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Engineered Solutions
Making Geothermal Easier
Installation, Operating, and Maintenance Manual
Geo-Flo Universal Pump Controller (UPC-GEO) by Grundfos
Geo-Flo Products Corporation
905 Williams Park Drive
Bedford, Indiana 47421, U.S.A.
3704-07-05-16
www.geo-flo.com
Document # 3704
Rev. 05JUL2016
Main Number:
Toll Free:
Fax:
812-275-8513
800-784-8069
888-477-8829
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Table of Contents
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Summary of Contents for Grundfos Geo-Flo Universal Pump Controller
- Page 1 Engineered Solutions Making Geothermal Easier Installation, Operating, and Maintenance Manual Document # 3704 Rev. 05JUL2016 Geo-Flo Universal Pump Controller (UPC-GEO) by Grundfos Geo-Flo Products Corporation Main Number: 812-275-8513 905 Williams Park Drive Toll Free: 800-784-8069 Bedford, Indiana 47421, U.S.A.
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Page 2: Table Of Contents
Setup Menu ....12 NOTES: This guide provides the installer with instructions specific to Grundfos Universal Pump Controller (UPC- GEO). Please refer to your heat pump manufacturer’s instructions or IGSHPA guidelines for additional detailed flushing, purging, and installation information. -
Page 3: General Description
The UPC-GEO then provides a PWM signal to the variable speed Magna GEO 32-140 pump (or 0-10 VDC output for other pumps) and monitors the output signal from the Grundfos VFS flow sensor and pump. The UPC-GEO increases or decreases the pump speed based on the flow rate input into the controller and the actual flow rate of the system. -
Page 4: T Based Control
| Installation, Operating, and Maintenance Manual Rev. 05JUL2016 ΔT based control (Two immersion thermistors required) The UPC-GEO receives a 24VAC signal from the heat pump or thermostat for heating or cooling. The UPC-GEO then provides a PWM signal to the Magna GEO 32-140 pump (or 0-10 VDC output for other pumps) and moni- tors the temperatures provided from the EWT and LWT thermistors and the return signal from the pump. -
Page 5: Agency Listing/Approvals
GEO-FLO UNIVERSAL PUMP CONTROLLER: UPC-GEO | Agency Listings/Approvals Certified to CSA C22.2 No 24 Conforms to UL Standard 873 Dimensional Data Weight 1/2” Inches 5-1/8 6-11/16 1-7/8 3-3/8 5-5/8 3-3/8 1-11/16 Φ1/4 Φ3/16 standard conduit 14.3 Φ0.7 Φ0.4 0.75 0.34 knockout... -
Page 6: Installation
All UPC-GEO kits include mounting hardware and a ten foot cable that allows the controller to be connected to the Grundfos Magna pump. This equipment should be installed and serviced by qualified personnel only. -
Page 7: Wiring (Single Unit -- Magna Geo Pump)
GEO-FLO UNIVERSAL PUMP CONTROLLER: UPC-GEO | Wiring the Controller (Single Heat Pump -- Magna Geo Pump) WARNING: OPEN THE POWER SUPPLY DISCONNECT SWITCH AND SECURE IT IN AN OPEN POSITION PRIOR TO PERFORMING ELECTRICAL WORK. VERIFY THAT POWER HAS BEEN DISCONNECTED PRIOR TO WIRING THE CONTROLLER. FAILING TO SECURE THE ELECTRI- CAL SUPPLY COULD RESULT IN SERIOUS INJURY OR DEATH. - Page 8 However, it also a ects the operation of the Grundfos UPC-GEO variable speed pump controller. This document will address wiring for systems without an accessory terminal.
- Page 9 GEO-FLO UNIVERSAL PUMP CONTROLLER: UPC-GEO | Field Supplied SPST Relay #1 SPST Relay #2 Relay(s)** From heat pump (230V coil) circuit board or transformer Pump Power Block Field Wiring (low voltage) Field Wiring (high voltage) Orange* Yellow* Red* Not all brands have the same wire colors for the pump power block.
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Page 10: Wiring (One Flow Center/Two Heat Pumps)
| Installation, Operating, and Maintenance Manual Rev. 05JUL2016 Wiring the Controller (One Flow Center / Two Heat Pumps) WARNING: OPEN THE POWER SUPPLY DISCONNECT SWITCH AND SECURE IT IN AN OPEN POSITION PRIOR TO PERFORMING ELECTRICAL WORK. VERIFY THAT POWER HAS BEEN DISCONNECTED PRIOR TO WIRING THE CONTROLLER. - Page 11 GEO-FLO UNIVERSAL PUMP CONTROLLER: UPC-GEO | To/From Ground Loop 1-1/4” or 2” HDPE Panel mount NOTE: If 2”, a 1-1/4” to 2” version available coupling is required Flo-Link x 1” with factory MPT w/ tting wired controls. Flo-Link x 1-1/4” for PT Port*...
