wilo Star-Z/ZD Water Circulator Pump Instruction Manual

wilo Star-Z/ZD Water Circulator Pump

General information

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. EC declaration of conformity: A copy of the EC declaration of conformity is a component of these operating instructions. If a technical modification is made on the designs named there without our agreement or the declarations made in the installation and operating instructions on product/personnel safety are not observed, this declaration loses its validity.

Safety

These operating instructions contain basic information which must be adhered to during installation, operation and maintenance. For this reason, these operating instructions must, without fail, be read by the service technician and the responsible specialist/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.

Symbols and signal words in the operating instructions

Symbols:

| General danger symbol
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| 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 damaging 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.
Information that appears directly on the product, such as:

• Direction of rotation/flow arrow
• Identification for connections
• Rating plate
• Warning sticker must be strictly complied with and kept in legible condition.

Personnel qualifications

The installation, operating and maintenance personnel must have the appropriate qualifications for this work. Area of responsibility, terms of reference and monitoring of the personnel are to be ensured by the operator. If the personnel are not in possession of the necessary knowledge, they are to be trained and instructed. This can be accomplished, if necessary, by the manufacturer of the product at the request of the operator.

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 the environment and the product/unit. Non-observance of the safety instructions results in the loss of any claims to damages. In detail, non-observance can, for example, result in the following risks:

• Danger to persons due to electrical, mechanical and bacteriological factors
• Damage to the environment due to leakage of hazardous materials
• Property damage · Failure of important product/unit functions
• Failure of required maintenance and repair procedures

Safety consciousness on the job

The safety instructions included in these installation and operating instructions, the existing national regulations for accident prevention together with any internal working, operating and safety regulations of the operator are to be complied with.

Installation and operating instructions Wilo-Star-Z/-ZD

Safety instructions for the operator

This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. Children should be supervised to ensure that they do not play with the appliance.

• If hot or cold components on the product/unit lead to hazards, local measures must be taken to guard them against touching.
• Guards protecting against touching moving components (such as the coupling) must not be removed whilst the product is in operation.
• Leakages (e.g. from the shaft seals) of hazardous fluids (which are explosive, toxic or hot) must be led away so that no danger to persons or to the environment arises. National statutory provisions are to be complied with.
• Danger from electrical current must be eliminated. Local directives or general directives (e.g. IEC, VDE etc.) and instructions from local energy supply companies must be adhered to.

Safety instructions for installation and maintenance work

The operator must ensure that all installation and maintenance work is carried out by authorised and qualified personnel, who are sufficiently informed from their own detailed study of the installation and operating instructions. Work on the product/unit must only be carried out when at a standstill. It is mandatory that the procedure described in the installation and operating instructions for shutting down the product/unit be complied with. Immediately on conclusion of the work, all safety and protective devices must be put back in position and/or recommissioned.

Unauthorised modification and manufacture of spare parts

Unauthorised modification and manufacture of spare parts will impair the safety of the product/personnel and will make void the manufacturer’s declarations regarding safety. 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 will absolve us of liability for consequential events.

 Improper use

The operating safety of the supplied product is only guaranteed for conventional use in accordance with Section 4 of the operating instructions. The limit values must on no account fall under or exceed those values specified in the catalogue/ data sheet.

Transport and interim storage

Immediately after receiving the product:

• Check product for transport damage.

• In the event of damage in transit, take the necessary steps with the forwarding agent within the respective time limits.
  CAUTION! Risk of property damage!
  Incorrect transport and interim storage can cause damage to the product.

• The pump is to be protected against moisture and mechanical damage.

• The pump must not be exposed to temperatures outside the range between -10 °C and +50 °C.

Intended use

These circulation pumps are suitable only for drinking water. Circulation pumps in the Wilo-Star-Z series are used for pumping fluids in the areas of drinking water/industrial water and foodstuffs. Intended use includes compliance with this manual. Any other use is regarded as improper use.

Product information

Type key

Example: Wilo-Star-Z 25/6

Star-Z| Z = domestic hot water circulation pump, glandless pump ZD = double circulation pump for domestic hot water, glandless pump
25| Screwed connection 25 (Rp1), 30 (Rp1 ½)
/6| 6 = maximum delivery head in m at Q = 0 m³/h

Technical data

Connection voltage| 1 ~ 230 V ±10%
3 ~ 400 V ±10%
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Mains frequency| 50 Hz
Mains frequency| See rating plate
Motor speed| See rating plate
Water temperature at max.
ambient temperature +40 °C| +2 °C to +65 °C
Max. ambient temperature| +40 °C
Max. operating pressure| 10 bar (1000 kPa)
Minimum inlet pressure 1) at +40 °C/+65 °C| 0.05 bar/0.2 bar (5 kPa/20 kPa)
Port-to-port length| 140 mm/180 mm
Variable speed control 2)| 3 stages

1) The values apply up to 300 m above sea level; addition for higher locations: 0.01 bar/100 m increase in altitude. To prevent cavitation noises, be sure to maintain the minimum inlet pressure at the suction port of the pump.
2) For Star-ZD double pumps, a switchgear is required in addition for time-dependent main/standby or parallel/peak-load operation.

