AERCO Variable Speed Pump Kit Maintenance Manual

Pioneering for You
Wilo-IF-Module Stratos
de en fr es it Einbau- und Betriebsanleitung
Installation and operating instructions
Notice de montage et de mise en service
Instrucciones de instalación y funcionamiento
Istruzioni di montaggio, uso e manutenzione
2 105 323-Ed.02 / 2013-11-Wilo
Fig. 1:
H/n
H max / n max
H min / n min
Off / Aus
1
2 3
10 U[V]
!
Achtung
Attention
1 - 230V
Achtung
Netzspannung
Attention
Mains Voltage
L N SSM
Option
IF-Modul
1
4e
IF-Modul
pannung
Attention
Mains Voltage
2
3
4d
4a
4b
4c
~15
mm
~15
mm
Fig. 2:
English
1 General
Installation
and operating instructions
1.1 About this document
The language of the original operating instructions is German. All other languages of these instructions are translations of the original operating instructions.
These installation and operating instructions are an integral part of the product.
They must be kept readily available at the place where the product is installed.
Strict adherence to these instructions is a precondition for the proper use and
correct operation of the product.
These installation and operating instructions correspond to the relevant version
of the product and the underlying safety standards valid at the time of going to
print.
2 Safety
These operating instructions contain basic information which must be adhered
to during installation and operation. For this reason, these operating instructions must, without fail, be read by the service technician and the responsible
operator before installation and commissioning.
It is not only the general safety instructions listed under the main point “safety”
that must be adhered to but also the special safety instructions with danger
symbols included under the following main points.
Installation and operating instructions Wilo-IF-Modules Stratos
21
English
2.1 Indication of instructions in the operating instructions
Symbols:
General danger symbol
Danger due to electrical voltage
Note
Signal words:
DANGER!
Acutely dangerous situation.
Non-observance results in death or the most serious of injuries.
WARNING!
The user can suffer (serious) injuries. 'Warning' implies that (serious) injury
to persons is probable if this information is disregarded.
CAUTION!
There is a risk of damage to the product/unit. 'Caution' implies that damage
to the product is likely if this information is disregarded.
NOTE: Useful information on handling the product. It draws attention to possible problems.
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English
2.2 Personnel qualifications
The installation, maintenance and repair personnel must have the necessary
qualifications for this work.
2.3 Danger in the event of non-observance of the safety instructions
Non-observance of the safety instructions can result in risk of injury to persons
and damage to product/unit. Non-observance of the safety instructions can
result in the loss of any claims to damages.
In detail, non-observance can, for example, result in the following risks:
• Failure of important product/unit functions
• Failure of required maintenance and repair procedures
• Danger to persons from electrical, mechanical and bacteriological influences
• Property damage
2.4 Safety instructions for the operator
The existing directives for accident prevention must be adhered to.
Danger from electrical current must be eliminated. Local directives or general
directives [e.g. IEC, VDE etc.] and those of local power supply companies must
be adhered to.
This device is not intended to be operated by persons (including children) with
impaired physical, sensory or mental capacities or lack of experience and/or lack
of knowledge, except in cases where they are supervised by a person responsible for their safety or where they receive instructions from such a person as to
how the device is to be operated.
Children must be kept under supervision in order to ensure that they do not play
with the device.
Installation and operating instructions Wilo-IF-Modules Stratos
23
English
2.5 Safety instructions for inspection and installation work
The operator must ensure that all inspection and installation work is carried out
by authorised and qualified personnel, who are sufficiently informed from their
