Heating, Air-conditioning, Cooling

(1)

Pumps, pump systems and

accessories for heating,

secondary hot water,

air-conditioning and cooling

Air-conditioning,

Cooling

(2)

`bjkqxxq{|j}~j{j|jq|j{jjjq|j``j{j{jj|q{jqj|{j|j{j{}j{|qq{|jjqjq|j xq{|jj{j`j{jjj{qq{|jj``jxj`j?@BEFBJKLJBEOQOLKRUKVRWRLXYEZRORLE[[[\[RW@\]@^_`J APPLIES TO EUROPEAN DIRECTIVE FOR ENERGY RELATED PRODUCTS

UJBFXEOKZRUFOE@EEVRWWR@UE`\E

{jjq{|j{jq¡¢jq|jj{|jxxjqj

{j£jqjq|xxq|

YYY

(3)

Heating, air-conditioning, cooling

Secondary hot water

Solar thermal, geothermal, systems

Accessories

Switchgears and control devices / pump management

Planning guide

11 Heating, air-conditioning, cooling

46

Wilo-StratosPICO, Stratos, Stratos-D, TOP-E, TOP-ED, Smart Wilo-Star-RS, Star-RSD, TOP-RL, TOP-S, TOP-SD, TOP-D

Wilo-Stratos GIGA, VeroLine-IP-E, VeroTwin-DP-E, CronoLine-IL-E, Wilo-CronoTwin-DL-E, Veroline-IPL, VeroTwin-DPL, CronoLine-IL, Wilo-CronoTwin-DL

Secondary hot water

314

Wilo-Star-Z NOVA, Stratos ECO-Z, Stratos-Z, Stratos-ZD Wilo-Star-Z, Star-ZD, TOP-Z, VeroLine-IP-Z

Solar thermal, geothermal energy, systems

366

Wilo-Stratos ECO-ST, Star-ST, Star-RSG

Wilo-Safe

Wilo-DrainLift Con, DrainLift Con Plus

Accessories

379

Pipeunions, adapter fittings Thermal insulation for pumps Pumpcold water insulation Serviceunits

Switchgears and control devices

397 Pump management

454

Wilo-S1R-h, SK, VR-HVAC, CRn, CC-HVAC Wilo-Protect-Module-C

Wilo-IF-Modules Buildingautomation

(4)

4 Wilo Building Services catalogue – 50 Hz – Heating, air-conditioning, cooling – Edition 2011/2012 – Subject to change without prior notice

Programme overview and fields of applications

Heating, air-conditioning, cooling

Pump type Main field of application

Page

Heating, air-conditioning, cooling Glandless high-efficiency pumps

- Single pumps

Wilo-Stratos PICO S/M – S/M S/M – – – 50

Wilo-Stratos M/C – – C M/C – – 58

- Double pumps Wilo-Stratos-D C – – C C – – 80

Energy-saving pumps

- Single pumps Wilo-TOP-E *) M/C – – – – – – 47

– Double pumps Wilo-TOP-ED *) C – – – – – – 47

Automatic pumps

– Single pumps Wilo-Smart S/M – S/M S – – 92

Glandless standard pumps

- Single pumps Wilo-Star-RS S/M – S/M S/M – – – 101

- Double pumps Wilo-Star-RSD *) S/M – – S/M – – – 48

- Single pumps Wilo-TOP-RL *)

(maximum 2660 rpm) M/C – – C – – – 49

Wilo-TOP-S(max. 2880 rpm) M/C – – C – – – 113

- Double pumps Wilo-TOP-SD (max. 2880 rpm) C – – C – – – 152

- Single pumps Wilo-TOP-D *) (max. 1400 rpm) M/G – – G – – – 49

Glanded high-efficiency pumps

- Single pumps

/

Wilo-Stratos GIGA M/C – – M/C – – – 214

Glanded energy-saving pumps

- Single pumps

/

Wilo-VeroLine-IP-E M/C – – M/C – – – 224

- Double pumps

/

Wilo-VeroTwin-DP-E *) M/C – – M/C – – – 207

- Single pumps

/

Wilo-CronoLine-IL-E M/C – – M/C – – – 240

- Double pumps

/

Wilo-CronoTwin-DL-E *) M/C – – M/C – – – 208

Glanded standard pumps

- Single pumps

/

Wilo-Veroline-IPL M/C – – M/C – – – 270

- Double pumps

/

Wilo-VeroTwin-DPL *) M/C – – M/C – – – 209

- Single pumps

/

Wilo-CronoLine-IL M/C – – M/C – – – 287

- Double pumps

/

Wilo-CronoTwin-DL *) M/C – – M/C – – – 210

*)Detailed information on these products can be found

in the Wilo Online Catalogue.

Key: Fields of application:

- Not applicable

S Single- and two-family houses MMulti-family houses C Commercial

New in the programme or series extension or modification

Heating Solar thermal

Secondary hot water circulation Geothermal

Floor heating

Condensate

Condensing boilers/air-conditioning units

(5)

Sanitary hot water

Accessories

Switchgears and control devices / pump management

Secondary hot water

Glandless high-efficiency pumps

- Single pumps

Wilo-Star-Z NOVA – S – – – – – 317

Wilo-Stratos ECO-Z – M – – – – – 321

Wilo-Stratos-Z – M/C M/C C M/C – – 325

- Double pumps Wilo-Stratos-ZD *) C – – C C – C 315

- Single pumps Wilo-Star-Z – S/M M – – – – 334

- Double pumps Wilo-Star-ZD *) – S/M M – – – – 315

- Single pumps Wilo-TOP-Z – M/C M/C – – – – 344

Glanded standard pumps

- Single pumps Wilo-VeroLine-IP-Z M/C M/C M/C M/C – – – 362

Solar thermal, geothermal Glandless high-efficiency pumps

- Single pumps Wilo-Stratos ECO-ST*) – – – – S/M – – 366

- Single pumps

Wilo-Star-ST*) – – – – S/M – – 366

Wilo-Star-RSG*) – – – – – S/M S/M 366

Systems

System separation for floor heating Wilo-Safe – – S/M – – – 368

Condensate lifting units Wilo-DrainLift Con – – – – – – S/M/C 371

/

Wilo-DrainLift Con Plus – – – – – – S/M/C 375

*)Detailed information on these products can be found

in the Wilo Online Catalogue.

Key: Fields of application:

- Not applicable

S Single- and two-family houses MMulti-family houses C Commercial

New in the programme or series extension or modification

Heating Solar thermal

Secondary hot water circulation Geothermal

Floor heating

Condensate

Condensing boilers/air-conditioning units

Air-conditioning/cooling

Pump type Main field of application

(6)

Heating, air-conditioning, cooling

Glandless high-efficiency pumps Series overview 46

Single pumps Wilo-Stratos PICO 50

Wilo-Stratos 58

Double pumps Wilo-Stratos-D 80

Energy-saving pumps Series overview 47

Single pumps Wilo-TOP-E *)

Double pumps Wilo-TOP-ED *)

Automatic pumps Series overview 47

Single pumps Wilo-Smart 92

Glandless standard pumps Series overview 48

Single pumps Wilo-Star-RS 101

Double pumps Wilo-Star-RSD *)

Single pumps Wilo-TOP-RL *)

Wilo-TOP-S 113

Double pumps Wilo-TOP-SD 152

Single pumps Wilo-TOP-D *)

Glanded high-efficiency pumps Series overview 206

Single pumps Wilo-Stratos GIGA 214

Glanded energy-saving pumps Series overview 207

Single pumps Wilo-VeroLine-IP-E 224

Double pumps Wilo-VeroTwin-DP-E *)

Single pumps Wilo-CronoLine-IL-E 240

Double pumps Wilo-CronoTwin-DL-E *)

Glanded standard pumps Series overview 209

Single pumps Wilo-Veroline-IPL 270

Double pumps Wilo-VeroTwin-DPL *)

Single pumps Wilo-CronoLine-IL 287

Double pumps Wilo-CronoTwin-DL *)

(7)

Sanitary hot water

Accessories

Switchgears and control devices / pump manage- ment

Secondary hot water

Glandless high-efficiency pumps Series overview 314

Single pumps Wilo-Star-Z NOVA 317

Wilo-Stratos ECO-Z 321

Wilo-Stratos-Z 325

Double pumps Wilo-Stratos-ZD *)

Glandless standard pumps Series overview 315

Single pumps Wilo-Star-Z 334

Double pumps Wilo-Star-ZD *)

Single pumps Wilo-TOP-Z 344

Glanded standard pumps Series overview 316

Single pumps Wilo-VeroLine-IP-Z 362

Solar thermal, geothermal, systems

Glandless high-efficiency pumps Series overview 366

Single pumps Wilo-Stratos ECO-ST *)

Glandless standard pumps Series overview 366

Single pumps Wilo-Star-ST *)

Wilo-Star-RSG *)

