100 %
Collector emitter breakdown voltage
on output transistor
U
c
< 70 V
Collector current on output transistor I
c
< 50 mA
Maximum power dissipation on output
resistor
P
R
125 mW
Zener diode working voltage U
z
36 V
Maximum power dissipation in Zener
diode
P
z
300 mW
English (GB)
15
6.4 Pump performance
Figure 19 shows the relation between pump setting and pump performance by means of curves.
Fig. 19 Pump setting in relation to pump performance
TM06 8818 1217
Setting Pump curve Function
I
Constant curve or constant
speed I
The pump runs at a constant speed and consequently on a constant curve.
At speed I, the pump is set to run on the minimum curve under all operating conditions.
II
Constant curve or constant
speed II
The pump runs at a constant speed and consequently on a constant curve.
At speed II, the pump is set to run on the intermediate curve under all operating conditions.
III
Constant curve or constant
speed III
The pump runs at a constant speed and consequently on a constant curve.
At speed III, the pump is set to run on the maximum curve under all operating conditions.
Quick venting of the pump can be obtained by setting the pump to speed III for a short
period.
Radiator heating mode
(proportional-pressure curve)
The duty point of the pump will move up or down on a proportional-pressure curve,
depending on the heat demand in the system.
The head (pressure) is reduced at falling heat demand and increased at rising heat demand.
Underfloor heating mode
(constant-pressure curve)
The duty point of the pump will move out or in on a constant-pressure curve, depending on
the heat demand in the system.
The head (pressure) is kept constant, irrespective of the heat demand.
III
II
I
H
Q
English (GB)
16
7. Setting the product
To set the product use the button on the operating panel. Every
time you press the button, the pump setting is changed. The
LEDs will indicate the chosen control mode. See fig. 20. A cycle
is five button presses.
The pump automatically enables the PWM input-signal control
mode when the signal cable is plugged in and the PWM signal is
detected by the pump. For details on setting the PWM input
signal, see section 7.1 Setting the PWM input signal.
To select the fixed proportional-pressure curve, press and hold
the button for 3 seconds. To disable this control mode, press and
hold the button for 3 seconds.
To learn more about each control mode, see section 6.2 Control
modes.
Fig. 20 Operating panel LEDs indicating the different control modes
TM07 0144 4817
3 s
The pump has been factory-set to radiator heating
mode.
English (GB)
17
7.1 Setting the PWM input signal
To enable the external control mode (PWM profile A), you need a
signal cable connected to an external system. The cable
connection has three conductors: the signal input, the signal
output and the signal reference.
The cable is not supplied with the pump but can be ordered as an
accessory.
Fig. 21 Mini superseal plug
Set the signal connection
1. Make sure that the pump is turned off.
2. Locate the PWM signal connection on the pump.
The three pins inside the signal connection are not energised.
Connect the signal cable with the mini superseal plug.
3. Switch on the power supply.
4. The pump automatically detects if a valid PWM signal is
available after which it enables the control mode on the pump.
See fig. 22.
Fig. 22 Connecting the signal cable to ALPHA1 L
8. Servicing the product
8.1 Dismantling the product
1. Switch off the power supply.
2. Pull out the plug. For instructions on how to dismantle the
plug, see section 8.2 Dismantling the plug.
3. Close the two isolating valves on both sides of the pump.
4. Loosen the fittings.
5. Remove the pump from the system.
8.2 Dismantling the plug
1. Loosen the cable gland and unscrew the union nut in the
centre of the terminal cover.
2. Detach the terminal cover.
3. Loosen the screws on the power supply plug and disconnect
the cable conductors.
4. Pull the power cable back through the cable gland and
terminal cover.
The cable must be connected to the control box via a
mini superseal plug. See fig. 21.
TM06 5821 0216TM06 7633 0918
1 x 230 V - 15 %/+ 10 %
∽ 50/60 Hz
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.
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.
All service must be carried out by an instructed
service technician.
English (GB)
18
9. Fault finding the product
If the pump has detected one or more alarms, the first LED
switches from green to red. When an alarm is active, the LEDs
indicate the alarm type as defined in fig. 23.
When there is no active alarm anymore, the operating panel
switches back to operating status and the first LED switches from
red to green.
Fig. 23 Fault finding table
If multiple alarms are active at the same time, the
LEDs only show the error with the highest priority.
The priority is defined by the sequence of the table.
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.
Status Fault Display Solution
Alarm
The pump stops.
The pump is
blocked.
Deblock the shaft.
See section
9.1 Deblocking the
shaft.
Warning
The pump keeps
running.
The supply voltage
is low.
Make sure that there
is sufficient voltage
supply to the pump.
Alarm
The pump stops.
Electrical error.
Replace the pump and
send the pump to the
nearest Grundfos
Service Center.
ON
230
V
2
3
0/Off
1/On
1
No.2
5 mm
ON
<160 V
ON
230
V
2
3 4
0/Off
1/On
1
English (GB)
19
9.1 Deblocking the shaft
If the pump is blocked it is necessary to deblock the shaft. The
pump deblocking device is accessible from the front of the pump
without having to demount the control box. The force of the
device is high enough to deblock pumps, which are seized by
lime, for example if the pump has been turned off during summer.
Course of action:
1. Switch off the power supply.
2. Close the valves.
3. Locate the deblocking screw in the centre of the control box.
Use a star screwdriver with a size 2 Phillips tip to push the
deblocking screw inwards.
4. When the screw can be turned counterclockwise, the shaft
has been deblocked. Repeat step 3, if necessary.
5. Switch on the power supply.
Fig. 24 Deblocking the shaft
TM07 1414 0619
Before, during and after the deblocking, the device is
tight and must not release any water.
2
3
0/Off
1/On
1
No.2
5 mm
English (GB)
20
10. Technical data
To avoid condensation in the stator, the liquid temperature must
always be higher than the ambient temperature.
Operating conditions
Sound pressure level The sound pressure level of the pump is lower than 43 dB(A).
Relative humidity Maximum 95 %, non-condensing environment
System pressure PN 10: Maximum 1.0 MPa (10 bar)
Inlet pressure
Liquid temperature Minimum inlet pressure
75 °C 0.005 MPa (0.05 bar), 0.5 m head
95 °C 0.05 MPa (0.5 bar), 5 m head
Ambient temperature 0-55 °C
Liquid temperature 2-95 °C
Liquid Maximum water/propylene glycol mixture is 50 %
Viscosity Maximum 10 mm
2
/s
Minimum switching time power on/off No specific requirements.
Maximum altitude of installation 2000 m above sea level
Electrical data
Supply voltage 1 x 230 V - 15 %/+ 10 %, 50/60 Hz, PE
Insulation class F
Standby power consumption < 0.3 W
Miscellaneous data
Motor protection The pump requires no external motor protection.
Enclosure class IPX4D
Temperature class (TF) TF95
Specific EEI values
ALPHA1 L XX-40: EEI ≤ 0.20
ALPHA1 L XX-60: EEI ≤ 0.20
ALPHA1 L XX-65: EEI ≤ 0.20
In domestic hot-water systems, we recommend that
you keep the liquid temperature below 65 °C to
eliminate the risk of lime precipitation.
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Grundfos ALPHA1 L 25-60 N Installation And Operating Instructions Manual

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ALPHA1 L 25-60 N
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Installation And Operating Instructions Manual
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