own detailed study of the operating instructions.
Work on the product/unit should only be carried out when it has been brought
to a standstill. It is mandatory that the procedure described in the installation
and operating instructions for shutting down the product/unit be complied
with.
2.6 Unauthorised modification and manufacture of spare parts
Modifications to the product are only permissible after consultation with the
manufacturer. Original spare parts and accessories authorised by the manufacturer ensure safety. The use of other parts can nullify the liability from the
results of their usage.
2.7 Improper use
The operating reliability of the supplied product is only guaranteed if the
product is used as intended in accordance with Section 4 of the operating
instructions. The limit values must on no account fall under or exceed those
specified in the catalogue/data sheet.
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English
3 Transport and interim storage
Immediately check the IF-Module for any transit damage on arrival. If damage is
found, the necessary procedure involving the forwarding agent must be taken
within the specified period.
CAUTION! Danger of damage to the IF-module!
Danger of damage due to incorrect handling during transportation and storage.
The unit must be protected from moisture, frost and mechanical damage
during transport and interim storage.
Installation and operating instructions Wilo-IF-Modules Stratos
25
English
4 Intended use
The Stratos IF-Modules are designed for external control and operating status
signalling of pumps in the Wilo-Stratos series.
The IF-Modules are not designed for proper safe deactivation of the pump.
DANGER! Risk of injury and material damage!
Using the control inputs for safety functions can lead to serious damage and
injury.
5 Product information
5.1 Type key
Example: IF-Module Stratos SBM
Stratos IF-Module
IF-Module
Stratos
SBM
26
= Interface module
= Suitable for these series
Model/function identifier:
Ext. Off = external off
Ext. Min = external minimum operation
SBM = collective run signal
Ext. Aus/SBM = external off and collective run signal
DP = double pump interface only
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English
5.2
Technical data
General data
Terminal cross-section
Safety in accordance with
EN 60950
Contact input
Version
Earth reference
Off-load voltage
Loop current
Contact output
Version
Load rating
Min. load
Control input 0-10 V
Version
Earth reference
Voltage range
Input resistance
Accuracy
Dielectric strength
1.5 mm² finely stranded
Up to mains voltage 230 V, configuration TN or TT
SELV, isolated
Shared with control input 0-10 V
Max. 10 V
Approx. 10 mA
Potential-free
30 V AC/60 V DC: 1 A AC1/DC1
12 V DC, 10 mA
SELV, isolated
Shared with contact input
0-10 V
> 100 k
5 % absolute
24 V DC
Installation and operating instructions Wilo-IF-Modules Stratos
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English
5.2
Technical data
Double pump interface (DP)
Interface
Voltage
Frequency
Cable length
Wilo-specific, sustained short circuit protection,
cannot be twisted out of place
Max. 10 Vss
Approx. 150 kHz
Max. 3 m
5.3 Scope of delivery
• IF-Module
• Metal EMC cable gland Pg 9 (Pg 9 and Pg 7 in case of DP model)
• Installation and operating instructions
• Connecting cable for double pump interface
• 2x2x0.22 mm² twisted and shielded pair (DP model)
• 2x0.5 mm² light plastic-sheathed cable, 670 mm long (other models)
6 Description and function
6.1 Description of the IF-Modules
The Stratos IF-Modules expand the pump to include additional inputs and outputs and provide the connections for the double pump interface. The DP model
plays a special role: it is used for through-connection of a BUS line for communication and provides the connections for the double pump interface.
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6.2 Function
Ext. Min
SBM
Ext. Off/
SBM
DP
Collective run signal output (SBM) as
a potential-free NO contact
Input for potential-free NC contact with the
function Ext. Min
Input for potential-free NC contact with the
function Ext. Off
Control input 0-10 V
Remote setpoint adjustment
Remote speed adjustment
DP interface for dual pump management
Ext. Off
Function/ Stratos IF-Module
-
-