Systems Series overview 367

System separation for floor heating Wilo-Safe 368

Condensate lifting units Wilo-DrainLift Con 371

Wilo-DrainLift Con Plus 375

Accessories

Pipe unions 379

Adapter fittings Wilo-(R), Wilo-(RF), Wilo-(F) 381

Thermal insulation for pumps 385

Pump cold water insulation 386

Service units 388

Wilo-IR-Monitor 391

Wilo-IR-Modul 393

(8)

Heating, air-conditioning, cooling

Switchgears and control devices

Series overview 397

Planning guide 399

Wilo-S1R-h 406

Wilo-SK 601 407

Wilo-SK 602, Wilo-SK 622 408

Control systems Wilo-VR-HVAC, Wilo-CRn, Wilo-CC-HVAC 421 Signal transmitters and accessories Wilo-CRn 432 Option modules, signal transmitters and accessories Wilo-CC-HVAC 436

Pump management Wilo-Control

Pump control Series overview 454

Planning guide 462

Wilo-IF-Modules Wilo-Stratos 467

Wilo-IF-Modules Wilo glanded pumps 486

Wilo-Protect-Module 492

Building automation (BA) Wilo-Control AnaCon 497

Wilo-Control DigiCon, DigiCon-Modbus 499

Wilo-Control DigiCon-A 501

Wilo-Control DigiCon-LBF 503

(9)

Abbreviation Meaning 1~ 1-phasecurrent 3~ 3-phasecurrent Autopilot

Automaticadjustmentofpumpperformance during setback phases, e.g. boiler setback operation ove r-night

blsf Blockingcurrent-proof, no motor protection required

DM Three-phase motor, 3~

DN Nominal diameter oftheflangeconnection p Differential pressure

p-c Control modefor constant differential pressure p-T Control modefor differential pressurecontrol

dependingon thefluid temperature

p-v Control modefor variable differential pressure T Control modefor differential temperature BACnet

Internationally defined company-neutral standard for datacommunication in buildingautomation systems (ISO 16484-5).

CAN

CAN (Controller Area Network) - Multi master bus system, in which several equal CAN-devices may communicateviaa2-core bus within veryshortcycle times. The Wilo-CAN bus includesa CANopen Sta nd-ard (EN 50325-4) which is independentofthe supplier.

EBM Individual run signal EM Single-phase motor, 1~ ESM Individual faultsignal

EnEV German Energy Conservation Legislation ECM

tech-nology

Electronicallycommutated motor with new wet rotor encapsulation, newly developed glandless driveco n-ceptfor high-efficiencypumps

Ext. Off “Overriding Off” control input

Ext. Min Control input “Overriding Min”, e. g. for setback operation withoutAutopilot

FI Residual current-operated protective device BA Buildingautomation

GRD/GLRD Mechanical seal

°dH Degreeof German water hardness; replaced bythe SI unit mmol/l; conversion 1 °dh = 0.1783 mmol/l H Delivery head

IF Interface Int. MS

Internal motor protection: pumps with internal pro -tection againstunacceptably high windingtempera -tures IR Infrared interface KDS Capacitor KLF PTC thermistor sensor Cataphoret-ic coating

Cataphoreticcoating (electrophoretically deposited paint, EDP): paintwork with high adhesivestrength for long-lastingcorrosion protection

KTW Approval for products with plastics, for utilisation in potable water applications

LON

Local Operating Network (open data bussystem, standardised and independentofanysingle manu -facturer, in LONWorks networks)

Modbus

Communication protocol based on a master/slavea r-chitecture. Ethernetand RS485areused asthe media oftransmission. Widespread in industrial and bu ild-ingautomation applications.

mmol/l

Millimolsper litre; SI unitfor assessing water ha rd-ness (total hardness, or concentration ofalkaline earth ions)

MOT Motor module (drive motor + impeller + terminal box/ electronics module) for replacement

P₁ Power consumption (power supplied from the net -work)

PELV

Protective Extra Low Voltage; PELV providesextra protection from electricshock, likeSELV. Thevoltage isso low thatcurrentflowingthrough the human body normally does no harm. However, unlikeSELV, activepartsand componentsoftheequipment must beearthed and connected with theprotectiveearth conductor.

PLR Pump master computer, Wilo-specific data interface Q (=) Volumeflow

RMOT Spare motor (drive motor + impeller + terminal box/ electronics module) for replacement

SBM Run signal or collective run signal

SELV

Safety Extra Low Voltage; SELV (formerly “safety low voltage”) isa low electrical voltagethatoffersextra protection againstelectricshockscompared toelec -triccircuits with higher voltages duetothe low volt -age level and the insulation. Thevoltage isso low thatelectrical shock currentsare normally not da n-gerous.

SSM Faultsignal or collectivefaultsignal Control

in-put, 0 - 10 V Analogue inputfor external control

Wilo-Control Buildingautomation management with pumpsand accessories

TrinkwV 2001

German Drinking Water Ordinanceof2001 (valid from 01.01.2003)

VDI 2035 VDI guidelinefor preventing damage in hot-water heating installations

WRAS Water RegulationsAdvisoryScheme (potable water approval for GreatBritain and Northern Ireland) WSK

Thermal windingcontacts (in motor for monitoring the windingtemperature, full motor protection through additional trippingunit)

O_t_i_ope_nr_ofatin_t_hg_e m_r_espectodeof_i d_veou_dbl_utyepu_pum_mps_p: Individual opera O_ofpe_b_otrat_hin_pug m_m_psodeof doublepumps: Parallel operation N₂_-u_pomb_l_ee_mr of_otopo_{r =}les_appofe_r_olect_x.₂ri₉c₀₀ m_roto_p_mrs_at: ₅₀_Hz N_4-u_pomb_l_ee_mr of_otopo_{r =}les_appofe_r_olect_{x. 14}ric₅₀ m_roto_p_mrs_at: ₅₀_Hz N_6-u_pomb_l_ee_mr of_otopo_{r =}les_appof_re_olect_{x. 9}ri₅₀c m_r_poto_m_atrs: ₅₀_Hz Abbreviation Meaning

(10)

10 WiloBuildingServicescatalogue – 50 Hz – Heating, air-conditioning, cooling – Edition 2011/2012 – Subjecttochange withoutprior notice

G

e

n

e

r

a

l n

otes

a

nd

a

bbr

ev

i

at

i

o

n

s

Wear and tear

Pumpsor partsofpumpsaresubjectto wear in accordance with state-of-the-arttechnology (DIN 31051/DIN-EN 13306). This wear mayvary dependingon operatingparameters (temperature, pressure, speed, water conditions) and the installation/usagesituation and may result in the malfunction or failureat differenttimesoftheafore -mentioned products/components, includingtheir electrical/electro n-iccircuitry.

Wearingpartsareall componentssubjectto rotaryor dynamicstress, includingelectroniccomponentsunder tension, in particular: •Seals (including mechanical seals), seal rings

•Stuffing boxes •Bearingsand shafts

•Impellersand pumpcomponents •Wear ringsand counter rings •Stationary wear rings / wear plates •Macerator

•Capacitor

•Relays / contactors / switches

•Electroniccircuits, semiconductor components, etc.

Pumpsand continuous-flow machines (likesubmersible mixersand recirculation pumps), as well astheir components with coatings (cataphoresiscoating, 2K- or Ceram-coating) aresubjecttoconstant wear duetotheabrasivefluid contents. For this reason thecoating is alsoamongthe wearingpartsoftheseunits.

We do notacceptany liabilityfor faultsor defectsarisingfrom natu -ral wear and tear.

Note

In accordance with German Energy Saving Ordinance [Energieein-spar-Verordnung EnEV] asofthe 1.2.2002at boiler outputsfrom 25 kW, heatingpumpsareto beequipped with switchgearsfor auto -maticperformancecontrol or electronically controlled pumps areto be installed.

In accordance with TrinkwV 2001 and DIN 50930-6, onlycirculating pumps with corrosion-resistantpump housings madeofstainless steel or red brass (CC 499K) areto beutilized in secondary hot water circulation systems.

Pump replacement

Detailed information on thesubjectof “Replacing heatingpumps” can befound in thecurrent Wilo replacementguidefor heating pumps.

