wilo 0804010157 Pico Circulating Pump Instruction Manual

Pioneering for You
Wilo-Yonos PICO Installation and operating instructions
ErP READY
APPLIES TO EUROPEAN DIRECTIVE FOR ENERGY-RELATED PRODUCTS

0804010157 Pico Circulating Pump

Fig. 1:

Fig. 2:

Fig. 3a:

Fig. 3b:

Fig. 3c:

Fig. 3d:

Fig. 3e:

Fig. 3f:

Fig. 4:

General information

About these instructions
These installation and operating instructions are an integral part of the product. Read these instructions before commencing work and keep them in an accessible place at all times. Strict adherence to these instructions is a precondition for the intended use and correct operation of the product. All information and markings on the product must be observed. The language of the original operating instructions is German. All other languages of these instructions are translations of the original operating instructions.

Safety

This chapter contains basic information which must be adhered to during installation, operation, and maintenance. Additionally, the instructions and safety instructions in the other chapters must be observed. Failure to follow the installation and operating instructions will result in a risk of injury to persons and damage to the environment and the product. This will result in the loss of any claims for damages. Failure to follow the instructions will, for example, result in the following risks:

• Danger to persons due to electrical, mechanical, and bacteriological factors as well as electromagnetic fields

• Environmental risks due to leakage of hazardous substances

• Property damage

• Failure of important functions of the product
  Identification of safety instructions
  These installations and operating instructions set out safety instructions for preventing personal injury and damage to property that is displayed in a different way

• Safety instructions relating to personal injury start with a signal word and are preceded by a corresponding symbol.

• Safety instructions relating to property damage start with a signal word and are displayed without a symbol.

Signal words DANGER!
Failure to observe the safety instructions will result in serious injuries or death!
WARNING!
Failure to follow the instructions can lead to (serious) injuries!
CAUTION!
Failure to follow the instructions can lead to property damage and a possible total loss.
NOTE
Useful information on handling the product.
Symbols These instructions use the following symbols:

|  Danger due to electrical voltage
---|---
|  General danger symbol
|  Warning of hot surfaces/media
|  Warning of magnetic fields

Notes
Personnel qualifications
Personnel must:

• Be instructed in the locally applicable accident prevention regulations.

• Have read and understood the installation and operating instructions. Personnel must have the following qualifications:

• Electrical work must be carried out by an authorized electrician (in accordance with EN 50110-1).

• Installation/dismantling must be carried out by a qualified technician who is trained in the use of the necessary tools and mounting materials.

• The product must be operated by persons who are instructed in the functioning of the complete system.
  Definition of “qualified electrician”
  A qualified electrician is a person with appropriate technical education, knowledge, and experience who can identify and prevent electrical hazards.
  Electrical work
  

• Electrical work must be performed by a qualified electrician.

• Nationally applicable guidelines, standards, and regulations as well as specifications by local energy supply companies for connection to the local power supply system must be observed

• Before commencing work, disconnect the product from the mains and secure it against being switched on again.

• The connection must be protected by means of a residual-current device (RCD).

• The product must be earthed.
  Obligations of the operator

• Have defective cables replaced immediately by a qualified electrician.

• Never open the control module and never remove control elements.

• Has all work been carried out by qualified personnel only?

• Ensure on-site contact protection from hot components and electrical hazards.

• Have defective gaskets and connecting cables been replaced? This device can be used by children from 8 years old as well as persons with limited physical, sensory or mental capabilities or lack of experience and knowledge if they are supervised or instructed in the safe use of the device and they understand the dangers that may arise. Children are not allowed to play with the device. Cleaning and user maintenance may not be carried out by children without supervision.

Product Description and function

Overview
Wilo-Yonos PICO (Fig. 1)

1. Pump housing with screwed connections
2. Glandless pump motor
3. Condensate drain openings (4x around the circumference)
4. Rating plate
5. Housing screws
6. Control module
7. LED display
8. Operating button
9. Wilo-Connector, electrical mains connection
10. Function key
11. Function LED
12. Fault signal LED

Function
High-efficiency circulator for hot-water heating systems with integrated differential pressure control. The Control mode and delivery head (differential pressure) are adjustable. The differential pressure is controlled via the pump speed.
Type key
Example: Wilo-Yonos PICO 25/1-6 130

6 = Maximum delivery head in m at Q = 0 m³/h
130| Port-to-port length: 130 mm or 180 mm

Technical data

LED display

| • Display the setpoint H of the delivery head (differential pressure) in m.
---|---
| • Display of selected constant speed (c1 = I, c2 = II, c3 = III).
| • Display of the current power consumption in W, alternating with the current flow
the rate in m³/h.
| • Display of warning and fault signals.