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Page 12: Wiring (0-10 Vdc Output)
CAL SUPPLY COULD RESULT IN SERIOUS INJURY OR DEATH. THIS EQUIPMENT SHOULD BE INSTALLED AND SERVICED BY QUALIFIED PERSONNEL ONLY. NOTE: The Grundfos Magna3 (or other pump receiving 0-10 VDC output from this controller) must be powered independently. This controller is not designed to power the pump. -
Page 13: Setup
GEO-FLO UNIVERSAL PUMP CONTROLLER: UPC-GEO | 11 Software version # Setup SETUP MENU 3.100 Quick Start Procedure 1) FLOW (or ∆T if MODE = ∆T) 1. Press and hold the center button to enter Setup Menu (Fig. 6). 2) SENSORS 3) MEDIA 2. -
Page 14: System Status
12 | Installation, Operating, and Maintenance Manual Rev. 05JUL2016 System Status SYSTEM STATUS Description Display NOTE: If system status display shows 1 PUMP RUNNING Magna GEO 32-140 is running pump(s) running, but heat pump is 2 PUMPS RUNNING Magna GEO 32-140 is running and relay not operating, check wiring vs. -
Page 15: T Configuration
SENSORS from the SETUP menu. Items 1) and 2) are provided 3) NONE [EWT Therm] for the various Grundfos Vortex Flow Sensors available including 4) NONE [LWT Therm] VFS 1-20, VFS 2-40, VFS 5-100, VFS 10-200, and VFS 20-400. Items 3) and 4) are provided for 10K thermistors. -
Page 16: Media Configuration
Figure 15: Mode Setup stage operation. This mode requires the installation of a Grundfos NOTE: Menu item 6 is only avail- VFS sensor. ΔT mode provides pump control and feedback based on able for software version 3.0 and... -
Page 17: Controller Output Signal Setup
4) MODE: FLOW Grundfos Magna GEO variable speed pump. The 0-10 VDC setting 5) LOCKOUT: PARAM is used for Grundfos Magna3 or other pumps that require a 0-10 6) SIGNAL: PWM Figure 17: Output Setup VDC input signal. The mode is selected by moving the cursor to... -
Page 18: Troubleshooting
16 | Installation, Operating, and Maintenance Manual Rev. 05JUL2016 Troubleshooting Screen Color Action / Display Indication Possible Cause / Solution Blue backlight comes on for Blue backlight Any button is pressed 30 seconds when a button is pressed. Display = “RUNNING” Display = “1 PUMP”... - Page 19 GEO-FLO UNIVERSAL PUMP CONTROLLER: UPC-GEO | 17 Troubleshooting (continued) Screen Color Action / Display Indication Possible Cause / Solution Magna GEO feedback signal “reports” to controller that motor has low voltage, but Incorrect power supplied to pump. Display = “LOWVOLT W”...
- Page 20 OUT terminals (UPS26-99) and/or a “FLOW SETPOINT” warning. Bad relay on controller PCB. Replace controller. Check direction of flow arrow on Grundfos VFS Sensor/ Senor tube sensor tube body and re-plumb if mounted incorrectly. necessary. Plumbing disturbance in front of Sporadic flow rate display on con- Re-plumb to remove disturbance.
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Page 21: Appendix A: Sensor Kit Descriptions
GEO-FLO UNIVERSAL PUMP CONTROLLER: UPC-GEO | 19 Appendix A: Sensor Kit Descriptions The following information provides descriptions of currently available controller kits. Although both kits work well, there is an advantage to installing the flow and temperature kit, as the ability to directly read heat of extraction and heat of rejection makes start up and troubleshooting much easier. -
Page 22: Appendix B: Installing Sensors
Figure 20 provides several examples of From Loop thermistor to fitting assemblies. Grundfos VFS Sensor Installation Install the VFS sensor and flow tube by utilizing the 1” hose barb transition fittings. Allow 6-10” of 1” rubber hose in front of and behind the flow tube. -
Page 23: Appendix C: Thermistor Temp/Resist Chart
GEO-FLO UNIVERSAL PUMP CONTROLLER: UPC-GEO | 21 Appendix C: Thermistor Temperature/Resistance Chart RESISTANCE VS. TEMPERATURE CHART 10K THERMISTOR*, UPC GEO Temp Temp Resistance Temp Temp Resistance Temp Temp Resistance (°F) (°C) (Ω) (°F) (°C) (Ω) (°F) (°C) (Ω) 20.0 -6.7 46,195 61.0 16.1 14,930 103.0 39.5 5,445 21.0... -
Page 24: Appendix D: Important Power Considerations
If the pump is powered on and off by an external relay, the contact material of the relay must be capable of higher in-rush currents. Grundfos recommends using a minimum 16 Amp relay for 230 VAC switched voltage, and a minimum of 250,000 electrical operation cycles at 4.0 Amps. A typical example is the Omron G7L general purpose relay. -
Page 25: Appendix E: Controller Mounting Template
GEO-FLO UNIVERSAL PUMP CONTROLLER: UPC-GEO | 23 Appendix E: Controller Mounting Template SUGGESTED MOUNTING HOLE LOCATIONS 6" SUGGESTED MOUNTING HOLE LOCATIONS This document must be printed full-scale to properly mark the mounting-hole locations. The Page Scaling in the Print dialog box in Adobe Acrobat must be set to None. The 6-inch line can... -
Page 26: Appendix F1
[0.63 1.26 1.89 2.52] Flow (U.S. GPM) [l/s] Pump Performance Curves Grundfos Magna GEO 32-140 Performance Curves (Single Pump) [149.2] The terminal box should be located in one of the following orientations: [134.3] [119.4] [104.5] [89.5] Pump operates in [74.6]... - Page 27 GEO-FLO UNIVERSAL PUMP CONTROLLER: UPC-GEO | 25 Appendix F1: Pressurized Variable Speed Flow Center Submittals Dimensional Data WEIGHT Inches 13-1/4 10-3/16 8-1/2 9-7/16 4-3/4 12-1.2 3/8” DRIVE SOCKET 33.6 25.9 21.6 24.0 12.0 31.7 12.7 Fluid connections are Flo-Link™ double O-ring style. Transition fittings are not included with the flow center packaging.