Wilo – General Terms of Delivery and Service

The latestversion ofour General Termsof Deliveryand Servicecan be found on the Internetat

www.wilo.com/agb

Material Meaning AISI

1.4021 Chromium steel X20Cr13 420 1.4034 Chromium steel X46Cr13

1.4057 Chromium steel X17CrNi16-2 431 1.4122 Chromium steel X39CrMo17-1

1.4301 Chromium-nickel steel X5CrNi18-10 304 1.4305 Chromium-nickel steel X8CrNiS18-9 303 1.4306 Chromium-nickel steel X2CrNi19-11 304L 1.4401 Chromium-nickel-molybdenum steel X5CrNiMo17-12-2 316 1.4408 Chromium-nickel-molybdenum steel GX5CrNiMo19-11-2 316 1.4462 Chromium-nickel-molybdenum steel X2CrNiMoN22-5-3 329 (2205) 1.4541 Chromium-nickel steel with titanium addition X6CrNiTi18-10 321 1.4542 Chromium-nickel steel with copper and

niobium additions X5CrNiCuNb16-4 630 1.4571 Chromium-nickel steel with titanium

addition X6CrNiMoTi17-12-2 316Ti Abrasite Chilled cast iron material for use in

stronglyabrasivefluids Al Light metal material (aluminium) Ceram

Coating with very high adhesive strength for long-lastingcorrosion pro -tection

Composite High-strength plastic material

EN-GJL

Cast iron with lamellar graphite, also re -ferred toasgreycast iron. Theuseof greycast iron in domestic water sys -tems isgoverned bythe Drinking Water Directive 98/83/EC and applicable rec -ognised technical rulesand standards!

EN-GJS

Cast iron with spheroidal graphite, also referred toasspheroidal cast iron. The useofspheroidal cast iron in domestic water systems isgoverned bythe Drinking Water Directive 98/83/EC and applicable recognised technical rules and standards!

G-CuSn10 Zinc-free bronze GfK Fibreglassplastic

GG See EN-GJL

GGG See EN-GJS

GJMW Special cast iron: white malleablecast iron (former designation: GTW) Inox Stainlesssteel

NiAl-Bz Nickel-aluminium bronze PPO Trade name: Noryl, fibreglass-re

in-forced plastic

PP-GF30 Polypropylene, reinforced with 30% fibreglass

PUR Polyurethane SiC Silicon carbide

St Steel

V2A Material group, e.g. 1.4301, 1.4306 304 V4A Material group, e.g. 1.4404, 1.4571 316

(11)

Pump selection: General remarks

Circulation pumpsshould always beselected sothatthespecified dutypoint is located ator as near aspossibletothepointof ma xi-mum efficiency (optimum volumeflow) ofthe maximum speed H/Q pumpcurve.

Fig.: Pumpcurve

Ifthespecified dutypoint lies between twopumpcurves, then the smaller pump isalwaysto beselected:

Fig.: Pumpselection

The resultingvolumeflow reduction has noappreciableeffecton the actual heatingoutput in heatingsystems. Thisappliestopumpsfor coolingsystems.

Pump selection: Secondary hot water circulation systems

Pump selection

•In order toensurethecorrectconfiguration ofthesecondary hot wa -ter circulation system, thepipesystem must be designed in acco rd-ance with DIN 1988 as well as DVGW worksheets W 551 to W 553. •Thevolumeflow should be determined accordingtothespecifica

-tions in thestandard and the DVGW guideline.

•Ifthe hydraulic dutypoint is between twopumpcurves, then the next largestcirculation pumpor speed stage isto beselected in ac -cordance with DVGW worksheet W 553.

•The heat losses in theascendingand circulation secondary hot water pipesareto be reduced toa minimum byappropriate insulation. Since mostsecondary hot water circulation systemspermitperiodic circulation pump deactivation (asa ruleat night), aclock timer should be included in thestandard equipmentfor automatic ON/OFF opera -tion.

The German energysavingsordinance (EnEV) demandsperiodic pumpactivation/deactivation. Legionellaeswitchingofthe heatge n-erator or the heatingcontroller areto beobserved and taken intoac -count duringprogramming.

Maximum secondary hot water temperature

In view ofthe hardness-formingcomponentscontained in the water, secondary hot water circulation systemsshould not beoperated at temperaturesabove 65 °C.

This limit is required toavoid theformation of lime deposits.

Circulation pipe

Wilo recommendsthe installation ofacheck valve in order toprevent faultycirculation and topreventgravitycirculation in pumpsthat have been shut down.

Variable speed control

Experienceshowsthatvariablespeed control isonly required in c ir-culation pumps in secondary hot water circulation systemsfor the basicadjustmentoftheperformance. An automaticspeed control is not required. Atime-dependentactivation/deactivation should ho w-ever beprovided for each installation.

Motor protection

Blockingcurrent-proofpumpsand pumps with internal protection againstunacceptably high windingtemperatures do not require mo -tor protection. All other pumps have integrated full motor protection includingtripelectronicsor full motor protection (WSK) in conjunc -tion with an external trippingunit. m_ax. (1 ) m_in. (3 ) (2 )

Optimal ﬂow rate

max. 1

max. 2 Duty point

Flow rate A

(12)

P

l

a

nnin

g

gu

id

e

Glandless pumps (general)

Pump duty splitting

General notes on double pumps

•Twopump heads mounted in acommon housing, hydraulicallysepa -rated byaswitchover valve

•Specific design characteristics like with correspondingsinglepump series

•Replacementofan equallypowerful singlepump with identical in-stallation dimensions

•Wide rangeofapplications duetostandard 3-stageswitching Pump duty splitting

Splittingtheassigned maximum design outputtoa double pump in parallel operation enables - particularly in termsof heating - signif i-cantly improved adaptability to partial-load conditions and opti-mum economic efficiency. Thepartial-load pumpoutputto be achieved on average duringtheseason, i.e. for morethan 85% ofthe heatingseason issufficientfor theoperation of one pump only; the second pump isavailablefor parallel operation for occasional fu ll-load requirements.

Benefits of splitting the output between two pumps: •Reduction oftheoperatingcosts by between 50% and 70% •Increased reliability duetotheconstantavailabilityofastandbyunit

readyfor operation

The individual performance mapsfor doublepumpsfeatured in the relevantchaptersspecifythe hydraulicperformancevaluesfor both individual and parallel operation.

Operating modes for double pumps

Doublepumpsaresuitablefor operation in either oftwo basically dif -ferentoperating modes:

•Main/standby mode •Parallel operation

Flow rates in pipe and pump

Theflow rateofthefluid in thepipework is determined bythecross -section sizes. Thevalues listed below should not beexceeded:

Theflow rates [m/s] in thepumparespecified in all dutychartsfor Wilopumpsasafunction ofthepumpoutput.

Viscous fluids

All pumpcurves included in thecatalogueapplytothepumpingof water (kinematicviscosity = 1 mm2/s). Iffluidsof different density and/or viscosityarepumped (e.g. water-glycol mixtures), the hy -draulicvaluesofthepumpand thepipesystem will deviate. Docu -mentson the calculation of the correction values for the selection of the pumps can beobtained from Wilo.

Correction values for the pipe system (increased pressure loss, spe -cificthermal output deficit) cannot beprovided bythepump manu -facturer. They must becalculated bytheplanningengineer in coop -eration with thechemical additivesuppliersand the manufacturersof thevalves.

Minimum inlet pressure for the prevention of cavitation

Topreventcavitation (vapour bubbleformation within thepump), it is necessaryto maintain asufficiently high over pressure (suction head) atthepumpsuction port in relation tothevapour pressureof thefluid beingpumped.

The minimum suction heads are listed in the respective tables for all glandless pumps. These guidance values apply for heating sys-tems up to 110 °C/130 °C feed temperature and installation loca-tion up to 300 m above sea level. Addiloca-tion for higher altitudes: 0.1 m/100 m height increase.

Thevalues must be increased accordingly when pumpingfluidsof higher temperaturesor lower densities, wherethere isgreater flow resistanceon thepumpsuction side, and in regionsof lower atmos -phericpressures. Main/standby mode (RESERVE) Parallel operation (ADDITION)

Pump I or Pump II in operation Both pumps in operation Theversion-specificpumpout

-put isprovided by whichever one ofthetwopumps isactingasthe main pump; thesecond pump re -mainson standby, readyfor time- or fault-actuated switchover.

Theversion-specificpumpout -put isprovided by both pumps operating in parallel. Onepump can beswitched off duringpa r-tial-load operation.

Nominal connection diameter DN [Ø mm] Flow rate v [m/s] In building installations Upto Rp 1¼ or DN 32 Upto 1.2 DN 40and DN 50 Upto 1.5 DN 65and DN 80 Upto 1.8 DN 100and greater Upto2.0

(13)

Notes on installation and operation

Permitted ambient temperature: 0 °C to +40 °C Installation

Installation inside a building

Glandlesspumps must be installed in dry, well-ventilated, frost-free rooms.