3.1 Controls
Operating button Turn

• Select application/control mode.
• Set setpoint H of the delivery head (differential pressure).
• Select constant rotation speed.

Function key Press

• Start pump venting function.
• activate pump manual restart.

3.2 Applications/control mode and functions
Radiator heating system
Recommended for two-pipe heating systems with radiators to reduce the flow noises at the thermostatic valves.

Variable differential pressure (Δp-v): The pump reduces the delivery head at a decreasing volume flow in the pipe network to half. Electrical energy saving by adjusting the delivery head to the volume flow requirement and lower flow rates.
NOTE Factory setting: Δp-v, ½ Hmax
Underfloor heating
Recommended for underfloor heating. Or for large-sized pipes as well as all applications without changeable pipe network curves (e.g. storage charge pumps) as well as single-pipe heating systems with radiators.

Constant differential pressure (Δp-c):
The controller keeps the set delivery head constant irrespective of the conveyed volume flow.
Constant speed
Recommended for systems with fixed system resistance requiring a constant volume flow.
Constant speed (I, II, III):
The pump runs uncontrolled in three prescribed fixed-speed stages.

Venting

The pump venting function is activated via the function key and vents the pump automatically. The heating system is not ventilated.
Manual restart

A manual restart is activated via the function key and deblocks the pump as required (e.g. after a prolonged standstill during the summer).

Intended use

The high-efficiency circulators in the Wilo-Yonos PICO series are exclusively designed for circulating fluids in hot-water heating systems and similar systems with constantly changing volume flows.
Permitted fluids:

• Heating water according to VDI 2035 (CH: SWKI BT 102-01).
• Water-glycol mixtures* with a maximum of 50 % glycol.
• Glycol has a higher viscosity than water. If glycol is added, the delivery date of the pump must be corrected to suit the mixing ratio.

NOTE
Only add ready-to-use mixtures to the system.
Do not use the pump to mix the fluid in the system.
Intended use includes observing these instructions and the data and markings on the pump.
Misuse Any use beyond the intended use is considered misuse and will result in the loss of all liability claims.
WARNING!
The danger of injury or material damage due to improper use!

• Never use non-specified fluids.
• Never allow unauthorised persons to perform work.
• Never operate the pump outside of the specified limits of use.
• Never carry out unauthorised conversions.
• Use authorised accessories only.
• Never operate with phase angle control.

Transportation and storage

Scope of delivery

• High-efficiency circulator with 2 gaskets
• Wilo-Connector
• Installation and operating instructions

Transport inspection
Inspect for transportation damage and check completeness immediately after delivery, and claim immediately if necessary.
Transport and storage conditions
Protect from moisture, frost, and mechanical loads.
Permissible temperature range: -10 °C to +50 °C.

Installation and electrical connection

6.1 Installation
May only be installed by qualified technicians.
WARNING! Risk of burns due to hot surfaces! Pump housing (1) and glandless pump motor (2) may become hot and result in burns on contact.

• During operation, touch the control module (6) only.
• Allow the pump to cool down before commencing any work.

WARNING!
Risk of burns due to hot fluids!
Hot fluids can result in scalding. Before installing or removing the pump, or undoing the housing screws (5), note the following:

• Allow the heating system to cool down completely.
• Close shut-off devices or drain the heating system.

Preparation

• Choose an installation point that is as easily accessible as possible.
• Observe the pump’s allowable installation position (Fig. 2), and rotate the motor head (2 + 6) if necessary.

CAUTION!
An incorrect installation position may damage the pump.

• Select the installation point in line with the allowable installation position (Fig. 2).
• The motor must always be installed horizontally.
• The electrical connection must never face upwards.
• Install shut-off devices upstream and downstream of the pump to facilitate pump replacement.

CAUTION!
Leaking water may damage the control module.

• Align the upper shut-off device such that leaking water cannot drip onto the control module (6).
• Align the upper shut-off device laterally.
• When installed in the feed of open systems, the safety supply must branch off upstream of the pump (EN 12828).
• Complete all welding and brazing tasks.
• Flush the pipe system.

Rotating the motor head
Rotate the motor head (2 + 6) before installing and connecting the pump.

• If necessary, remove the thermal insulation shell.

WARNING!
Risk of fatal injury from the magnetic field!
Risk of death for people with medical implants due to permanent magnets installed in the pump.

• Never remove the rotor.

• Hold the motor head (2 + 6) and unscrew the 4 housing screws (5).
  CAUTION!
  Damage to the inner gasket leads to leakages.

• Carefully rotate the motor head (2 + 6) without removing it from the pump housing (1).

