Wilo Circulation Pumps

Glandless Circulators

and Accessories,

Package Heat Exchanger Assembly

Glandless Pumps

2 4 10 12 Wilo-Jet WJ B1 1 Wilo-Sub TW5/TW5-SE B1 2 Wilo-SilentMaster B1 3 Wilo-Sub TWU 3 B1 4 Wilo-RainSystem AF Comfort B1 5 Wilo-Comfort-Vario CO 1/MVIE B4 6 Wilo-Comfort-Vario CO 1/MVIE B4 Wilo-EasyStar A1 7 Wilo-Safe A1 8 Wilo-Star-Z 15 TT A1 9 Wilo-DrainLift Con C3 10 Wilo-Stratos A1 11 Wilo-Drain TM/ TMW 32 Twister C1 12 Wilo-DrainLift S C3 13 Series Catalogue 1 2 3 4 5 6 7 8 Wilo-CronoBloc-BL A3 8 9 10 11 7 1 2 3 6 5 8 9 10 4 11 Series Catalogue

Glandless pumps

Pump type Main field of application

Page

Heating, Air-conditioning, Cooling 36

High-Efficiency Pumps

– Single-head pumps

Wilo-Stratos ECO S/M S/M 40

Wilo-Stratos M/C C M/C 40

– Twin-head pumps Wilo-Stratos-D C C C 40

Energy-saving Pumps

– Single-head pumps

Wilo-Star-E (EasyStar) S/M 76

Wilo-TOP-E M/C 76

– Twin-head pumps Wilo-TOP-ED C 76

Automatic Pumps – Single-head pumps Wilo-Smart S/M S/M S 108 Standard Pumps – Single-head pumps Wilo-Star-RS(ClassicStar) S/M S/M 116

Wilo-AXL(max. 2440/1 min) M/C 116

Wilo-TOP-RL (max. 2660/1 min) M/C C 116

Wilo-SE(max. 2880/1 min) M/C C 118

Wilo-TOP-S(max. 2880/1 min) M/C C 118

Wilo-TOP-D(max. 1400/1 min.) M/C C 118

Wilo-RP(max. 1400/1 min) S/M 120

Wilo-P(max. 1400/1 min) M/C 120

– Twin-head pumps Wilo-Star-RSD (ClassicStar) S/M S/M 122

Wilo-TOP-SD(max. 2850/1 min) C C 122

Wilo-SE-TW (max. 2880/1 min) C 122

Wilo-DOP(max. 1400/1 min) C 124

Potable water circulation 245

High-Efficiency Pumps

– Single-head pumps

Wilo-Stratos ECO-Z M 246

Wilo-Stratos-Z M/C M/C C M/C 246

– Twin-head pumps Wilo-Stratos-ZD C C C 246

Standard Pumps

– Single-head pumps

Wilo-Star-Z 15 (CircoStar) S 272

Wilo-Star-Z 20/25 (CircoStar) M M 272

Wilo-TOP-Z (max. 2850/1 min) M/C M/C 272

- Special single-head pumps Wilo-VeroLine-IP-Z M/C M/C M/C M/C 272

Solar thermal 303 High-Efficiency Pumps – Single-head pumps Wilo-Stratos ECO-ST S/M 304 Standard Pumps – Single-head pumps Wilo-Star-ST(SolarStar) S/M 314

Legend: Fields of application:

• Applicable

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

New in the program or series expansion or modification

Heating Air-conditioning/cooling sector

Potable water circulation Solar

High-efficiency pumps Wilo-Stratos and Wilo-Stratos ECO.

Up to 80 % power savings.*

Highly efficient.

The Wilo-Stratos-ECO is the world's first high-efficiency pump. And it is the reference

for the energy label. Allowing power savings of up to 80 %*, it set the standard for the

energy efficiency class A as early as in 2001. The Wilo-Stratos ECO offers this

state-of-the-art technology now also for one- and two-family homes.

Ingenious? We call it Pumpen Intelligenz.