Installation outside a building (outdoor installation)

Theglandlesspumpsofthefollowingseriesaresuitablefor outdoor installation:

•Wilo-Stratos/-D •Wilo-TOP-S/-SD •Wilo-TOP-RL

Thefollowingconditions must becomplied with:

•Installation ofthepump in asump (e.g. lightsump, ringsump) with cover or in acabinet/housingfor protection againstthe weather •Avoidanceof directsunlighton thepump

•Protection ofthepumpagainst rain. Dripping water from above is permitted provided thattheelectrical connection has been esta b-lished in accordance with the installation and operating instructions and theterminal box has been properlysealed

•Provideadequateventilation/heating in situations wherethepermit -ted ambienttemperature isexceeded or fallen shortof

•Permissibleambienttemperaturefor outdoor installation:

Condensation water

All standard pumpsfor cold water operation thatare intended for ap -plicationsupto -10 °C/-20 °C arefullycondensation-proof. Thegrey cast iron pump housingofthefollowingseries isused for surfacef in-ishing:

•Stratos/Stratos-D •TOP-S/-SD •TOP-D

with aspecial coating (KTL: (cataphoreticcoating). The benefitsofthiscoatingare:

•Optimum corrosion protection againstcondensation formation on thepump housings in cold-water installations

•Very high scratch and impact resistance Intermittent operation

Theseries

•Stratos/Stratos-D/Stratos-Z/Stratos-ZD •StratosPICO/ECO

•Star-RS/RSD •TOP-S/-SD •TOP-D •TOP-Z

can also beused for intermittentoperation.

Operating pressure

The maximum system pressure (operatingpressure) and theflange versionsfor thepumpsare listed in the relevanttables. All flangeson glandlesspumps (exceptStratos, Stratos-Z, Stratos-D and

Stratos-ZD) havepressure-measurementconnections R 1/₈

Connections

Screw-end pumps

Screw-end pumpsareequipped with connectingthreads in acco rd-ance with DIN EN ISO 228, Part 1. Sealsare included in thescopeof delivery.

Pipeunions with pipethread in accordance with DIN EN 10226-1 must beordered separately.

Flange-end pumps

Thepumpflangesare designed in accordance with DIN 2531, DIN 2533 or DIN EN 1092-2. Detailed information isprovided for the respectivepumpseries.

Combination flange pumps

Flange-end pumps with combination flangescan be mounted with counter flangesPN 6 and PN 16 in accordance with DIN or DIN EN up toand including DN 65. The installation ofacombination flange with acombination flange is notpermitted. Screws with atensilestrength classof 4.6 or higher must beused for theflanged connections. The washers included in thescopeof delivery must befitted between headsofthescrews/nutsand thecombination flange.

Recommended screw lengths:

Motor

Glandlesspump motors with protection class:

Electrical connection

•All Wilopumpsare madefor avoltageof230 V or 400 V (tolerance ±10%) in accordance with DIN IEC 60038.

•All Wilopumps madeafter 1 January 1995 have been labelled with the CE marking in accordance with the EU Machinery Directive. •When pumpsareused in systems with fluid temperaturesabove

90 °C, asuitably heat-resistantconnectingpipe must beused. Stratos/-D: -10 °C to +40 °C

TOP-S/-SD: -20 °C to +40 °C TOP-RL: -20 °C to +40 °C

DIN 2999 (pipe thread sealing in the thread)

DIN EN ISO 228/1

(sealing pipe thread with flat gasket on longitudinal side)

Femalepipethread Rp 1½ Femalepipethread G 1½ Malepipethread R 1½ Malepipethread G 1½

Thread Tightening torque

Minimum screw length DN 32/DN 40 DN 50/DN 65 Flange connection PN 6 M12 40 Nm 55 mm 60 mm Flange connection PN 10 M16 95 Nm 60 mm 65 mm •Wilo-Stratosseries ₄₄ •Wilo-Star series ₄₄ •Wilo-TOP range ₄₄ •Remainingpump range _I_P₄₂ •Insulation class _F/H •Emitted interference _{EN 61}₀₀₀_-6-3 •Interference resistance _{EN 61}₀₀₀_-6-₂

(14)

P

l

a

nnin

g

gu

id

e

Glandless pumps (general)

Electronic performance control

Heatingpumpsare, duetotheir high annual operating hours, among the largestpower-consumingappliances in buildings.

Automaticpumpperformancecontrol helps drasticallyto reduce power consumption in heatingpumps. Reductionsofupto50% can thus beachieved. Compared tostandard pumps, high-efficiency pumpscan even saveupto 80% electricitycosts.

All operatingstates, in particular in thepartial load rangethat istyp i-cal for heatingsystems, can beoptimised hydraulically by meansof automaticpumpperformancecontrol.

Afurther significanteffectconnected with theprevention ofa rise in pumppressure istheavoidanceofflow noise in thermostaticvalves.

German Energy Savings Ordinance, EnEV

In thecontextofthe legal measuresfor the reduction of

CO₂emissions, with regard totheelectricityconsumption of heating circulation pumps, the legislator hasstipulated in the EnEV (as amended on October 1, 2009) thatcirculation pumps in central heat -ingsystem with a nominal thermal outputexceeding25 kW must be equipped in such a waythattheelectrical power consumption isau -tomaticallyadjusted tothespecificpumpingoperation requirements in at leastthreestages.

Even though the EnEV does not demand theuseofan automatic pumpoutputcontroller for pumps with a nominal thermal output be -low 25 kW, it is neverthelessthecasethat byfar thegreater potential savings in termsofelectricityand CO2areto befound in theone-

and two-family housesector, i.e. with installations below 25 kW. Thepumpoutputcontroller does not replacethe need for thecorrect dimensioningofthecirculation pump. The installed pumpoutput mustalso bechecked when thepump is replaced. Controlled pumps thatareslightlyoverdimensioned do notposeany risk iftheyareco r-rectlysettothe nominal load requirement.

Standards/directives

•CE marking (all Wilopumps) •Certification accordingto:

- DIN EN ISO 9001. - DIN EN ISO 14001

Pump curves

Thepumpcurvesapplyto water at +20°C and a kinematicviscosityof 1 mm2/s.

Thepumpcurvestakethe European voltagesof230 V and 400 V into account.

Pump control

When Wilopumpsareoperated with control devicesor moduleac -cessories, theelectrical operatingconditions in accordance with VDE 0160areto becomplied with.

When operatingglandlessand glanded pumps with brandsoffre -quencyconvertersother than thosesupplied by Wilo, outputfilters for reducing motor noiseand for preventing harmful voltagepeaks areto beused and thefollowing limitvaluesareto becomplied with: •Glandlesspumps with P2 Õ 2.2 kW and glanded pumps with

P₂ Õ 1.1 kW

rateofvoltage rise du/dt < 500 V/×s voltagepeaks û < 650 V

For glandlesspump motors, sinefilters (LC filters) are recommended for noise reduction instead of du/dtfilters (RC filters).

•Glanded pumps with P2 > 1.1 kW

rateofvoltage rise du/dt < 500 V/×s voltagepeaks û < 850 V

Installations with longcable lengths (l > 10 m) between converter and motor may increasethe du/dtand û levels (resonance). Thesame appliestooperation with morethan 4 unitsusingacommon power supply. Theoutputfilters must be designed bythe manufacturer of thefrequencyconverter or thefilter supplier. If losses in the motor arecaused bythefrequencyconverter, thepumpsareto be run ata maximum of 95 % oftheir nominal speed. Ifglandlesspumpsofthe TOP-S/-SD, TOP-D and TOP-Z seriesareoperated on onefrequency converter, thefollowing limitvaluesattheconnection terminalsof thepumps must not befallen shortof:

U_min = 150 V fmin = 30 Hz

Minimum volume flow

Larger pumps requirea minimum flow ratetoensuretrouble-freeop -eration. Operatingagainstaclosed slidevalve, volumeflow Q = 0 m3/h, can lead tooverheating insidethepump. •Limitconditionsfor pumpoperation at Q = 0 m3/h:

uptoP₂ = 1 kW areunproblematic ifthefluid temperature is 10 K below the maximum permissiblefluid temperature.

•AboveP₂ > 1 kW permanentoperation, a minimum volumeflow of Q = 10 % Qnominal is required

For the limit ranges, pleaseconsult Wilo.

Motor protection

Service lifeand operational reliabilityofacirculation pump depend to agreatextenton thechoiceofthecorrect motor protection. These -lection ofthecorrect motor protection isa decisivefactor for the service lifeand operational reliabilityofacirculation pump. Motor protection switchesare no longer suitablefor multi-speed pumps, sincetheir motors have deviating nominal currents in the different stages, which requirefusesfor each ofthesestages.

All circulation pumpsareeither •blockingcurrent-proof

•provided with internal protection againstunacceptably high winding temperatures

•with full motor protection bythermal windingcontact (WSK) and separateexternal trippingunit

•with full motor protection byan integrated tripping mechanism For theexactequipment, seethe “Motor data” table.

Noother motor protection is required bythecustomer, unless de -manded bythe regional electricitysupplycompany.

(15)

Sound pressure level

Glandlesspumpsare low-noise duetotheir design. Their air-borne noisevalues with measuring-surfacesound pressure level Lp (A) [dB] depend on the motor power output, and are determined under no r-mal operatingconditions.

