Wilo 4092521 Stratos ECO Circulation Pump Instruction Manual

: June 5, 2024
: wilo

Table of Contents

Wilo 4092521 Stratos ECO Circulation Pump
General
Safety
Transport and interim storage
Applications
Product data
Description and operation
Installation and electrical connection
Starting-up
Maintenance
Problems, causes and remedies
Spare parts
References
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Wilo 4092521 Stratos ECO Circulation Pump

General

About this document
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 conform to the relevant version of the product and the underlying safety standards valid at the time of going to press.

Safety

These instructions contain important information which must be followed when installing and operating the pump. It is therefore imperative that they be read by both the installer and the operator before the pump is installed or operated. Both the general safety instructions in this section and the more specific safety points in the following sections should be observed.

Instruction symbols used in this operating manual

Signal words:

DANGER!
Imminently hazardous situation. Will result in death or serious injury if not avoided.

WARNING!
Risk of (serious) injury. ‘Warning’ implies that failure to comply with the safety instructions is likely to result in (severe) personal injury.

CAUTION!
Risk of damage to the pump/installation. ‘Caution’ alerts to user to potential product damage due to non-compliance with the safety instructions

NOTE:
Useful information on the handling of the product. It alerts the user to potential difficulties

Personnel qualification
The personnel installing the pump must have the appropriate qualification for this work.

Risks incurred by failure to comply with the safety instructions
Failure to comply with the safety precautions could result in personal injury or damage to the pump or installation. Failure to comply with the safety precautions could also invalidate any claim for damages. In particular, failure to comply with these safety instructions could give rise, for example, to the following risks:

Failure of important pump or system functions,
Personal injury due to electrical and mechanical causes.

Safety instructions for the operator
The relevant accident precaution regulations must be observed. Potential dangers caused by electrical energy must be excluded. Local or general regulations [e.g. IEC, BSI, UL etc.] and directives from local energy supply companies are to be followed.

Safety instructions for inspection and assembly
The operator must ensure that all inspection and assembly work is carried out by authorised and qualified specialists whohave carefully studied these instructions. Work on a pump or installation should only be carried out once the latter has been brought to a standstill.

Unauthorised modification and manufacture of spare parts
Changes to the pump/machinery may only be made in agreement with the manufacturer. The use of original spare parts and accessories authorised by the manufacturer will ensure safety. The use of any other parts may invalidate claims invoking the liability of the manufacturer for any consequences.

Improper use
The operating safety of the pump or installation can only be guaranteed if it is used in accordance with paragraph 4 of the operating instructions. All values must neither exceed nor fall below the limit values given in the catalogue or data sheet.

Transport and interim storage

Inspect the pump/system for transport damage immediately upon arrival. Any transport damage found must be reported to the carrier within the prescribed periods.

CAUTION! Risk of damage to the pump!
Risk of damage due to improper handling during transport or storage.

The pump is to be protected against moisture and mechanical damage due to impact/shock.
The pumps must not be exposed to temperatures outside the range -10°C to +50°C.

Applications

Stratos ECO:
WARNING! Health hazard! The pump must not be used for pumping liquids in the fields of service/drinking water and food related liquids. Series Wilo- Stratos ECO circulating pumps are intended for use in conjunction with hot water heating or similar water circulating systems of variable volume characteristics. The pump-integrated electronic differential pressure control provides infinitely-variable speed control to match pump capacity to actual load demand.

Stratos ECO-Z:
Series Wilo-Stratos ECO-Z circulating pumps are also suitable of handling liquids in the fields of service/drinking water and food related liquids.

Product data

5.1 Technical Data Stratos ECO Stratos ECO Stratos ECO-Z

25(30)/1-3 25(30)/1-5 25/1-5

Stratos ECO-Z 25/1-5

| from +15°C

to +110°C

Water temperature rangemax. 110 °C at ambient temperature max. 25 °C max. 95 °C at ambient temperature max. 40 °C

Suitable fluids:

Heating water acc. to VDI 2035,
water and water/glycol mixtures up to a 1:1 ratio. Use of glycol mixtures require a reassessment of the pump hydraulic data in line with the increased viscosity at the various mixing ratios. Only approved makes of additives with corrosion inhibitors must be used in strict compliance with manufacturers’ instructions.
For the use of other fluids contact Wilo first.