3 Wilo Catalogue A1 - Circulating pumps in glandless design

Heating, Air-condition in g, C oolin g Potabl e wate r cir cul a tion S o la r th er mal Se rvi c e /Accessories , Syst ems Switchgears and Co ntrol Devi ce s Pump Mana ge ment Systems

General Notes and Abbreviations

4

Planning Guide

6

Heating, Air-conditioning, Cooling

Contents 36

Wilo-Stratos ECO, Stratos, Stratos-D Wilo-Star-E, TOP-E, TOP-ED Wilo-Smart

Wilo-Star-RS, AXL, TOP-RL Wilo-SE, TOP-S, TOP-D Wilo-RP, P

Wilo-Star-RSD, SD, SE-TW, DOP

Potable water circulation

Contents 245

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

Solar thermal

Service/Accessories

Systems

Wilo-TOP Motor Technology, circuit diagrams Switching plug, servicing apparatus

Threaded pipe unions, adapter fittings

Wilo thermal insulation shells, ClimaForm, Motor-Modules (MOT)

Contents Systems 343

Wilo-Safe-WS, DrainLift Con

Switchgears and Control Devices

Pump Management Systems Wilo-Control

Contents Switchgears and Control Devices 351

Wilo-S1.../S2.../S4, SK, SR, SD, AS, VR-HVAC, CRn, CR

Contents Pump Management Systems Wilo-Control 421

Wilo-IF-Moduls, IR-Monitor, Protect-Modul-C Wilo-Control AnaCon/DigiCon/DigiCon-A

Abbreviations and what they mean Abbreviation Meaning

1~ 1-phase alternating current

1/min Revolutions per minute (rpm)

3~ 3-phase alternating current

Autopilot Automatic adjustment of pump performance during setback phases, e.g. boiler setback mode overnight blsf Blocking current-proof, no motor protection

required

DM 3-phase AC motor

'p-c Control mode for constant differential pressure 'p-T Control mode for differential-pressure control as a

function of fluid temperature

'p-v Control mode for variable differential pressure 'T Control mode for differential temperature

EM 1-phase AC motor

EnEV German energy saving act (Energie-Einsparverordnung) ECM

technology

Electronically commutated motor with new wet rotor encapsulation, newly developed glandless drive con-cept for high-efficiency pumps

Ext. Aus Control input “Overriding Off”

Ext. Min Control input “Overriding Min”, e.g. for setback mode without autopilot

FI Residual-current device

GA Building automation

GRD Mechanical seal

GTW Special cast iron: white malleable cast iron

°d Degree of German water hardness, unit for assessing water hardness

H Delivery head

IF Interface

Inox Stainless steel

Int. MS Internal motor protection: Pumps with internal pro-tection against unacceptably high winding tempera-tures

IR Infrared interface

KDS Capacitor

KLF PTC thermistor sensor

KTL coating Cataphoretic painting: Paintwork with high adhesive strength for long-lasting corrosion protection KTW Authorisation for products with plastics, for

utilisa-tion in potable water applicautilisa-tions

LON Local operating network (open,

non-manufacturer-dependent, standardised data bus system in LONWORKS networks)

Abbreviation Meaning

MOT Motor module (drive motor + impeller + terminal box/electronics module) for replacement in the TOP .. Series

PLR Pump master computer, Wilo-specific data interface PT 100 Platinum temperature sensor with a resistance value

of 100 : at 0 °C

Q (= ) Flow volume

SBM Run signal or collective run signal SSM Fault signal or collective fault signal Control input

0 - 10 V

Analogue input for external activation of functions

Wilo-Control

Building automation management with pumps and accessories

TrinkwV 2001 German potable water ordinance of 2001 (valid from 01.01.2003)

VDI 2035 VDI guideline for the prevention of damage in hot-water heating installations

WRAS Water Regulations Advisory Scheme

WSK thermal winding contacts (in motor for monitoring winding temperature, full motor protection through additional tripping unit)

Operating mode of twin-head pumps:

Individual operation of the respective operating pump

+ Operating mode of twin-head pumps:

Parallel operation of both pumps No. of poles for the pumps: 2-pole

No. of poles for the pumps: 4-pole

No. of poles for the pumps: 6-pole

5 Wilo Catalogue A1 - Circulating pumps in glandless design

Heating, Air-condition in g, C oolin g Potabl e wate r cir cul a tion S o la r th er mal Se rvi c e /Accessories , Syst ems Sw itch gear s and C o ntrol De vic es P u mp Ma nag em en t S y st ems

Wear and tear

Pumps or parts of pumps are subject to wear in accordance with state-of-the-art technology (DIN 31051/DIN-EN 13306). This wear may vary depending on operating parameters (temperature, pressure, water conditions) and the installation/usage situation and may result in the malfunction or failure at different times of the aforementioned products/components, including their electrical/electronic circuitry. Wearing parts are all components subject to rotary or dynamic strain, including electronic components under tension, in particular: - seals/gaskets (including rotating mechanical seals), seal ring - bearings and shafts

- stuffing boxes - capacitors

- relays/contactors/switches

- electronic circuits, semiconductor components, etc. - impellers

- wearing rings/wearing plates

We do not accept liability for faults or defects arising from natural wear and tear.

Note

According to the German energy saving act EnEV, starting from

1.2.2002, boilers with outputs in excess of 25 kW must be equipped with either switchgear-equipped heating pumps for automatic per-formance control or electronically controlled pumps.

In accordance with TrinkwV 2001 and DIN 50930-6 only circulating

pumps with corrosion-resistant pump housings in stainless steel or red bronze (CC 491K) are to be used in potable water circulation systems.

Pump replacement

Please refer to the current Wilo heating pumps replacement guide for more detailed information on replacing heating pumps.

WILO – General Terms of Delivery and Service

The latest version of our General Terms of Delivery and Service can be found on the Internet at

Pump selection: General Notes

Circulating pumps should always be selected such that the specified duty point is located on or as near as possible to the point of max. efficiency (optimum capacity) of the max. speed H/Q pump curve.

Fig.: Pump curve

If the specified duty point is between two possible pump curves, it is always good practice to choose the smaller pump.

Fig.: Pump selection

The resulting flow volume reduction has no appreciable effect on the actual heating performance in heating systems. This applies to pumps for chilled water applications.

Pump selection: Potable water circulation systems Pump selection

- In order to ensure correct configuration of the potable water circula-tor, the pipeline system must be designed in accordance with both DIN 1988 and the DVGW Worksheets W 551 to W 553.

- The necessary flow volume should be based on the figures recom-mended in the standard and the DVGW guideline.

- If the hydraulic duty point lies between two pump curves, then the next-largest circulator pr speed stage is to be selected in accordance with DVGW Worksheet W 553.

- The thermal losses in the ascending and circulation pipelines for potable water are to be reduced to a minimum through the installa-tion of appropriate insulainstalla-tion.

Because most potable water circulation systems permit periodic stops of the circulating pump (generally at night), a time switch for automatic On/Off control should always be part of standard equip-ment.

The German EnEV requires periodic pump shutdown.

Legionellae blocking circuits in the heat generator and/or in the heat-ing control unit are to be observed and taken into account durheat-ing programming.

Maximum potable water temperature

In view of the hardness-forming particles contained in water, potable water circulation systems should not be operated at temperatures in excess of 65 °C.

This limit is required to avoid the formation of lime deposits.

Circulation pipe

A gravity brake should always be installed in order to exclude the possibility of incorrect circulation and for the prevention of gravity circulation when the pump is switched off.

Control systems for automatic time-sensitive On/Off switching: Wilo-SK switchgear 601 for Wilo-TOP-Z Series pumps

ll

Fig.: Wilo-SK switchgear 601

- Wall-mounted installation, protection class IP 31

- Direct connection for AC pumps (EM) without thermal winding con-tacts (WSK)

Not for three-phase pumps or for AC pumps with WSK except in con-junction with Wilo-SK 602 or contactor

- Time switch for On/Off daily programme with 15-minute switch interval

Special-design time switch with daily/weekly program and battery backup (120 hrs.), with digital display

Variable speed control

Experience shows that variable speed control is only required in cir-culating pumps in potable water circulation systems for basic adjust-ment of performance. Automatic speed control is not required. A time-sensitive On/Off control should however be provided for each installation.