Thermal insulation for heating applications

All Wilo-Stratos/Stratos-Z, Wilo-TOP-E/-S/-Z/-D and

StratosPICO/ECO singlepumpsareequipped asstandard with insu -latingshells in order toprevent heat lossesfrom thepump housing. Material: EPP, polypropylenefoam

Thermal conductivity: 0.04 W/m K in accordance with DIN 2612 Flammability: ClassB2 in accordance with DIN 4102; FMVSS 302 When insulatingthepumponsite, care must betaken tocover the pumpuptothetopedgeofthepump housingonly (the motor must be leftuncovered).

Insulation for air-conditioning/cooling applications

Ifpumpsfrom theseries •Stratos, Stratos-D, Stratos-Z •TOP-S/-SD

•TOP-D •TOP-Z •TOP-RL

areused in air-conditioning/coolingapplications, no diffusion-proof insulation ispermitted tocover the drain labyrinth between thepump housingand the motor. Thatensuresthatanycondensate having possiblyaccumulated in the motor can drain offfreelythrough the condensate drain openings in the motor housing.

The Wilo-ClimaForm diffusion-proof insulation availableasaccesso -ryfor theStratos, TOP-Sand TOP-RL seriesfor the insulation of pump housings in cold water applicationsensuresthisautomatically dueto itsspecific design.

Wilo-ClimaForm:

•Water vapour diffusion resistance × > 7000

•Normal flammability, in accordance with DIN 4102-B2 •Part 1 Quality monitoring in accordance with DIN 18200

Quality and safety marks

For pumptypes: •StratosPICO •Stratos ECO

•Star-RS25/ ..., -RS 30/ ..., •Star-RSD 30/ ...,

•Star-Z NOVA, Star-Z 20/1, -Z 25/6

Certificate of conformity

Availableon requestatadditional chargefor all glandlesscirculation pumpsoftheseries:

•Stratos, Stratos-D, Stratos-Z, Stratos-ZD •TOP-S/-SD

•TOP-D •TOP-Z

• Certificate of conformity 2.1

Content: Certification thatthesupplied productcomplies with the order, without detailsoftest results.

• Certificate of conformity 2.2

Content: Certification thatthesupplied productcomplies with the order, with detailsofseriestest results.

• Acceptance test certificate 3.1

Content: Certification thatthesupplied productcomplies with the order, with detailsoftest resultsactually measured on theproduct. The required testscope must bespecified in advance.

60 50 40 20 30 10 0 10 20 50 100 200 500 1000 2000 5000 [W] Rate motor output P2

Lp (A) [dB], 2-pole standard pumps (max. 2900 1/min.) and Stratos series Lp (A) [dB], 4-pole standard pumps (max. 1450 1/min.) and TOP-E series

3000

(16)

P

l

a

nnin

g

u

id

e

Glandless pumps (general)

Special versions

Pumpsfor other voltagesor 60 Hz frequencypossibleon request (at additional charge).

Other materialsand versions (RG, PN 16) for pumpsare listed in the pumptables.

The glandless circulation pump

With this design, all rotatingcomponents insidethecanned motor run in thepumped fluid. The required shaftseal in conventional pump typesachieved bytheuseofstuffing boxesor mechanical seals is omitted. Thepumped fluid lubricatestheshaft bearingsand coolsthe componentsoftheelectric motor.

Theelectrical partofthepump motor (stator with winding) issepa -rated from theencapsulated rotor compartment by meansofan e

n-capsulated motor cartridge (with the TOP Wiloseries) and/or byacan

sealed off with O-rings. Impeller Winding Rotor Bearings Spacer can Fluid Hydraulic seal

Installation positions for glandless pumps

Installation positions not permitted

Permitted without restrictions All energy-saving pumps,

infinitelyvariablecontrol

Permitted without restrictions

All standard and secondary hot water circulation pumps, 1 or 3 speed stages

Additional terminal box positions for single and double pumps

Pump types TOP-E 25 (30)/1-7 TOP-E 30/1-10 TOP-E 40/1-4 TOP-E 50/1-6

•

–

•

– TOP-ED 32/1-7 TOP-ED 40/1-7 TOP-ED 50/1-6 – – – –

•

– –

•

Star-RS, Star-Z, Smart

•

– – – –

Stratos ECO-Z

•

–

•

– – – – –

Star-RSD – – – –

•

Stratos PICO

•

–

•

– – – – –

Stratos ECO

•

–

•

– – – – –

Install pumpsunder stress-freeconditions. Valid for all operatingconditions. Pleaseask Wilo.

(17)

Connection of Wilo-TOP... and Stratos ... to Wilo switchgear provided by the customer

New pump type Switchgear connection

possible according to wiring diagram

Accessories: Modules Wilo-IF-Module single-phase current Wilo-TOP-S Wilo-TOP-Z Wilo-TOP-RL Wilo-TOP-SD or 2 x Wilo-TOP-S 2 x Wilo-TOP-Z 2 x Wilo-TOP-RL Wilo-TOP-D Wilo-TOP-E Stratos Stratos-Z Wilo-TOP-ED Stratos-D Stratos-ZD or 2 x TOP-E 2 x Stratos 2 x Stratos-Z Wilo-TOP-E Stratos Stratos-Z Wilo-TOP-ED Stratos-D Stratos-ZD or 2 x TOP-E 2 x Stratos 2 x Stratos-Z Available Wilo switchgear 1~ 3~ 1~ 3~ 1~ 3~ 1~ 1~ 1~ 1~ IP WSK SSM IP SSM IP WSK SSM IP SSM IP WSK IP WSK SK 601 A B C 1) D 1) A B C 1) D 1) T V X 1) Y S S Yes Yes SK 602/622 F C H I F C H I U W X1 Y1 J J Yes Yes SK 632 – – K L – – K L – – K L – – Yes Yes S2R 3D – – – – M N o P – – – – – Q or R Yes Yes AR/DR/CR – – – S – – – S – – – – – – – –

IP: Internal protection against unacceptably high winding temperatures, WSK: Thermal winding contacts SSM: Collective fault signal

- = connection notpossible,

1)_Onl_y_in_co_nj_u_n_ct_i_o_{n wi}_t_h_co_n_tacto_r_a_nd/_o_{r Wil}_o_-_S_{K 6}₀₂_/6₂₂_;_S_K6₀₂_/6₂₂_ca_n_a_l_so_b_e_use_d_as_On/O_ff_s_wi_tc_h_o_r_co_n_tacto_r

Wiring diagram A power supply 1~230 V/N/50 Hz 1) Wilo-TOP-S/-Z/-SD/-RL Wiring diagram B power supply 1~230 V/N/50 Hz 1) 3) Wilo-TOP-S/-Z/-SD N SK 601 N L PE PE PE L1 N N 2 L PE PE L1 U L2 V L3 W N PE L1 N N N 15 L N WSK 1 10 2 10 11 WSK SK 602 SK 622 SK 601 N PE PE PE L1 N N 2

(18)

P

l

a

nnin

g

u

id

e

Connection information for Wilo-TOP and Wilo-Stratos

Connection of Wilo-TOP... and -Stratos... to Wilo switchgear provided by the customer

Wiring diagram C power supply 3~400 V/N/50 Hz 1) 3) Wilo-TOP-S/-Z/-SD Wiring diagram D power supply 3~400 V/N/50 Hz 1) 2) 3) Wilo-TOP-S/-Z/-SD Wiring diagram E power supply 1~230 V/N/50 Hz

1) Wilo-TOP-E/-ED Wilo-Stratos/-Z/-D/-ZD Wiring diagram F power supply 1~230 V/N/50 Hz 1) Wilo-TOP-S/-Z/-SD/-RL Wiring diagram G power supply 3~400 V/N/50 Hz 1) 3) Wilo-TOP-S/-Z/-SD Wiring diagram H power supply 3~400 V/N/50 Hz 1) Wilo-TOP-S/-Z/-SD PE PE L1 U L2 V L3 W N PE L1 L2 L3 N N N 15 L2 L1 L3 1 10 2 10 11 WSK SK 602 SK 622 SK 601 N PE PE PE L1 N N 2 PE PE L1 U L2 V L3 W N PE L1 L2 L3 N N N 15 L2 L1 L3 SSM 1 10 2 10 11 WSK SK 602 SK 622 SK 601 N PE PE PE L1 N N 2 N SK 601 N L PE PE PE L1 N N 2 L SSM PE PE L1 U L2 V L3 W N PE L N N N 15 L N 1 10 2 10 11 WSK SK 602 SK 622 PE PE L1 U L2 V L3 W N PE L N N N 15 1 10 2 10 11 WSK SK 602 SK 622 L N WSK PE PE L1 U L2 V L3 W N PE L1 L2 L3 N N N 15 L2 L1 L3 1 10 2 10 11 WSK SK 602 SK 622

(19)

Heating, air-conditioning, cooling Wiring diagram I power supply 3~400 V/N/50 Hz 1) 2) 3) Wilo-TOP-S/-Z/-SD Wiring diagram J power supply 3~400 V/N/50 Hz or 1~230 V/N/50 Hz