Scope of supply

Circulating pump, complete,
Installation and operating instruction.

Description and operation

Pump (Fig 1) The circulating pump is fitted with a wet (canned rotor) motor. The circulating water service pump Stratos ECO-Z 25/1-5 is specially designed for use in conjunction with domestic/drinking water service systems. It is by material selection and design, corrosion proofed against any residual, parts in domestic/drinking water. For thermal insulation the pump housing is lagged with an insulation shell. The motor housing is with an electronic control module (Item 1) capable of maintaining the pump generated differ-ential pressure constant at a preset value between 1 and 3 m, or 1 and 5 m. Pump capacity is thus matched to the changing load demand which is particularly significant when using thermostatic control valves.

The essential advantages and benefits are:

no bypass relief valves required,
power savings,
reduction of flow noise.

Control mode (Fig 2): Variable differential pressure (Δp-v) : The differential pres-sure setpoint levels being proportionally increased between ½H and H over the permissible flow range. The pump-gener-ated differential pressure will thus be controlled to the respective level.
The pump automatically responds to the night setback of the central heating installation by electronic evaluation from a temperature sensor. The pump will then switch to the min-imum speed. On renewed boiler heat up the pump will switch back to the previously adjusted setpoint level. The night set-back control can be switched off (Fig. 1, Item 2):

auto: Night setback ON, control operation to the preselected setpoint value and automatic, temperature-activated night setback (additional power savings).
Night setback OFF, control operation to the preselected setpoint value.
Factory setting: Night setback OFF.
NOTE:
In the case of insufficient heating/cooling capacity of the installation (too low a heat transfer) it must be checked whether the night setback control is on. In this case it must be switched off.

Operating elements (Fig 1):

Dial knob for the differential pressure setpoint (Fig. 1, Item 2).
Setting range:
- Stratos ECO 25(30)/1-3: Hmin = 1 m, Hmax = 3 m
- Stratos ECO 25(30)/1-5: Hmin = 1 m, Hmax = 5 m
- Stratos ECO-Z 25/1-5: Hmin = 1 m, Hmax = 5 m

Installation and electrical connection

Installation and electrical connection should be carried out in accordance with local regulations and only by qualified personnel!

WARNING! Risk of personal injury!
The relevant accident precaution regulations must be observed.

WARNING! Risk of electric shock!
Potential dangers caused by electrical energy must be excluded. Local or general regulations [e.g. IEC etc.] and directives from local energy supply companies are to be followed.

Installation

Install pump only after completion of all welding/soldering and after the pipe system had been thoroughly flushed out.
Mount the pump in an easily accessible location in order to facilitate later inspections or exchange.
When installed in the flow pipe of an open-vented system, the safety vent must be connected on the inlet side of the pump.
Isolating valves should be provided and installed at both suc-tion and discharge ports of the pump in order to facilitate a possible pump exchange. They must be located in such a way to prevent valve spindle leakage from spilling onto the con-trol module (upper valve turned sideways).
Install pump free of stress and with the motor shaft horizon-tally located. For module locations refer to Fig. 3. Other arrangements on request.
Directional arrows on pump body and the insulation shell indicate the direction of flow.
If the mounting location of the module is to be altered, turn the motor housing as follows:
Unclip insulation shell with the aid of a screwdriver and remove,
undo the 2 Allen screws,
turn motor housing including control module.
CAUTION! Risk of damage to the pump! When turning on the motor housing the gasket may be damaged. Replace damaged gaskets immediately. Size of gasket: ∅86 mm OD x ∅76 mm ID x2,0 mm thick, EP.
Reset and fix Allen screws,
refit insulation shell.

Electrical connection

WARNING! Risk of electric shock! Electrical connection must be carried out by an electrical installer authorised by the local power supply company in accordance with the applicable local regulations.