Motor protection

Blocking current-proof pumps and pumps with internal protection against unacceptably high winding temperatures do not require motor protection. All other pumps contain integrated full motor pro-tection including trip electronics or are equipped with full motor protection (thermal winding contacts [WSK]) for utilisation in con-junction with the Wilo-SK 602/SK 622 tripping units.

max. (1 ) min. (3 )(2 )

Optimal flow rate

max. 1 max. 2 Pump A Duty point Flow rate Pump B

7 Wilo Catalogue A1 - Circulating pumps in glandless design

Heating, Air-condition in g, C oolin g Potabl e wate r cir cul a tion S o la r th er mal Se rvi c e /Accessories , Syst ems Sw itch gear s and C o ntrol De vic es P u mp Ma nag em en t S y st ems Pump-performance splitting General notes on twin-head pumps

- Two pump heads mounted in a common housing, hydraulically sepa-rated by a switchover valve

- Specific design features in accordance with single-head pump series - Replacement of an equal-performance single-head pump with

iden-tical installation dimensions

- Wide range of applications thanks to standard series 3-/4-speed control

Pump-performance splitting

Splitting the assigned max. design performance to a twin-head pump in parallel operation makes possible - particularly in the

heat-ing field - significantly improved adaptability to partial-load condi-tions and optimum economic efficiency.The average partial-load

pump performance required for a particular season, i.e. during 85% of the heating season, can be achieved through the operation of only one pump; the second pump is available for parallel operation on the

occasions that full-load requirements need to be met.

Advantages of splitting the performance output between two pumps:

- Reduced operating costs of between 50 % and 70 %

- Increased reliability thanks to the constant availability of a standby unit ready for operation

The individual pump duty charts for twin-head pumps featured in the relevant chapters specify the hydraulic performance values for both individual and parallel operation.

Operating modes for twin-head pumps

Twin-head pumps are suitable for operation in either of two dis-tinctly different modes:

- Main/Standby operation - Parallel operation

Rates of flow in pipes and pump

The rate of flow of the fluid through the pipe system is determined by the cross-section sizes in the pipeline network.

The values listed below should not be exceeded:

Rates of flow inside the pump [m/s] are shown on all individual Wilo pump curves in relation to flow performance.

Viscous fluids

All the pump curves contained in this catalogue apply to the pumping of water (kinematic viscosity = 1 mm2_{/s). The hydraulic} characteris-tics of both pump and pipe system will change when handling fluids with different densities and/or viscosities (e.g. water/glycol mix-tures)!

Documents for calculating the correction factors for pump selec-tion can be obtained from Wilo on request.

Correction factors applicable to the individual pipe system

(increased pressure loss, lower specific heat capacity) cannot be fur-nished by the pump manufacturer.They must be calculated by the planner in co-operation with the chemical additive suppliers and the makers of pipes, valves and fittings.

Minimum inlet pressure for the prevention of cavitation

To avoid cavitation (vapour bubble formation within the pump), it is necessary to maintain at the pump suction port a sufficiently high positive pressure (suction head) in relation to the vapour pressure of the fluid being handled.

The minimum suction heads are shown in respective tables for all glandless pumps. These guide values apply to heating systems with feed temperatures of up to 130°C that are installed at alti-tudes up to 300 m above seal level.

For higher altitudes: 0.1 m/100 m head increase.

These minimum heads must be respectively increased when handling fluids of higher temperatures or lower densities, with there is greater flow resistance on the pump suction side and in regions of lower atmospheric pressures.

Main/Standby operation (STANDBY)

Parallel operation (ADDITION)

No. I or No. II pump operating Both pumps operating The model-specific pump

perform-ance is provided by whichever one of the two pumps is acting as the main pump; the second pump remains on standby, ready for time- or fault-actuated switchovers.

The model-specific pump perform-ance will be provided by both pumps operating in parallel. One pump can be switched off during partial-load states.

Nominal connection diameter DN [ø mm] Rate of flow v [m/s] In building installations Up to Rp 11_/ 4 or DN 32 up to 1.2 DN 40 and DN 50 up to 1.5 DN 65 and DN 80 up to 1.8 DN 100 and greater up to 2.0

Notes on installation and operation Permissible ambient temperature: 0 °C to +40 °C Installation

Glandless pumps must be installed in dry, well-ventilated, frost-free spaces. They are not suitable for outdoor installation.