1) 2) 3) Wilo-TOP-E/-ED Wilo-Stratos/-Z/-D/-ZD Wiring diagram K power supply 3~400 V/N/50 Hz 1) Wilo-TOP-S/-Z/-SD Wiring diagram L power supply 3~400 V/N/50 Hz 1) 2) Wilo-TOP-S/-Z/-SD Wiring diagram M power supply 1~230 V/N/50 Hz 1) 3) Wilo-TOP-S/-Z/-SD/-RL Wilo-SE/SE-TW Wiring diagram N power supply 1~230 V/N/50 Hz 1) Wilo-TOP-S/-Z/-SD PE PE L1 U L2 V L3 W N PE L1 L2 L3 N N N 15 L2 L1 L3 SSM 1 10 2 10 11 WSK SK 602 SK 622 PE PE L1 U L2 V L3 W N PE L1 L2 L3 N N N 15 L N SSM 1 10 2 10 11 WSK SK 602 SK 622 PE PE L1 U L2 V L3 W PE L1 L2 L3 N 15 L2 L3 L1 10 10 11 WSK SK 632 PE PE L1 U L2 V L3 W PE L1 L2 L3 N 15 L2 L3 L1 10 10 11 WSK SK 632 SSM PE PE L1 U L2 V L3 W N PE L N N 15 L N 10 11 WSK S2R 3D 1 2 PE PE L1 U L2 V L3 W N PE L N N 15 L N WSK 10 11 WSK S2R 3D 1 2

(20)

P

l

a

nnin

g

u

id

e

Connection information for Wilo-TOP and Wilo-Stratos

Connection of Wilo-TOP... and -Stratos... to Wilo switchgear provided by the customer

Wiring diagram O power supply 3~400 V/N/50 Hz 1) Wilo-TOP-S/-Z/-SD Wiring diagram P power supply 3~400 V/N/50 Hz 1) 2) Wilo-TOP-S/-Z/-SD Wiring diagram Q power supply 3~400 V/N/50 Hz

1) 2) Wilo-TOP-E/-ED Wilo-Stratos/-Z/-D/-ZD

Wiring diagram R

power supply 1~230 V/N/50 Hz

1) 2) Wilo-TOP-E/-ED Wilo-Stratos/-Z/-D/-ZD Wiring diagram S power supply 3~400 V/N/50 Hz 1) Wilo-TOP-S/-Z/-SD Wiring diagram T power supply 1~230 V/N/50 Hz 1) PE PE L1 U L2 V L3 W PE L1 L2 L3 N 15 L2 L3 L1 10 11 WSK S2R 3D 1 2 N N PE PE L1 U L2 V L3 W PE L1 L2 L3 N 15 L2 L3 L1 SSM 10 11 WSK S2R 3D 1 2 N N PE PE L1 U L2 V L3 W PE L1 L2 L3 N 15 N L1 SSM 10 11 WSK S2R 3D 1 2 N N PE PE L1 U L2 V L3 W PE L1 N 15 N L1 SSM 10 11 WSK S2R 3D 1 2 N N PE PE L1 U L2 V L3 W PE L1 L2 L3 N 15 L3 L1 L3 SSM 10 WSK AR/DR/CR N N SK 601 TOP-D N L1 PE PE PE L1 N N 2 U1 V1 W1 W2 U2 V2

(21)

Heating, air-conditioning, cooling Wiring diagram U power supply 1~230 V/N/50 Hz 1) Wiring diagram V power supply 1~230 V/N/50 Hz 1) 3) Wiring diagram W power supply 1~230 V/N/50 Hz 1) 3) Wiring diagram X power supply 3~400 V/N/50 Hz 1) 3) Wiring diagram X1 power supply 3~400 V/N/50 Hz 1) Wiring diagram Y power supply 3~400 V/N/50 Hz 1) 3) TOP-D U1 V1 W1 W2 U2 V2 PE PE L1 U L2 V L3 W N PE L1 N N N 15 1 10 2 10 11 WSK SK 602 SK 622 TOP-D U1 V1 W1 W2 U2 V2 PE PE L1 U L2 V L3 W N PE L1 N N N 15 1 10 2 15 10 10 11 WSK WSK SK 602 SK 622 SK 601 N PE PE PE L1 N N 2 TOP-D U1 V1 W1 W2 U2 V2 PE PE L1 U L2 V L3 W N PE L1 N N N 15 1 10 2 15 10 10 11 WSK WSK SK 602 SK 622 TOP-D U1 V1 W1 W2 U2 V2 PE PE L1 U L2 V L3 W N PE L1 N N N 15 1 10 2 10 11 WSK SK 602 SK 622 L2 L3 SK 601 N PE PE PE L1 N N 2 TOP-D U1 V1 W1 W2 U2 V2 PE PE L1 U L2 V L3 W N PE L1 N N N 15 1 10 2 10 11 WSK SK 602 SK 622 L2 L3 PE PE L1 U L2 V L3 W N PE L1 N N N 15 1 10 2 15 10 10 11 WSK WSK SK 602 SK 622 L2 L3 SK 601 N PE PE PE L1 N N 2 TOP-D U1 V1 W1 W2 U2 V2

(22)

P

l

a

nnin

g

u

id

e

Connection information for Wilo-TOP and Wilo-Stratos

Connection of Wilo-TOP... and -Stratos... to Wilo switchgear provided by the customer

1) Automatic restartafter apower failure 2) After an overload faulttripofthepump (TOPor Stratos), acknowledgethefaultfirstatthepump, then attheswitchgear 3) SK 622additionally with terminalsfor collective run signalsand collectivefaultsignals. On replacingathree-phasepump (3~400 V) with asingle-phase pump (1~230 V) ensureprotective multipleearthing.

Consultation with Wilo is required when installing Wilo pumps in conjunction with Wilo switchgears not listed or with switchgears not supplied by Wilo. For terminal circuit diagrams for Wilo circula-tion pumps, see the “Service/accessories” chapter or the pump data. Wiring diagram Y1 power supply 3~400 V/N/50 Hz 1) 3) PE PE L1 U L2 V L3 W N PE L1 N N N 15 1 10 2 15 10 10 11 WSK WSK SK 602 SK 622 L2 L3 TOP-D U1 V1 W1 W2 U2 V2

(23)

Name plate designation of the Wilo-Stratos series

Rating plate identification Wilo-Stratos PICO/ECO, Wilo-Star

Series design Seriescodefor the Wilo-Stratos range Type Wilo... Version High-efficiency pumps, infinitely variable speed

Stratos Singlepump Stratos-D Doublepump Stratos-Z Singlepumpfor secondary hot water circulation systems Stratos-ZD Doublepumpfor secondary hot water circulation systems Series/pumptype Insulation class Protection class IP PN = nominal pressureofthepump SW = softwareversion

Tmax = maximum ﬂuid temperature

Item no./dateof manufacture Sequential numbering Voltage/Frequency Power consumption/current Typ: Stratos 30/1-12 Art.-Nr.: 2030540/11w01 1~230V 50/60Hz P1: 16-310 W I: 0,16-1,37 A Class F IP 44 PN 6/10 SW≥5.01 Tmax. 110° C Made by WILO WILO SE Nortkirchenstr.100 44263 Dortmund Germany S/N20000100000 Series design Seriesabbreviation for theprogrammes Wilo-Star and Wilo-StratosPICO/ECO

Type Wilo...

Version

High-efficiency pumps, infinitely variable speed

Stratos ECO StratosPICO Singlepump Standard pump, 3 speed stages Star-RS Singlepump Star-RSD Doublepump Star-RSL Ventilation pump

Secondary hot water circu-lation pumps Stratos ECO-Z Star-Z NOVA Singlepump in hig h-efficiencyversion Star-Z Singlepumps, 1 or 3 speed stages

Solar thermal pumps

Stratos ECO-ST Singlepump, high-efficiency version for solar thermal sys -tems Star-ST Singlepumps, 3 speed stages, for solar thermal systems Star-RSG Singlepumps, 3 speed stages, for geothermal energysys -tems

Art.-No. Stratos ECO 25/1-5 4092510/11w01

1 ~ 230 V 50 Hz 5,8-59 W Imax 0,46 A PN 10 TF 110 IP 44 WILO SE Nortkirchenstr.100 44263 Dortmund Germany 11w01 Voltage Frequency Power consumption Maximum current I PressurestagePN

Maximum ﬂuid temperature Tmax Protection class

Series/pumptype

Item no./dateof manufacture

Week Year

(24)

