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Gas Boiler Pump Head Replacement
Installation, Operation and Maintenance Manual
COMPLIANT
Part 3
ISO9001
High Efficiency
General Notes - ErP (Ecological Design) Directive
– The benchmark for the most efficient circulators is EEI ≤ 0.20 Part 3
– Information on recycling/disposal: this product should be disposed of
separately from household waste in line with local laws and regulations.
When this product reaches its end of life, dispose of it at your local
waste collection point/recycling centre.
– The separate collection and recycling of your product at the time
of disposal will help conserve natural resources and ensure that it is
recycled in a manner that protects human health and the environment
Warning Prior to installation, read these installation and operating
instructions. Installation must comply with local regulations and
accepted codes of practice.
GBPHR/8/CCW
GBPHR/8/CW
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Summary of Contents for Tucson GBPHR/8/CCW
- Page 1 Gas Boiler Pump Head Replacement Installation, Operation and Maintenance Manual GBPHR/8/CCW GBPHR/8/CW COMPLIANT Part 3 ISO9001 High Efficiency General Notes - ErP (Ecological Design) Directive – The benchmark for the most efficient circulators is EEI ≤ 0.20 Part 3 – Information on recycling/disposal: this product should be disposed of separately from household waste in line with local laws and regulations.
- Page 2 General Information The Tucson Gas Boiler Pump Head Replacement or GBPHR is available as a range of Easy to Install, Retro-fit products for Gas Boilers and is available as both clockwise and counter-clockwise rotating units. These products are designed as replacement components to be used across an array of market leading boilers brands.
- Page 3 QR code linking to tucsonpumps.ie Rotation direction Light fields indicating the pump setting The Tucson Gas Boiler Pump Head Replacement has three optional settings which can be selected with the push-button. Push button when selecting pump setting Every time the push button is pressed, the pump setting is changed.
- Page 4 Control Panel Operation Procedure Depress Button Function Function Definition Visual Display LED CS III (Factory Constant curve, speed III Settings) AUTO Adaptive mode PP I Proportional pressure curve, speed I PP II Proportional pressure curve, speed II PP III Proportional pressure curve, speed III CP I Constant pressure curve,...
- Page 5 Gas Boiler Pump Head Replacement Installation, Operation and Maintenance Manual Automatic Venting Feature Function Description Operation Venting Pump venting/purging Press & hold the function button for 5 seconds until is the process of air LED1+LED2+LED3 light up and then release. The removal from within pump will vent automatically for 5 minutes.
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Page 6: Technical Data
Suction Minimum Inlet Pressure ≤+75°C 0.05 bar ≤+90°C 0.28 bar ≤+110°C 1.08 bar EMC Standard EN61000-6-1, EN61000-6-3 Decibel Rating 43dB Operating Environment Temperature 0°C - 40°C Liquid Temperature +2°C - 110°C Surface Temperature Maximum 125°C ≤0.23 Part 3 Performance GBPHR/8/CCW & GBPHR/8/CW... - Page 7 Gas Boiler Pump Head Replacement Installation, Operation and Maintenance Manual Product Components (Fig. 2 & 3) 1. Pump body model 2. Wet rotor motor 3. Body fixing screws 4. Electronic control board 5. Pump identification plate 6. Function button 7. LED light field 8.
- Page 8 Fig. 3 Fig. 4 Brown AC Power Cable: 230 Vac Yellow Blue Brown: (L) Live Yellow/Green: Earth Blue: (N) Neutral Fig. 5 Yellow PWM Control Cable Black Yellow: PWM output (from pump) Red: PWM imput (from controller) Black: Ground cable (GND)
- Page 9 Gas Boiler Pump Head Replacement Installation, Operation and Maintenance Manual Pump Dimensions Fig. 6 Dimension (mm) Model GBPHR/8/CW GBPHR/8/...
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Page 10: Electrical Connection
1. Installation position 2. Position the AC 3. Completed assembly & PWM cable plugs towards the control box sockets and firmly insert The Tucson GBPHR/8/CCW is compatible and interchangable with the following pump models: - Grundfos UPM3 ® - Grundfos UPM2 ®... -
Page 11: Replacement Instructions
Gas Boiler Pump Head Replacement Installation, Operation and Maintenance Manual The Tucson GBPHR/8/CW is compatible and interchangable with the following pump models: - Wilo PARA ™ - Wilo PICO ™ - Wilo ™ YONOS Old RS xx/X models and other brands... - Page 12 Rotational direction of the motor: Dimension of the fixing flange: 68mm 69mm 68mm 69mm ATTENTION The rotating direction is determined by looking at the data plate on the front of the motor. The delivery head detail of the old circulator is shown on the original data plate of the circulator to be replaced.