Condensation

All standard series pumps for cold-water operation that are intended for standard usage down to -10 °C/-20 °C are fully condensation-proof.

The grey cast iron pump housing that comes with the following series: - Stratos/Stratos-D - TOP-E/-ED - TOP-S/-SD - TOP-D - TOP-RL - P/RP (not RP 25/60-2) - DOP - AXL/SE/SE-TW

is provided with a special coating for surface finishing (KTL: cataphoretic painting).

The benefits provided by this coating are:

- optimum corrosion protection against condensation formation on the pump housings in cold-water installations

- very high scratch and impact resistance

To avoid condensation forming on Wilo-Top-E/-ED pumps, it is essential to ensure that the fluid temperature is equal to or greater than the ambient temperature at all times.

Intermittent operation The series - Stratos/Stratos-D - Star-RS/RSD - TOP-S/-SD - TOP-D - TOP-Z - TOP-RL - AXL/SE/SE-TW

can also be utilised for intermittent operation.

Operating pressure

The max. system pressure (operating pressure) and the flange ver-sions for the pumps are listed in the relevant tables. All flanges on glandless pumps (except Stratos, Stratos-Z, Stratos-D and Stratos-ZD) have pressure-measurement connections R1_e

8.

Connections Screw-end pumps

Screw-end pumps are equipped with connecting threads in accord-ance with DIN EN ISO 228 Part 1. Seals are included in the scope of delivery. Threaded pipe unions with threads in accordance with DIN 2999 must be ordered separately.

Flange-end pumps

The pump flanges are designed in accordance with DIN 2531 or DIN 2533 and/or in accordance with DIN EN 1092-2. Detailed infor-mation on the respective Data Sheets.

Combination flange pumps

Flange-ended pumps with combination flanges can be mounted with mating flanges PN 6 and PN 16 in accordance with DIN or DIN EN up to and including DN 65. Installation linking combination flanges to one another is not permissible. Bolts of tensile strength class 4.6 or higher must be used for the flanged connections. The washers supplied must be mounted between the bolt head and the combination flange. Recommended bolt lengths:

Motor

Glandless pump motors with protection class: - Wilo-Stratos Series IP 44

- Wilo-EasyStar Series IP 42 - Wilo-ClassicStar Series IP 44 - Wilo-TOP product range IP 44 - Other pump product rangeIP 42

- Insulation class F

- Emitted interference: EN 61000-6-3 - Immunity to interference: EN 61000-6-2

Electrical connection

- All Wilo pumps are designed to run on European standard voltage 230/400 V (±10 %) in accordance with DIN IEC 60038.

- As of 1.1.1995, all Wilo pumps are labelled with the CE mark in accordance with EU machinery directives.

- When pumps are utilised in installations with pumping media tem-peratures above 90°C, a corresponding heat-resistant connection line must be used.

Electronic performance control

Heating pumps are, due to their high annual operating hours, among the largest power-consuming appliances in buildings.

Automatic pump performance control helps drastically reduce power consumption in heating pumps. Reductions of up to 50% can be achieved. With high-efficiency pumps, it is possible to achieve power savings of up to 80% over standard pumps.

Automatic pump performance control will hydraulically optimise operations in all load conditions, particularly the partial-load periods so typical for heating systems.

A further significant effect connected with the prevention of a rise in pump pressure is the avoidance of flow noise in thermostatic valves. DIN 2999

(pipe thread sealed in thread)

DIN EN ISO 228/1 (sealing pipe thread with flat

gasket at the front) Female thread of pipe Rp 11_/

2 Female thread of pipe G 11/2

Thread Starting torque Minimum bolt length

DN 32/DN 40 DN 50/DN 65

Flanged connection PN 6

M12 40 Nm 55mm 60mm

Flanged connection PN 10

9 Wilo Catalogue A1 - Circulating pumps in glandless design

Heating, Air-condition in g, C oolin g Potabl e wate r cir cul a tion S o la r th er mal Se rvi c e /Accessories , Syst ems Sw itch gear s and C o ntrol De vic es P u mp Ma nag em en t S y st ems