P

l

a

nnin

g

u

id

e

Designation key

Glandless pumps

Name plate designation of the Wilo-TOP range

Name plate designation of special versions

On request, somepumpscan besupplied in thefollowingspecial ve

r-sionsatadditional charge (thetypeofthespecial version is indicated on the nameplate): • 130 Pump with shortoverall length • RG Red brassversion Series design Seriescodefor the Wilo-TOP range Type Wilo... Version Energy-saving pumps, infinitely variable speed TOP-E Singlepump TOP-ED Doublepump Standard pumps, 2 or 3 speed stages TOP-S/-RL Singlepump TOP-SD Doublepump Standard pumps, 1 speed stage TOP-D Singlepump Circulation pumps for secondary hot water circulation systems, 3 speed stages TOP-Z Singlepump 3~400/230 V 50 Hz Typ TOP-S30/10 Art.-No. 2066133/ 11w26 Class H Made by Wilo WILO SE Nortkirchenstr. 100 44263 Dortmund Germany S/N20000099999 IP 44 P1 (W) 380 0,78 1,35 270 0,48 0,84 195 0,35 0,61 I (A) 400V 230W PN 6/10 Tmax 130 ˚C Voltage Frequency Insulation class Protection class IP PN = nominal pressureof thepump Maximum ﬂuid temperature Tmax Series/pumptype Item no./ dateof manufacture 11w26 Week Year Maximum current Maximum power consumption Sequential numbering Example Type Wilo... Special version Star-RS25/4 RG Star-RS24/4 with red brass housing

(25)

Energy efficiency class

In thecontextofthe KyotoAgreement, European governments in particular arepursuingthegoal of drastically reducing CO2emissions.

Energy labelling, particularlyfor high-consumption household devicessuch as washing machinesand refrigerators, isprescribed as an importantcontrol elementfor providingtheend consumer with an aid for making decisions in favour ofenergy-savingappliances. Duetothefactthat heatingcirculation pumpsareamongthe biggest individual electricityconsumers in household use becauseoftheir long runningtimes, leading European heatingpump manufacturers

havevoluntarily declared their intention of henceforth attachinge n-ergy labelstotheir heatingpumps. This makes itpossiblefor users and end consumersto recognise, on the basisofan alreadyfamiliar

classification system, whether a heatingcirculation pump in use is particularlyenergy-efficient.

Theclassification oftheenergyefficiencyof heatingpumps iscarried out by meansofatechnical measuringprocedure, which providesthe Energy Efficiency Index, EEI. Thesmaller the EEI, the lesselectrical energythepumpconsumesand the morefavourabletheenergy classification.

Table: Classification ofthe Energy Efficiency Index in 7 different

energycategories.

Thefollowingtables listthecorrespondingenergyclassfor all heat -ingpumpsto be labelled, which is incorporated in theenergy label on thepackaging. In accordance with the letteringsystem familiar from household appliances, A isthe bestpossibleand G isthe worstposs i-bleoftheenergyclasses.

Acomparison of hydraulicallysimilar pumps with differentenergy classifications revealsthatthere isa differenceofapproximately 22% in termsofenergyconsumption between twosequentially numbered energyclasses. Accordingly, an energyclassApump re -quireson averageonlyaround 33% oftheelectrical energyco n-sumed byaclass D pump. Even though theenergy requirementsofaclassApumparevery high, high-efficiencyenergyclassApumps have in the meantime be -comeavailablefor usethroughouttheentireperformance rangefrom single-family housesto large buildings. Fig.: Comparison oftheenergyconsumption ratesofpumps with thesame hydraulicoutput Fig.: Energy label for heatingcirculation pumps, Example: EnergyclassA

Energy class Energy Efficiency Index

A EEI < 0.4 B 0.4 Õ EEI < 0.6 C 0.6 Õ EEI < 0.8 D 0.8 Õ EEI < 1.0 E 1.0 Õ EEI < 1.2 F 1.2 Õ EEI < 1.4 G 1.4 Õ EEI 0% 20% 40% 60% 80% 100% 120% 140% 160% 180% A B C D E F G Energy class

(26)

P

l

a

nnin

g

u

id

e

EEI classifications

Glandless pumps

EEI classification - Single pumps/double pumps (field of application: single and two-family house)

Nominal diameter Wilo-Stra -tos PICO... EEI class Wilo-Stra -tos ECO... EEI class Wilo -Smart... EEI class Wilo-Sta r-RS... EEI class Wilo-Sta r-RSD... EEI class DN 15 (Rp ½) 15/1-4 A – – 15/4 B 15/4 B – – 15/1-6 A – – 15/6 B 15/6 C – – DN 25 (Rp 1) 25/1-4 A 25/1-5 A 25/4 A 25/2 C – – 25/1-6 A – – 25/6 B 25/4 B – – – – – – – – 25/6 C – – – – – – – – 25/7 D – – – – – – – – 25/8 D – – DN 30 (Rp 1 ¼) 30/1-4 A 30/1-5 A 30/4 A 30/2 C 30/4 D 30/1-6 A – – 30/6 B 30/4 B 30/6 D – – – – – – 30/6 C – – – – – – – – 30/7 D – – – – – – – – 30/8 D – –

EEI classification – Single pumps (range of applications: multi-family house, commercial applications)

Nominal diameter

Wilo-Stratos... EEI

class

Wilo-TOP-E... EEI

class

Wilo-TOP-S... EEI

class DN 25 (Rp 1) 25/1-6 A 25/1-7 C 25/5 1~/3~ D/D 25/1-8 A – – 25/7 1~/3~ D/D – – – – 25/10 1~/3~ D/D – – – – 25/13 1~/3~ F/F DN 30 (Rp 1 ¼) 30/1-6 A 30/1-7 C 30/4 1~/3~ D/D 30/1-8 A 30/1-10 C 30/5 1~/3~ D/D 30/1-12 A – – 30/7 1~/3~ D/D – – – – 30/10 1~/3~ D/D DN 32 32/1-12 A – – – – DN 40 40/1-4 A 40/1-4 C 40/4 1~/3~ D/D 40/1-8 A 40/1-10 B 40/7 1~/3~ D/C 40/1-12 A – – 40/10 1~/3~ D/C – – – – 40/15 1~/3~ D/D DN 50 50/1-8 A 50/1-6 C 50/4 1~/3~ D/D 50/1-9 A 50/1-7 B 50/7 1~/3~ C/C 50/1-12 A 50/1-10 B 50/10 1~/3~ C/C – – – – 50/15 C DN 65 65/1-9 A 65/1-10 B 65/7 1~/3~ C 65/1-12 A – – 65/10 1~/3~ C – – – – 65/13 C – – – – 65/15 C DN 80 80/1-12 A 80/1-10 B 80/7 1~/3~ C – – – – 80/10 C – – – – 80/15 C – – – – 80/20 C DN 100 100/1-12 A 100/1-10 B 100/10 C

(27)

EEI classification – Single pumps (range of applications: multi-family houses, commercial applications) (continued)

Nominal diameter Wilo-TOP-D... EEI

class

Wilo-TOP-RL... EEI

class DN 25 (Rp 1) – – 25/7.5 E DN 30 (Rp 1 ¼) 30 1~/3~ G/F 30/4 D – – 30/6.5 E – – 30/7.5 E DN 32 – – – – – – – – DN 40 40 1~/3~ E/E 40/4 D – – – – DN 50 50 1~/3~ E/E – – – – – – DN 65 65 1~/3~ E/E – – DN 80 80 1~/3~ E/E – – DN 100 100 1~/3~ E/E – – DN 125 125 D – –

EEI classification – double pumps (field of application: multi-family house, commercial applications)

Nominal diameter Wilo-Stratos-D.... EEI Class Wilo-TOP-ED... EEI Class Wilo-TOP-SD... EEI Class

DN 25 (Rp 1) – – – – – – DN 30 (Rp 1 ¼) – – – – 30/5 1~/3~ D/D DN 32 32/1-8 A 32/1-7 C 32/7 1~/3~ E/D 32/1-12 A – – 32/10 1~/3~ D/D DN 40 40/1-8 A 40/1-7 C 40/3 1~/3~ E/D 40/1-12 A 40/1-10 B 40/7 1~/3~ D/D – – – – 40/10 1~/3~ E/C – – – – 40/15 1~/3~ E/D DN 50 50/1-8 A 50/1-6 C 50/7 1~/3~ F/D 50/1-12 A 50/1-7 B 50/10 1~/3~ E/D – – 50/1-10 B 50/15 D DN 65 65/1-12 A 65/1-10 B 65/10 1~/3~ F/D – – – – 65/13 D – – – – 65/15 D DN 80 80/1-12 A 80/1-10 B 80/7 1~ F – – – – 80/10 D – – – – 80/15 C – – – – 80/20 C DN 100 – – – – – – DN 125 – – – – – –

(28)

P

l

a

nnin

g

u

id

e

Glandless high-efficiency pumps

Wilo-Stratos / Stratos-Z / Stratos-D / Stratos-ZD

Planning guide:

Wilo-Stratos/Stratos-Z/Stratos-D/Stratos-ZD

Wilo-Stratos isthefirst high-efficiencypump in glandless design with thefollowingadvantages:

•Upto 80% electricitysavingscompared tostandard pumps

•For all heating, air-conditioningand coolingsystems in thetempera -ture rangeof -10 °C to +110 °C

•Automaticadjustmentofpumpoutputtocontinuouslyvarying load

conditionsofthe hydraulicsystem •Prevention offlow noise

•Safetyand comfort during installation and operation

Field of application

The Wilo-Stratosseries isused asa high-efficiencypump in circula -tion systemsfor heating, ventilation and air-conditioningsystems in

commercially-used residential and functional buildings: •Large residential buildings •Apartment blocks •Residential complexes •Hospitals •Schools •Administrativeoffice buildings •Real estate developments Temperature range Fluid temperature rangeof -10 °C to +110 °C without restriction at an ambienttemperatureof -10 °C toa maximum of +40 °C.