-
-

-
-
-

-
-

-



-
-





Ext. Off: Input for potential-free NC contact.
• Contact closed: pump operates under auto control.
• Contact open: pump off.
Ext. Min: Input for potential-free NC contact.
• Contact closed: pump operates under auto control.
• Contact open: pump operates at a fixed minimum speed.
Installation and operating instructions Wilo-IF-Modules Stratos
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English
SBM: Output as potential-free NO contact.
• Contact closed: pump operates in the specified operating mode.
• Contact open: pump off.
0-10 V: Control input.
• Remote setpoint adjustment: differential pressure control is active on the
pump. The setpoint for differential pressure is given by the analogue voltage
0-10 V (Fig. 1).
• Remote speed adjustment: differential pressure control is de-activated on the
pump. The pump operates as an actuator with a constant speed, which is
given by the voltage 0-10 V (Fig. 1).
DP: Interface between two pumps acting together as a double pump. The roles
of the two pumps (master/slave) and the operating mode (main/standby or parallel operation) can be set.
7 Installation and electrical connection
Installation and electrical connection must be carried out in accordance with
local regulations and only by qualified personnel.
Warning! Risk of personal injury!
The existing directives for accident prevention must be adhered to.
Warning! Risk of fatal electrical shock!
Danger from electrical current must be eliminated. Local directives or general directives [e.g. IEC, VDE etc.] and those of local power supply companies
must be adhered to.
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7.1 Installation
To ensure immunity in industrial environments (EN 61000-6-2) the data and
control cables must be shielded cables and must be used with an EMC-compliant cable gland (included with the module).
WARNING! Danger of electric shock!
The pump should be electrically isolated and secured against unauthorised
switch-on before beginning installation of the IF-Module.
•
•
•
•
•
•
•
•
•
Installation steps in accordance with Fig. 2:
Remove the lid of the pump's terminal box
Remove the cover (1)
Install the IF-Module in the pump's terminal box (2)
Push the connection plug in all the way (3)
Remove the existing Pg 9 screwed connections (4a)
Install the accompanying metal EMC cable glands (4b)
Strip and prepare the shield and the core wires (4c)
Insert the cable (4d)
Screw the cable gland into place (4e)
Electrical connection follows (see section below).
Installation and operating instructions Wilo-IF-Modules Stratos
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English
7.2 IF-Module Stratos DP
Installation steps in accordance with Fig. 2:
• Remove the lid of the pump's terminal box
• Remove the cover (1)
• Install the IF-Module in the pump's terminal box (2)
• Push the connection plug in all the way (3)
• Remove the existing Pg 7 / Pg 9 screwed connections (4a)
• Install the accompanying metal Pg 7 and Pg 9 EMC cable glands (4b)
• Strip and prepare the shield and the core wires of the accompanying cable
2x2x0.22 mm², shielded pair (4c)
• Insert the cable (4d)
• Screw the cable gland into place (4e)
Electrical connection follows (see section below).
7.3 Electrical connection
WARNING! Danger of electric shock!
Electrical connection must be carried out by an electrician authorised by the
local electricity supply company and in accordance with the applicable local
regulations [e.g. VDE regulations].
• Carry out installation as described in the previous section
• Carry out electrical installation of the pump as specified in the relevant installation and operating instructions
• Check the technical specifications of the electric circuits being connected to
ensure they are compatible with the electrical specifications of the IF-Module
Terminal numbering as shown in Fig. 2, Pos. (3) from bottom to top
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7.3.1 IF-Module Stratos Ext. Off
Terminal No.
Terminal
1
2
3
4
5
6
Ext. Off
Ext. Off
0-10 V
GND (for 0-10 V)
DP
DP
• Check that the Ext. Off wires are free of interference voltage
• Connect the Ext. Off wires to external devices
• Connect the 0-10 V wires (make sure polarity is correct)
7.3.2 IF-Module Stratos Ext. Min
Terminal No.
Terminal
1
2
3
4
5
6
Ext. Min
Ext. Min
0-10 V
GND (for 0-10 V)
DP
DP
• Check that the Ext. Min wires are free of interference voltage
Installation and operating instructions Wilo-IF-Modules Stratos
33
English