Power supply must correspond to name plate data.
Power wiring to be in accordance with Fig. 4:
power connections: L, N, PE.
max. line fuse: 10 A, slow action.
The connecting cable can optionally be lead through the cable gland on either right or left. The gland and the blank plug (PG 11) must than be changed.
Strictly comply with local earthing regulations.
All wiring and external switchgear to comply with local regu-lations (use of conduits, switch air gaps and allpole switches) in strict accordance with locally ruling regulations.
The incoming power cable must be of sufficiently large sized to maintain protection from moisture ingress and to ensure a tight gland grip (e.g. H05W-F3G1,5 or AVMH-3×1,5).
Heat resisting cable must be used when installing the pump in systems with water temperatures above 90°C.
Cable leads to be routed such to avoid any contact with the adjoining pipework and/or the pump or motor housings.

Starting-up

WARNING! Risk of burning! Note the acute danger of the pump becoming very hot, depending on the operating conditions of the pump or sys-tem respectively (fluid temperature). Danger of burning when touching the pump!

Initial start-up
Ensure that the pipe system is properly filled and air-vented. The pump rotor space is automatically vented after a short running period. Short-term dryrunning will not do harm to the pump. If, however, manual venting of the pump may become necessary (not apply for air-venting pump) the fol-lowing procedure is to be adopted:

switch-off pump,
close discharge isolating valve,
WARNING! Risk of scalding! Depending on fluid temperature and system pressure there is the possibility of hot water in liquid or gaseous state suddenly erupting under great force when opening the vent plug. Note the severe danger of scalding!
break through the perforation, centrically the name plate and open the vent screw carefully,
protect electrical parts from released water,
carefully move and push pump shaft with a screwdriver,
CAUTION! Risk of damage to the pump! There is the possibility, depending on the system pressure, of the pump jamming with the vent plug open. Before switching on the pump refit and tighten the vent plug.
refit and tighten vent plug,
reopen discharge valve,
switch on pump.

8.2 Adjusting the pump capacity

Select desired control mode (refer to chapter 6.1).
Preselect pump capacity (head) at the dial button according to requirements (Fig. 1, Item 2).
If head requirements are not known it is recommended to begin with a 1,5 m setting.
If the heating capacity proves insufficient increase head set-ting step by step.
Reduce head setting step by step if the heating capacity is too high or noise generation is excessive.
Select night setback mode; switch either to On or Off (refer to chapter 6.1).

Maintenance

Maintenance and repair work should only be carried out by qualified personnel!
WARNING! Risk of electric shock! Potential dangers caused by electrical energy must be excluded.

The pump must be switched off for all repair work and secured against unauthorised operation.
In principle, damage to the connecting cable should only be repaired by a qualified electrician.

Problems, causes and remedies

Pump is switched-on but does not run:

check electrical fuses,
check voltage available at the pump (note nameplate data),
Locked rotor:
switch off pump,
WARNING! Risk of scalding!
Depending on fluid temperature and system pressure there is the possibility of hot water in liquid or gaseous state suddenly erupting under great force when opening the vent plug. Note the severe danger of scalding!
close isolating valves at both pump ports and let pump cool down. Remove vent plug, check freedom of rotation and re-lock pump rotor by turning the shaft at its slotted end with the aid of a screwdriver
switch on pump.
Should the blockage not be automatically resolved via the automatic deblocking system, please consult the manual procedural instructions as described above.

Noisy pump operation

check differential pressure setting and adjust respectively.
Heating capacity too low, possibilities to increase:
Stepp-up setpoint value,
switch off night setback,
to briefly switch off night setback mode (check on control operations) it is sufficient to just turn the dial button a little.
On cavitation, increase system pressure within the permissible limit.

If no solution can be found, please contact your plumbing and heating specialist or your nearest Wilo Customer Serv-ice or representative.

Spare parts

Spare parts are ordered via a local specialist dealer and/or Wilo customer service.
In order to avoid queries and incorrect orders, make sure to mention all data indicated on the rating plate when placing your order.