- Page 28 Engineer: Order Number: Additional Information: Technical Data Max. Fluid Temperature: 140°F [60°C] Circulators: Grundfos UPS26-99 & Magna GEO variable spd. (requires controller) Min. Fluid Temperature: 20°F [-7°C] Cabinet: High Impact Polystyrene plastic Max. Oper. Press.: 145 psi [1 Mpa] Insulation: CFC-free, polyurethane foam Min.
- Page 29 GEO-FLO UNIVERSAL PUMP CONTROLLER: UPC-GEO | 27 Appendix F1: Pressurized Variable Speed Flow Center Submittals Pump Power Curves Grundfos UPS26-99 Power Curves NOTES: The Magna GEO (variable speed) pump adjusts speed (when used with con- troller) to maintain flow rate or tempera- ture difference.
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Page 30: Appendix F2
1.26 1.89 2.52] Flow (U.S. GPM) [l/s] The pump terminal Pump Performance Curves box should be located in one of the Grundfos Magna GEO 32-140 Performance Curves (Single Pump) following orienta- [149.2] tions: [134.3] [119.4] [104.5] [89.5] Pump operates in [74.6]... - Page 31 GEO-FLO UNIVERSAL PUMP CONTROLLER: UPC-GEO | 29 Appendix F2: Non-Pressurized Variable Speed Flow Center Submittals Dimensional Data 51.0 23.1 *Requires two Flo-Link™ (double O-ring) transition fittings. Typically, PE fusion or PVC glue fittings are used for the ground loop; a hose kit or PVC glue fitting is used for the heat pump connection.
- Page 32 Project Name: Contractor: Engineer: Order Number: Additional Information: Technical Data Circulators: Grundfos UPS26-99 & Magna GEO variable speed (requires controller) Max. fluid temp.: 140°F [60°C] Cabinet: Powder coated galvanized steel Min. fluid temp.: 20°F [-7°C] Tank: Polyvinyl chloride (PVC) Max. operating press.: 13 psig [89.6 kPa]...
- Page 33 GEO-FLO UNIVERSAL PUMP CONTROLLER: UPC-GEO | 31 Appendix F2: Non-Pressurized Variable Speed Flow Center Submittals Pump Power Curves Grundfos UPS26-99 Power Curves NOTES: The Magna GEO (variable speed) pump adjusts speed (when used with con- troller) to maintain flow rate or tempera- ture difference.
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Page 34: Appendix G: Antifreeze Fluid Factors
32 | Installation, Operating, and Maintenance Manual Rev. 05JUL2016 Appendix G: Antifreeze Fluid Factors The UPC-GEO controller calculates Heat of Extraction (HE) and Heat of Rejection (HR) based upon the Media Configuration menu (Figure 14). The Media Configuration page allows setting the type and percentage of an- tifreeze used in the ground loop system. - Page 35 Added formula for HE/HR. Updated external relay recommendations based upon the latest Appendix C Grundfos communications. Added new appendix for information on HE/HR calculations Appendix F Reformatted manual to match other product IOMs. Replaced UP26-99 with UPS26-99 (pump upgrade).
- Page 36 Installation, Operating, and Maintenance Manual Grundfos Universal Pump Controller: UPC-GEO www.geo-flo.com Members of ... Geo-Flo Products Corporation Main Number: 812-275-8513 905 Williams Park Drive Toll Free: 800-784-8069 Bedford, Indiana 47421, U.S.A. Fax: 888-477-8829 Geo-Flo Products Corporation is continually working to improve its products. As a result, the design and specifications of products in this catalog may change without notice and may not be as described herein.
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