German energy-saving ordinance EnEV

Within the framework of statutory measures for CO₂ reduction in connection with the power consumption of heating circulating pumps, the German legislature has established in the EnEV that cir-culating pumps fitted after 01 Feb. 2002 with nominal thermal out-put ratings starting at 25 kW must be configured in such a way that electrical power consumption is automatically adjusted in at least three stages to the delivery demands required by operation. Although EnEV prescribes the application of automatic pump per-formance controls starting with a nominal thermal output of 25 kW, by far the greater savings potential for power and CO2 can be found in single- and two-family houses, i.e. in systems that fall below the 25 kW minimum.

Pump performance control does not replace the need for correct dimensioning of the circulating pump! The pump performance installed must also be checked when the pump is replaced. Controlled pumps that are slightly overdimensioned do not pose any risk if they are correctly set to the nominal load requirement.

Standards/guidelines

- CE mark (all Wilo pumps) - Certification in accordance with:

- ISO 9001, - ISO 14001, - VDA 6.1

Pump curves

The pump curves apply to water at + 20°C and with a kinematic vis-cosity of 1 mm2_/s.

The pump curves take into account the standard European voltages of 230/400 V.

Pump control

When operating Wilo pumps with control units or module accesso-ries, it is essential to adhere to the electrical operating conditions as set out in VDE 0160.

When operating glandless and glanded pumps in conjunction with frequency-converter models not supplied by Wilo, it is necessary to use output filters to reduce motor noise and prevent harmful voltage peaks and to adhere to the following limit values:

- Glandless pumps with P₂d 1.3 kW and glanded pumps with P₂d 1.1 kW

Rate of voltage rise du/dt < 500 V/µs Voltage peaks û < 650 V

For noise reduction on glandless pump motors, it is recommended that sine filters (LC filters) be used rather than du/dt filters (RC filters).

- Glanded pumps with P2 > 1.1 kW Rate of voltage rise du/dt < 500 V/µs Voltage peaks û < 850 V

Installations with large cable lengths (l > 10 m) between converter and motor may cause increases of the du/dt and û levels (resonance). The same may happen for operation with more than 4 motor units at one voltage source.

The output filters must be selected as recommended by the con-verter manufacturer or filter supplier, respectively.

The pumps must be operated at a max. of 95 % of their rated motor speed if the frequency converter causes motor losses.

The following limit values at the pump connection terminals must not be undershot if TOP-S/-SD, TOP-D and TOP-Z Series glandless pumps are operated in conjunction with a frequency converter: U_min = 150 V

fmin = 30 Hz

Minimum flow volume

Larger pumps require a minimum flow volume to ensure trouble-free operation. Operation against closed gate valves, flow volume Q = 0, can lead to overheating inside the dry well and damage to the shaft seal.

- Constraints on pump operation when Q = 0: Permitted operating temperature 10 K less than Tmax - to P2 = 1 kW unproblematic

- starting with P2 > 1 kW continuous operation, a minimum flow volume of

Q = 10 % QNom is required

Further information in special cases on request.

Motor protection

Service life and operational reliability of a circulating pump depend to a great extent on the choice of the correct motor protection device. Motor protection switches are unsuitable for utilisation in conjunc-tion with multi-speed pumps due to their different nominal current ratings at different speed settings which require correspondingly dif-ferent fuse protection.

All circulating pumps are either - blocking current-proof

- provided with internal protection against unacceptably high winding temperatures

- provided with full motor protection in the form of thermal winding contacts (WSK) and a separate Wilo tripping unit (e.g. Wilo-SK 602/ SK 622)

- equipped with full motor protection and a fully integrated trip mechanism (Wilo-Stratos Series, Wilo-TOP Series, except TOP-D, see pump data).

No further motor protection by the customer is required except where this is stipulated for blocking current-proof motors and motors with internal protection against unacceptably high winding temperatures by the energy supply company.