• Carefully rotate the motor head (2 + 6).

• Observe the allowable installation position (Fig. 2and the direction arrow on the pump housing (1).

• Tighten the 4 housing screws (5) (4-7.5 Nm).

Installing the pump

Observe the following points when installing the pump:

• Note the direction arrow on the pump housing (1).
• Install without tension, with a glandless pump motor horizontal (2).
• Place gaskets in the screwed connections.
• Screw on threaded pipe unions.
• Secure the pump with an open-end wrench against twisting and screw tightly with the piping
• Re-mount the thermal insulation shell, if applicable.

CAUTION!
Insufficient heat dissipation and condensation water may damage the control module and the glandless pump motor.

• Do not thermally insulate the glandless pump motor (2).
• Ensure all condensate drain openings (3) are kept free.

6.2 Electrical connection
The electrical connection may only be performed by a qualified electrician.
DANGER!
Danger to life due to electrical voltage!
Immediate danger to life if live components are touched.

• Before commencing work, switch off the power supply and secure it against being switched on again.
• Never open the control module (6) and never remove control elements.

CAUTION!
Pulsed mains voltage can lead to damage to electronic components.

• Never operate the pump with phase angle control.
• When switching the pump on or off using an external control unit, deactivate any voltage pulsing (e.g. phase angle control).
• For applications where it is not clear whether the pump is operated with pulsed voltage, get the control/system manufacturer to confirm that the pump is operated with sinusoidal AC voltage.
• Switching the pump on/off via triacs/solid-state relays must be examined on a case-by-case basis.

Preparation

• The current type and voltage must agree with the specifications on the rating plate (4).

• Maximum backup fuse: 10 A, slow-blow.

• Only operate the pump with sinusoidal AC voltage.

• Note switching frequency:
  – On/off switching operations via mains voltage
  ≤ 100/24 h.
  – ≤ 20/h for a switching frequency of 1 min. between switching on/off via mains voltage.
  NOTE
  The inrush current of the pump is < 5A. If the pump is switched „On“ and „OFF“ via a relay, it must be sure that the relay is designed to switch an inrush current of a minimum 5A. If necessary, the boiler-/regulation manufacturer needs to give a statement.

• The electrical connection must be made via a fixed connecting cable equipped with a connector device or an all-pole switch with a contact opening width of at least 3 mm (VDE 0700/Part 1).

• Use a connecting cable with a sufficient outer diameter (e.g. H05VV-F3G1.5) to protect against leaking water and to ensure strain relief at the threaded cable connection.

• Use a heat-resistant connecting cable where fluid temperatures exceed 90 °C.

• Ensure that the connecting cable does not make contact with either the pipes or the pump.
  Fitting the Wilo-Connector
  

• Disconnect the connecting cable from the power supply.

• Observe the terminal allocations (PE, N, L).

• Connect and fit the Wilo-Connector (Fig. 3a to 3e).
  Connecting the pump

• Earth the pump.

• Connect the Wilo-Connector (9) to the control module (6) until it snaps into place (Fig 3f).
  Removing the Wilo-Connector
  

• Disconnect the connecting cable from the power supply.

• Remove the Wilo-Connector using a suitable screwdriver (Fig. 4).

Commissioning

Commissioning only by qualified technicians.
7.1 Venting

• Fill and vent the system correctly.
  The pump vents automatically when first started.
  If the pump does not vent automatically:

• Activate the pump venting function via the function
  key, briefly press 1x, LED lights green.
  Pump venting function starts after 5 seconds, duration of 10 minutes.
  LED display shows bars running from bottom to top.

• To cancel, press the function key for a couple of seconds.
  NOTE
  After venting, the LED display shows the previously set values of the pump.

7.2 Setting the control mode and the delivery head
The size of the displayed house symbols and data for setting the delivery head is provided as a guide only. A more detailed calculation for the setting is recommended. The
values of the delivery head are displayed in increments of 0.1 m with the setting.
Radiator heating system

Variable differential pressure (Δp-v):

• Select the setting range of the application.
• Set setpoint H of the delivery head (variable differential pressure).
  The LED display shows the setpoint H of the delivery head in m.

Underfloor heating

Constant differential pressure (Δp-c):

• Select the setting range of the application.
• Set setpoint H of the delivery head (constant differential pressure).
  The LED display shows the setpoint H of the delivery head in m.

Constant speed

Constant speed I II III:

• Select the setting range of the constant speed.
• Select speed stage I II or III.
  The LED display shows the set speed of c1, c2, or c3 according to the characteristic curve.

Completing the setting

• Do not rotate the operating button for 2 seconds.
• LED display flashes 5 times and changes to the current power consumption in W, alternating with the current flow rate in m³/h.