Scope of delivery

• Complete circulation pump
• 2 flat gaskets
• Installation and operating instructions

Accessories

Accessories must be ordered separately:

• Thermal insulation shell (for single pumps only)
• Screwed connections
• S1R-h plug-in module, only for blocking-current proof 1~types, not for Star-Z 25/6. See catalogue for a detailed list

Description and function

Description of the product

The circulation pumps in the Wilo-Stratos Star-Z series are coordinated specifically for the operating conditions in domestic hot water circulation systems. Thanks to the choice of materials and design, they are corrosion- resistant to all the constituents in the drinking water. The pump (fig. 1) consists of a hydraulic system and a glandless pump motor with terminal box. All the rotating parts in the glandless pump are in contact with the fluid, this is also true for the motor rotor. A shaft sealing, which is subject to wear, is not necessary. The fluid lubricates the plain bearings and cools the bearing and the rotor. Motor protection is not necessary. Even the maximum overload current cannot damage the motor. The motor is blocking-current proof.

Terms (fig. 1) :

1. Suction port
2. Condensate drain
3. Pump housing
4. Pressure port
5. Terminal box
6. Cable feed-in
7. Speed switch
8. Venting
9. Rating plate
10. Motor housing

Function of the product

Variable speed control (fig. 8)
The pump types Z 25/6 and ZD 25/6 have a rotary knob on the terminal box for manual switching to the three speed stages [1 ­ 2 ­ 3]. The speed in the smallest stage is approx. 40 to 50% of the maximum speed with a reduction of the current consumption to 50%.
Special pump features
For a double pump, the two motor impeller units are fitted identically and are mounted in a common pump housing with integrated switchover valve. Each pump can run individually, but both pumps can also run at the same time in parallel operation. The operating modes are main/standby or parallel/peak-load operation. The individual units can be configured for different capacities. With the double pump, a system can be adapted to individual operating situations. It is necessary to connect a corresponding switchgear for switching-over in order to control the different operating modes.

Installation and electrical connection

| DANGER! Risk of fatal injury! Incorrect installation and improper electrical connections can be life-threatening..
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• The installation and electrical connection may only be carried out by qualified personnel in accordance with the applicable regulations!
• Adhere to regulations for accident prevention!

Installation

• Only install the pump after all welding and soldering work has been completed and the pipe system has been flushed through.

• Mount the pump in a readily accessible place for easy inspection and dismantling.

• If the pump is installed in a domestic hot water circulation system, a non-return valve must be installed on the pressure side.

• Shut-off valves should be installed upstream and downstream of the pump to facilitate a possible pump replacement.

• Perform installation so that any possible leaking water cannot drip onto the terminal box.

• To do this, align the upper gate valve laterally.

• In thermal insulation work, make sure that the pump motor and the module are not insulated. The condensate-drain openings must remain uncovered (fig. 3, item 2).

• Install the pump with the pump motor horizontal and free from mechanical tension. See fig. 2 for installation positions of the pump.
  

• Direction arrows on the pump housing and the insulation shell (accessories) indicate the direction of flow (fig. 3, item 1).
  

• Use an open-end wrench to secure the pump against twisting (fig. 4).
  

• The motor housing can be twisted after undoing the motor attachment screws if it is necessary to position the terminal box (fig. 5).
  

| Note: In general, turn the motor head before the installation is filled. When turning the motor head in a system that has already been filled, do not pull the motor head out of the pump housing. Turn the motor head with a small amount of pressure on the motor unit so that no water can come out of the pump.
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| CAUTION! Risk of property damage!.
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• Star-Z 25/2 (3~):The motor terminal box must not face downwards or watermay easily enter into it. It may be necessary to turn the motorhousing after the motor fastening screws have beenloosened
• In the case of pumps that have been fitted or retrofitted witha plug-in module, the passage of air to the module must notbe restricted.
• The gasket may be damaged when the motor housing isturned. Replace defective gaskets immediately:Ø 86 x Ø 76 x 2.0 mm EP.

Electrical connection

| DANGER! Risk of fatal injury! Incorrect electrical connections can cause fatal electric shocks.
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• Have the electrical connection set up by an electrician approved by the local electricity supplier only and in accordance with local regulations.

• Disconnect the power supply before any work.

• The current type and voltage of the mains connection must correspond to the details on the rating plate

• The electrical connection must be made in accordance with VDE 0700/part 1 (CH: NIN 2010) via a fixed connecting cable, which is provided with a plug device or an all-pole switch with a contact opening width of at least 3 mm.

• To ensure drip protection and strain relief at the PG screwed connection, a connected load with an adequate outer diameter is necessary (e.g. H05VV-F3G1.5).