Sound pressure level

The construction of the glandless pumps is the reason for their low-noise operation. Its air-borne low-noise values with measuring-surface sound pressure level Lp (A) [dB] depend on the motor power output and are determined under normal operating conditions.

Fig.: Sound pressure level of glandless pumps, determined in accordance with DIN EN ISO 3745

Heat insulation with heating applications

All Wilo-Stratos/Stratos-Z, Wilo-TOP-E/-S/-Z/-D and Stratos ECO single-head pumps are standard-equipped with thermal insulation shells for the prevention of thermal losses at the pump housing. Material: EPP, polypropylene foam

Thermal conductivity: 0.04 W/m K in accordance with DIN 52612 Flammability: Class B2 in accordance with DIN 4102; FMVSS 302 When insulating the pump on-site, care must be taken to cover the pump up to the top edge of the pump housing only (the motor must be left uncovered).

Thermal insulation for air-conditioning/cooling applications

If pumps from the following series: - Stratos, Stratos-D, Stratos-Z - TOP-S/-SD

- TOP-D - TOP-Z - TOP-RL - SE/SE-TW

are utilised in air-conditioning/cooling applications, no vapour-proof insulation is permitted to cover the drain labyrinth between the pump housing and the motor. This is to ensure that any condensate having possibly accumulated in the motor can drain off freely through the condensate drain openings in the motor housing.

The Wilo-ClimaForm vapour-proof insulation that is obtainable as an accessory for the Stratos, TOP-S, TOP-RL and SE series for insulating pump housings in cold water applications guarantees this automati-cally, thanks to its specific construction.

Wilo-ClimaForm:

- Water vapour diffusion resistance µ t 7000

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

Quality and safety marks

For pump types: Star-E 25/ ..., -E 30/ ..., Stratos ECO

Star-RS 25/ ..., -RS 30/ ...,

RSD 30/ ..., Star-Z 20/1, -Z 25/6, Star-ZE 25/ ..., Rp 25/60-2

Certificate of conformity/acceptance test certificate

Available upon request at additional charge for all glandless circulat-ing pumps of the series

- Stratos, Stratos-D, Stratos-Z - TOP-E/-ED - TOP-S/-SD - TOP-D - TOP-Z - TOP-RL - P/RP (not RP 25/60-2) - DOP - SE/SE-TW -Certificate of conformity 2.1

Contents: Certification that the product supplied conforms to the order, without details of test results.

-Certificate of conformity 2.2

Contents: Certification that the product supplied conforms to the order, with details of series test results.

-Acceptance test certificate 3.1B

Contents: Certification that the product supplied conforms to the order, with details of test results actually measured on the product. The required test procedure and scope must be specified with the order. 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 [dB]

11 Wilo Catalogue A1 - Circulating pumps in glandless design

Heating, Air-condition in g, C oolin g Potabl e wate r cir cul a tion S o la r th er mal Se rvi c e /Accessories , Syst ems Sw itch gear s and C o ntrol De vic es P u mp Ma nag em en t S y st ems

1) _{For installation positions for Wilo-Stratos/-Stratos-Z/-Stratos-D/-Stratos-ZD, refer to “Planning Guide High-Efficiency Pumps“} Non-standard versions

Pumps for other voltages or 60 Hz frequency possible on request (at additional charge).

Other materials and design versions (RG, PN 16) for pumps are listed in the pump tables.

The glandless circulating pump

With this design, all of the rotating components inside the canned motor run in the fluid being pumped. Shaft sealing by means of a stuffing box or mechanical seal as required with conventional pumps is not required. The pumped fluid lubricates the shaft bearings and cools the electric-motor components.

The electrical section of the pump motor (stator with winding) is separated from the encapsulated rotor compartment by means of an encapsulated motor cartridge (TOP-Wilo Series) or by a can sealed with O-rings.

Installation positions for glandless pumps1)

Installation positions not permitted

Permitted without limitation All energy-saving pumps,

stepless control

Permitted without limitation All standard and potable water circulators,

1-, 3- or 4-speed stages

Additional terminal box positions for single and twin-head pumps

Pump types Energy-saving pumps Star-E 20 (25, 30)

•

•

•

•

•

•

Standard and potable water circulators Star-RS, Star-Z

RP 25/60-2

•

•

•

•

Stratos ECO-Z

•

•

Star-RSD

•

•

•

•

Install pumps under voltage-free conditions. Valid for all operating conditions.