NOTE
All settings and displays are retained if the power supply is interrupted.

Decommissioning

Shutting down the pump

Shut down the pump immediately in case of damage to the connecting cable or other electrical components.

• Disconnect the pump from the power supply.
• Contact Wilo customer service or a specialist technician.

Maintenance

Cleaning

• Carefully remove soiling from the pump on a regular basis using a dry duster.
• Never use liquids or aggressive cleaning agents.

 Faults, causes and remedies

The troubleshooting must only be performed by a qualified specialist, and work on the electrical connection must only be performed by a qualified electrician.

Check the delivery head and set it to a lower head if necessary
The building does not get warm| The thermal output of the heating surfaces is too low| Increase setpoint Set control mode to Δp-c

10.1 Warning signals

• The warning signal is indicated by the LED display.
• The fault signal LED does not light up.
• The pump continues to run with limited output.
• The indicated faulty operating status must not occur for a prolonged period. The cause must be eliminated.

specifications (e.g. high module temperature). The speed is lower than during normal operation.| Check the ambient conditions

10.2 Fault signals

• The fault signal is indicated by the LED display.
• Fault signal LED lights up red.
• The pump switches off (depending on the error code) and attempts a cyclical restart.

customer service
E23| Short-circuit| Motor current too high| Request customer service
E25| Contacting/ winding| Winding defective| Request customer service
E30| The excessive temperature of the module| The module interior is too warm| Check conditions of use
E36| Module defective| Electronics defective| Request customer service

Manual restart

• The pump attempts an automatic restart upon detecting a blockage.
  If the pump does not restart automatically (E10):

• Activate the manual restart via the function key, briefly press 2x, LED lights green.
  A restart is performed after 5 seconds, duration of 10 minutes.
  LED display shows the outer segments in a clockwise fashion.

• To cancel, press the function key for a couple of seconds.
  NOTE
  After the restart, the LED display shows the previously set values of the pump.

If the fault cannot be remedied, contact a specialist technician or Wilo customer service.

Disposal

Information on the collection of used electrical and electronic products Proper disposal and appropriate recycling of these products prevent damage to the environment and dangers to your personal health.
NOTE
Disposal of domestic waste is forbidden! In the European Union, this symbol can appear on the product, the packaging, or the accompanying documentation. It means that the electrical and electronic products in question must not be disposed of along with the domestic waste.
To ensure proper handling, recycling, and disposal of the used products in question, please note the following points:

• Only hand over these products at designated, certified collecting points.
• Observe the locally applicable regulations! Please consult your local municipality, the nearest waste disposal site, or the dealer who sold the product to you for information on proper disposal. For further information on recycling, go to www.wilo-recycling.com.

DECLARATION OF CONFORMITY
We, the manufacturer, declare under our sole responsibility that these glandless circulating pump types of the series,
Yonos PICO …
(The serial number is marked on the product site plate) in their delivered state comply with the following relevant directives and with the relevant national legislation:
2014/35/EU – LOW VOLTAGE / N1EDERSPANNUNGSRICHTLINIE
2014/30/EU – ELECTROMAGNETIC COMPATIBILITY / ELEKTROMAGNETISCHE VERTRAGLICHKEIT – RICHTLINIE
_ 2009/125/EC – ENERGY-RELATED PRODUCTS / NERGIEVERBRAUCHSRELEVANTER PRODUKTE – RICHTLINIE (and according to the regulation 641/2009 on glandless circulators amended by 622/2012 / and gemari der Verordnung (EG) Nr. 641/2009 fiber Nasslauferpumpen, gender durch 622/2012)
2011/65/EU + 2015/863 – RESTRICTION OF THE USE OF CERTAIN HAZARDOUS SUBSTANCES / BESCHRANKUNG DER VERWENDUNG BESTIMMTER GEFAHRLICHER STOFFE-RICHTLINIE comply also with the following relevant standards:
Dortmund,

Digital unterschrieben kmvon Holger Herchenhein Datum: 2021.12.21 10:45:46 +01’00’
WILO
Wilopark 1 D-44263 Dortmund H. HERCHENHEIN Senior Vice President – Group Quality & Qualification
Declaration n°2117812-rev12 PC As-SA n°4216446-EU-rev10 Ll-P+LOJ LAJMI11.111U wHo

Local contact at
www.wilo.com/contact
Pioneering for You
WILO SE
Wilopark 1
D-44263 Dortmund
Germany
T +49(0)231 4102-0
F +49(0)231 4102-7363
wilo@wilo.com
www.wilo.com

References

• Recycling | Wilo
• Wilo Corporate - Pioneering for You | Wilo

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