• The connection line is to be installed in such a way that it cannot under any circumstances come into contact with the pipe and/or the pump and motor housing.

• Make the mains connection according to fig. 6 and 7:
  
  
  
  
  

• Fig. 6: 1~230 V, blocking-current proof

• Fig. 7: 3~400 V, blocking-current proo

• The connection cable can be taken through the cable feed-in right or left. Exchange dummy plugs and cable feed-in as necessary. When the terminal box is positioned laterally, always arrange the cable feed-in from below (fig. 5).

| CAUTION! Risk of short circuit! Once electrical connection is complete and in order to protect the terminal box from moisture, the terminal box cover must be sealed according to regulations..
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• Earth the pump/installation in accordance with the regulations.
• When connecting automatic switchgears (for double pumps), observe the relevant installation and operating instructions.
  | Note: Double pumps: Provide a separate mains connection cable and a separate fuse on the mains side for both motors of the double pump.
  ---|---

Commissioning

WARNING! Risk of injury and damage to property! Incorrect commissioning can cause personal injury or property damage. · Commissioning by qualified personnel only! · Depending on the pump or system operating conditions (fluid temperature), the entire pump can become very hot. Touching the pump can cause burns!

Filling and venting

Fill and vent the system correctly. The pump rotor room is vented automatically after a short operating period. Dry running for short periods will not harm the pump. Please proceed as follows if it is necessary to vent the rotor room:

• Switch off the pump.
  | WARNING! Risk of injury! Depending on the pump or system operating conditions (fluid temperature), the entire pump can become very hot. Touching the pump can cause burns!
  ---|---

• Close the shut-off device on the pressure side piping
  | WARNING! Risk of injury! Depending on the temperature of the fluid and system pressure, when the venting screw is opened, hot liquid or gaseous fluid may escape or shoot out at highpressure. Escaping fluid can cause scalding!
  ---|---

• Undo the venting screw carefully with a suitable screwdriver and unscrew it completely (fig. 9).
  

• Carefully push back the pump shaft with a screwdriver several times.

• Protect electrical parts from any escaping water. · Switch on the pump.
  | Note: The pump may jam if the vent screw is undone, depending on the operating pressure level
  ---|---

• Screw the venting screw back in again after 15 to 30 seconds.

• Open the shut-off device again.

Adjusting

Rotation direction monitoring for three-phase motors: To check the direction of rotation, remove the screw plug on the longitudinal side of the motor. Switch on briefly to check whether the direction of rotation of the pump matches the arrow on the rating plate. If the direction ofrotation is incorrect, swap two electrical phases.
Speed
The speed is adjusted by means of the rotary knob on the terminal box (fig. 8).

Note: If on a double pump both the individual pumps are in operation at the same time, the selected speeds must be identical for both pumps.

Maintenance

| DANGER! Risk of fatal injury! There is a risk of fatal injury from electric shock when working on electrical equipment.
---|---

• The pump should be electrically isolated and secured against unauthorised switch-on for any maintenance or repair work.
• Any damage to the connection cable should only ever be eradicated by a qualified electrician.
  After successful maintenance and repair work, install and connect the pump according to the “Installation and electrical connection” chapter. Switch on the pump according to the “Commissioning” chapter.

 Faults, causes and remedies

Have faults remedied by qualified personnel only! Observe the safety instructions in chapter 9!

Pump is not running although the current entry is switched on.

| Electrical fuse defective.| Check fuses
Pump has no voltage.| Check the voltage on the pump (Observe the rating plate) Reconnect the voltage.
Condenser defective.| Check the condenser (Observe the rating plate) Exchange the condenser.
Motor is blocked, e.g. due to deposits| Unscrew the venting screw completely and check the ease of movement of the pump rotor or make it easy to move by turning the slotted end of the shaft with a screwdriver (fig. 9). ATTENTION! Close the shut-off devices upstream and downstream of the pump at high water temperatures and system pressures. Allow the pump to cool down first
Cavitation due to insufficient suction pressure.| Increase the system suction pressure within the permissible range.
Pump is noisy.|  | Check the speed setting and switch to a lower speed as necessary.

If the operating fault cannot be remedied, please consult a specialist technician or the Wilo factory after sales service.

Spare parts

Spare parts are ordered from a local specialist retailer and/or Wilo’s customer service. To avoid queries and incorrect orders, all data from the rating plate must be specified with every order

Disposal

Proper disposal and recycling of this product prevents damage to the environment and risks to personal health.

1. Use public or private disposal organisations when disposing of all or parts of the product.
2.  For more information on proper disposal, please contact your local council or waste disposal office or the supplier from whom you obtained the product.

| Note: The pump must not be disposed of along with household waste! For further information on recycling, visit www.wilo-recycling.com
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Subject to change without prior notice.

WILO SE
Nortkirchenstraße 100
D-44263 Dortmund
Germany
T +49(0)231 4102-0
F +49(0)231 4102-7363
wilo@wilo.com
Pioneering for Youwww.wilo.com

References

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

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