• Connect the Ext. Min wires to external devices
• Connect the wires to 0-10 V (make sure polarity is correct)
7.3.3 IF-Module SBM
Terminal No.
Terminal
1
2
3
4
5
6
SBM
SBM
0-10 V
GND (for 0-10 V)
DP
DP
• Connect the SBM wires to external devices
• Connect the wires to 0-10 V (make sure polarity is correct)
7.3.4 IF-Module Stratos Ext. Off/SBM
34
Terminal No.
Terminal
1
2
3
4
5
6
Ext. Off
Ext. Off
SBM
SBM
DP
DP
WILO SE 11/2013
English
• Check that the Ext. Off wires are free of interference voltage
• Connect the Ext. Off and SBM wires to external devices
7.3.5 IF-Module Stratos DP
Terminal No.
Terminal
Wire
1
2
3
4
5
6
BUS (joined with 3)
BUS (joined with 4)
BUS (joined with 1)
BUS (joined with 2)
DP
DP
White (WH)
Blue (BU)
Red (RD)
Black (BK)
• Connect the wires as shown in the table
• Connect the wires in the same order for the partner pump
• The BUS lines are connected in the partner pump, on terminals 1 and 2
(make sure polarity is correct)
7.4 Final work (all modules)
• Connect the DP wires to the partner pump (double pump only)
• Check the terminal box seal for any visible damage
• Close the terminal box lid with the screws provided so that the seal is tight all
around
• Carry out commissioning / functional test in accordance with the following main
section
Installation and operating instructions Wilo-IF-Modules Stratos
35
English
8 Commissioning / functional test
The following sections describe testing the functioning of the inputs/outputs.
It is recommended to test together with the connected system. The pump's
installation and operating instructions are needed for some settings.
8.1 Ext. Off input
• Contact via Ext. Off terminals is closed
• Switch on the pump via the menu: symbol for “On” appears
• Contact via Ext. Off terminals is opened: pump switches off, symbol disappears
8.2 Ext. Min input
• Contact via Ext. Min terminals is closed
• Switch on the pump via the menu: symbol
appears, symbol
indicating
setback operation is not visible (may need to increase setpoint/speed via menu
or de-activate the “Auto Night” function)
• Contact via Ext. Min terminals is opened: symbol
appears “Pump is at min.
speed”
8.3 0-10 V input
• Pump in “Manual control mode”, symbol
visible
• Input voltage to 10 V: pump runs; the displayed speed is the maximum speed
• Input voltage to 2 V: pump runs; the displayed speed is the minimum speed
• Input voltage < 1 V: pump does not run
• Input voltage to 2 V: pump runs; the displayed speed is the minimum speed
8.4 SBM output
• Contact via Ext. Off terminals is closed (if installed)
• Switch on the pump via the menu: symbol
appears
• SBM contact is closed
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WILO SE 11/2013
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• Switch off the pump via the menu: symbol changes to
• SBM contact is opened
8.5 DP interface
• Set dual pump operation in accordance with the pump's installation and operating instructions: function is as described
9 Maintenance
The modules described in these instructions are maintenance-free.
10 Faults, causes and remedies
Have repairs done by qualified skilled personnel only!
WARNING! Danger of electric shock!
Any danger from electrical current should be ruled out.
• The pump should be electrically isolated and secured against unauthorised
switch-on prior to any repair work.
• Damage to the mains connection cables should always be rectified by a qualified electrician only.
WARNING! Risk of scalding!
At high fluid temperatures and system pressures, allow the pump to cool
down first and then depressurise the system.
Installation and operating instructions Wilo-IF-Modules Stratos
37
English
Faults
Causes
Remedy
Pump does not start
Ext. Off contact not closed
Voltage at 0-10 V input not sufficient
Ext. Min contact not closed
Voltage at 0-10 V input not sufficient
Wiring damaged
Incorrect menu setting
Check the external control
Pump stays at minimum speed
Dual pump function
does not work
Check the external control
Check wiring
Set pumps in accordance
with manual
If the operating fault cannot be remedied, please consult a specialist technician or the nearest Wilo after-sales service point or representative.
11 Spare parts
Spare parts may be ordered via a local specialist retailer and/or Wilo customer
service.
To avoid queries and incorrect orders, all data on the name plate should be submitted with each order.
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May 2013
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