Heating application

In nearlyall circulation systems, correctlysized controlled glandless pumpsensureadequate heatsupplyatall timesatsignificantly re -duced energycosts, whileatthesametimepreventing noisegenera -tion.

Controlled heating circulation pumps have been mandated by law under the German energy savings ordinance (EnEV)since 01.01.2002 for a nominal thermal output exceeding 25 kW. Dueto itscorrosion-resistantpump housing madeof red brass, the Wilo-Stratos-Z pump isparticularlysuitablefor installations with possibleoxygen entrysuch asfloor heatingsystems madeofplastic tubing.

Thermal insulation for heating

The Wilo-Stratos/-Stratos-Z singlepumpseriesareequipped as standard with athermal insulation shell for theprevention of heat lossesthrough thepump housing. ThePP material used, foamed polypropylene, hasthefollowingproperties:

•Environmental compatibility: easily recyclable •Thermal resistance: upto 120 °C •Heattransmission coefficient: 0.04 W/mK in accordance with DIN 52612 •Flammability: ClassB2 in accordance with DIN 4102 (normal flamma -bility)

Normallyflammable materialsarepermitted for use in heated rooms

in Germany in accordance with fireprevention regulationsas longas a minimum clearanceof20cm is maintained between them and the fireplace.

Air-conditioning/cooling application

The restriction for conventional variablespeed pumps in termsofthe dependencyofthefluid temperatureon theambienttemperature does notapplytothe Wilo-Stratospump.

Condensation formson cold surfaces ifthefluid temperature is lower than theambienttemperature. The Wilo-Stratospumpcan also be used in such cases. It is designed in such a waythat damagetoelec -trical partscaused bycondensation water isavoided.

1 Drain labyrinth for condensation water

Insulation for air-conditioning/cooling

Ifthepump housing isgiven diffusion-proof insulation onsite, the

in-sulation may notcover the drain labyrinth between pump housing and motor. Thatensuresthatanycondensate havingpossiblyaccu -mulated in the motor can drain offfreelythrough thecondensate drain openings in the motor housing.

The diffusion-proof Wilo-ClimaForm insulation availableasaccesso -ryfor the Wilo-Stratosseriesfor thepurposeof insulatingpump housings in cold water applicationsensuresthisautomatically dueto itsspecific design.

Corrosion-proof pump design

Corrosion-proof designsare required for e.g. coolingceilingsor ce il-ing heatingpanels. For theseapplications, thepump housing iscoat -ed.

Asan alternative, the Wilo-Stratos-Z with itscorrosion-resistant pump housing madeof red brasscan beused asthe highest-quality version available.

(29)

Secondary hot water circulation application (Wilo-Stratos-Z/Stratos-ZD)

Pumps which areused in secondary hot water circulation systemsare subjecttospecific requirementsthatarefulfilled bythe

Wilo-Stratos-Z/Stratos-ZD series:

•Thefluidsarepotable water and water for food-processingcompa -nies in accordance with TrinkwV 2001 (German drinking water o rdi-nance). Anyformation of lime deposits istaken intoaccount bythe design, meaningthatatotal carbonate hardnessof20°dH ispermis

-sibleata max. fluid temperatureof +80 °C. •All plasticpartsthatcome intocontact with thepumped fluid comply with KTW recommendations. •The differential pressurecontrol modes Üp-cand Üp-venablethe automaticadjustmentofthepumpoutput in volumeflow-variable secondary hot water circulation systems with thermostaticallyco n-trolling lineshut-offvalves. •The manual control modeenablestheoptimum manual adjustment ofthepumpoutputtotheconstantvolumeflow circulation system. Thiscan be done with the Wilo-IR-Monitor/IR-Modulefor example. Thecriterion for this isthetemperatureofthesecondary hot water in thecirculation pipe, which must not be morethan 5 K below thesto r-agetemperature when itentersthesecondary hot water storage tank.

High-efficiency pumps

Theefficiencyofthe hydraulicsand motor determinethepump's overall efficiency. Both components were doubled with the Wilo -Stratospumpcompared totheglandlesspumpspreviouslyused in buildingservices, thus resulting in aconsiderable improvement. Theapplied ECM technology drastically reducestheannual power consumption, That results in considerablesavingscompared toco n-ventional pumps. ECM technology

The new ECM technology isthe basisfor theoutstandingefficiency of Wilo-Stratospumps. It includes:

EC motor

EC standsfor electronicallycommutated motor. Its basis isasy

n-chronous motor with permanent magnet rotor. The rotatingstator's

magneticfield isgenerated byelectroniccommutation, meaningthat thestator windingsareactivated specificallyfor the interaction of theelectrical and magneticpoles.

Comparison of the motor components

Wilo-TOP-E with AC motor

Wilo-Stratos with EC motor

This hasthefollowing benefits: •The magneticfield required in the rotor does not need to begenerat -ed with any losses. •Especially in thepartial load range (upto 98% oftheoperatingtime), the difference in efficiency iseven greater than italready is in thefull load rangecompared toan asynchronous motor.

•Higher speedsarepossiblecompared toan asynchronous motor. This

results in the reduction ofthesizeand weightofthepump with s imi-lar hydraulics.

Wet rotor encapsulation

The rotor oftheglandlesspump motor runs in thefluid. Thisfluid lu -bricatesthe bearingsand coolsthe motor. Thecurrent-carryingsta -tor isseparated from thefluid byacan, referred toas wet rotor e

n-capsulation. This wet rotor encapsulation hasa directeffecton the efficiency •duetothesizeofthe necessarygap between stator and rotor, •and duetothe magnetic resistanceoftheselected can material. The improvement in termsofefficiencyofthe Wilo-Stratospump here isthe resultof: •Reduction oftheair gapand

•Application ofan innovativecan material with smaller lossestothe magneticflux between stator and rotor.

Hydraulic optimisation

The hydraulicconditionsareoptimised by meansofa 3D spiral hous -ingand 3D impeller as well asasmooth surface in thepump housing

(cataphoreticcoating). Thesuction throatseal between impeller and pump housing reduces radial gap losses. Axial lossesare reduced by thesealing lipon thefrontsideofthe impeller.

Annual power consumption of a heating pump (DN 30) with setback operation* Comparison of different pump types

High-efﬁciency pump Stratos 30/1-12

Energy-saving pump TOP-E 30/1-10

Standard pump TOP-S 30/10

* Load proﬁle with 5500 operating hours per year:

1832

0 1000 2000

Power consumption [kWh/a] 1216 396 2% ( 110 hrs.) at 100% QN (peak load) 25% (1375 hrs.) at 65% Q N (partial load) 40% (2200 hrs.) at 30% Q N (low load) 33% (1815 hrs.) setback operation

Heating, Air-conditioning, Cooling

Pumps, pump systems and

accessories for heating,

secondary hot water,

air-conditioning and cooling

Air-conditioning,

Cooling

UJBFXEOKZRUFOE@EEVRWWR@UE`\E

{jjq{| j{jq¡¢jq|j j{|jxxjqj

 { j£jqjq|xxq|

Y Y Y

Planning guide

11

Heating, air-conditioning, cooling

46

Secondary hot water

314

Solar thermal, geothermal energy, systems

366

Accessories

379

Switchgears and control devices

397

Pump management

454

Programme overview and fields of applications

Heating, air-conditioning, cooling

/

/

/

/

/

/

/

/

/

/

Heating, air-conditioning, cooling

Contents

Heating, air-conditioning, cooling

Secondary hot water

Solar thermal, geothermal, systems

Accessories

Heating, air-conditioning, cooling

Contents

Switchgears and control devices

Pump management Wilo-Control

G

e

n

e

r

a

l n

otes

a

nd

a

bbr

ev

i

at

i

o

n

s

P

l

a

nnin

g

gu

id

e

Glandless pumps (general)

P

l

a

nnin

g

UJBFXEOKZRUFOE@EEVRWWR@UE`\E

{jjq{|j{jq¡¢jq|jj{|jxxjqj

{j£jqjq|xxq|

YYY