- Page 13 6. On Loosening the studs, allow any remaining water to bleed from the pump, before removing the faulty pump head. 7. Insert the Tucson GBPHR Pump into the Boiler pump manifold ensuring to utilize the O-Ring washer supplied. 8. Insert the suitable studs supplied and tighten the pump head into position.
- Page 14 L/m or metres cubed per hour /Hr). Once this value is attained, refer to the Tucson GBPHR performance curve on page 6. Viewing the performance curve, select the desired flow rate at...
- Page 15 Gas Boiler Pump Head Replacement Installation, Operation and Maintenance Manual 1. Replacing a Grundfos Pump with plug connection: ® Use the adapter cable as shown in Fig 7. This adapter allows the installer to connect directly onto the original boiler panel electrical cable connection, allowing for a quick and safe retro-fit.
- Page 16 3. Note: Should it not be possible to utilize the electrical adapter cable options supplied with this pump, the installer must use the stripped cable connection adapter option supplied and shown in Fig 9. This stripped cable connection adapter provides and IP Rated connection. This option allows the installer to connect the pump safely and securely to the boilers electrical cable without opening the boilers electrical panel.
- Page 17 Gas Boiler Pump Head Replacement Installation, Operation and Maintenance Manual Adjustment Modes and Functions Variable differential Recommended in such cases of heating pressure systems with delivery and return pipes with radiators, for the reduction of flow noise on thermostatic valves and zone disconnectors. The pump halves the delivery in case of flow reduction in the pipeline network (radiators or closed areas).
- Page 18 External Adjustment via iPWM signal The pump speed is controlled according to the PWM = External adjustment PWM input signal, when corrected. with iPWM signal If there is no PWM signal or if the cable is not connected, the pump operation is controlled by internal logic.
- Page 19 Gas Boiler Pump Head Replacement Installation, Operation and Maintenance Manual PWM Input Signal (P1 heating systems for Modulex Hybrid models) At high PWM signal rates (duty cycles), a hysteresis prevents the circulation pump from starting and stoping if the input signal fluctuates around the change point.
- Page 20 PWM Input Signal (P2 solar systems for Modulex Solar models) With a low percentage of PWM signal (duty cycles), a hysteresis prevents the circulation pump from starting and stopping if the input signal oscillates around the change point. Without PWM signal percentage, the circulation pump will stop for safety reasons.
- Page 21 Gas Boiler Pump Head Replacement Installation, Operation and Maintenance Manual PWM Signal: Technical Data Galvanic isolation in the pump PWM frequency input 1000 - 2500Hz High level input voltage UiH 4.0 - 5.5V Low level input voltage UiL <0.7V High input current IH Max 3.5mA @4700 Ohms Max 20mA @100 Ohms PWM input duty cycle...
- Page 22 PWM Feedback Signal (energy consumption) PWM Input Qualification Pump Disqualification Priority Signal (%) Time QT (S) Information Time DT (S) Standby by PWM signal (STOP) Alarm, stop, blocked error 0-30 Alarm, stop, 1-12 electrical error Warning 0-70 0-70W (slope1W/ %PWM) Output 75Hz+/-5% frequency...
- Page 23 Gas Boiler Pump Head Replacement Installation, Operation and Maintenance Manual Repositioning of the Pump Head/ Control Panel Repositioning of the pump head can sometimes be required where the screen operational control, and the screens visible data is not displayed squarely to the installer or operator. Follow this detailed procedure should the product interface require repositioning.
- Page 24 Product Warranty – The warranty period of this product is 1 year from date of retail sale and warranty registration of the product. – The warranty is void should the product be mishandled prior to or during installation. – The warranty is void should the product be misapplied, misused or exceed the products designed scope of use.
- Page 25 Installation, Operation and Maintenance Manual Questions? Should you wish to speak with our product support team please contact us via, Email sales@tucsonpumps.ie techsupport@tucsonpumps.ie Website www.tucsonpumps.ie Company Details Tucson Pumps Ltd, Instantor Works, Santry Avenue, Dublin, D09 K160, Ireland. Irish Company Registration Number – IE669658...
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Page 26: Ec Declaration Of Conformity
Signed on behalf of Tucson Pumps Ltd. Product Manager Issue 1 – 1 February 2022 Tucson Pumps Ltd, Instantor Works, Santry Avenue, Dublin, Ireland D09 K160 Tel +353 1 842 6255 Registered office as above - Company Number: IE669658 – Vat Number: IE3685037DH... - Page 27 Gas Boiler Pump Head Replacement Installation, Operation and Maintenance Manual Notes...
- Page 28 T 01 842 6255 E sales@tucsonpumps.ie www.tucsonpumps.ie Tucson Pumps Ltd Instantor Works, Santry Avenue, Santry, Dublin D09 K160...
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