TOP-ED twin-head pumps can not be utilised for additional installation units because of the tilted alignment of the terminal boxes. If in doubt, please contact Wilo.

Impeller Winding Rotor Bearings Spacer can Pumping medium Hydraulic seal

Connection of Wilo-TOP... and -Stratos ... to Wilo switchgears present on-site

New pump type

Switchgear connection possible as per circuit diagram

Accessories: Modules Wilo-IF-Module AC Existing Wilo switchgear Wilo-TOP-S Wilo-TOP-Z Wilo-TOP-RL Wilo-SE Wilo-TOP-SD Wilo-SE-TW or 2 x Wilo-TOP-S 2 x Wilo-TOP-Z 2 x Wilo-TOP-RL 2 x Wilo-SE 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 1~ 3~ 1~ 3~ 1~ 3~ 1~ 1~ 1~ 1~ IS WSK SSM IS SSM IS WSK SSM IS SSM IS WSK IS WSK SK 601 A B C 1) _D1) _{A B G} 1) _D1) _{U W Y} 1) _{Z E E Yes Yes} SK 602/622 F G H I F G H I V X Y1 Z1 J J Yes Yes SK 632 – – K L – – K L – – K L – – Yes Yes S2R 0,2-1

Switchgear not suitable with pumps of the Wilo-TOP series. Alternatively use exchange motor for faulty pump.

S2R 2,5

S2R 3D – – – – M N o P – – – – – Q or R Yes Yes

S4R 2,5

Switchgear not suitable with Wilo-TOP series. Alternatively use exchange motor for faulty pump.

S4R 2.5D AS 08/1.5(µP) – S – T – – – – – – – – – – – – 2 Pcs. AS 08/1.5(µP) – – – – – S – T – – – – – – – – AS 08/1.5(µP) plus S2R 3D – – – – – N + S – P + T – – – – – – – – AR/DR/CR – – – T – – – T – – – – – – – –

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

– = Connection not possible,

1) _{Only in conjunction with contactor or Wilo-SK 602/622; SK602/622 also can be used as On/Off switch or contactor}

Circuit diagram A Mains 1~230 V/N/50 Hz Circuit diagram B Mains 1 ~230 V/N/50 Hz Circuit diagram C Mains 3 ~400 V/N/50 Hz 1) Wilo-TOP-S/-Z/-SD/-RL Wilo-SE/SE-TW 1) 3) Wilo-TOP-S/-Z/-SD 1) 3) Wilo-TOP-S/-Z/-SD

1) Automatic restart after power failure

2) After an overload fault trip of the pump (TOP or Stratos), confirm fault first at the pump, then at the switchgear 3) SK 622 additionally with terminals for collective operation and fault signals

Ensure correct grounding when replacing a three-phase pump (3~400 V) with an AC pump (1~230 V).

Consult your Wilo representative prior to installation of Wilo pumps in conjunction with non-listed Wilo switchgears or switchgears not supplied by Wilo.

For circuit diagrams for Wilo circulating pumps, refer to the “Service/Accessories” chapter or to the pump data. 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 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

13

Connection of Wilo-TOP... and -Stratos ... to Wilo switchgears present on-site

Wilo Catalogue A1 - Circulating pumps in glandless design

Heating, Air-condition in g, C oolin g Potabl e wate r cir cul a tion S o la r th er mal Se rvi c e /Accessories , Syst ems Sw itch gear s and C o ntrol De vic es P u mp Ma nag em en t S y st ems Circuit diagram D Mains 3 ~400 V/N/50 Hz Circuit diagram E Mains 1~230 V/N/50 Hz Circuit diagram F Mains 1~230 V/N/50 Hz 1) 2) 3) Wilo-TOP-S/-Z/-SD 1) Wilo-TOP-E/-ED Wilo-Stratos/-Z/-D/-ZD 1) Wilo-TOP-S/-Z/-SD/-RL Wilo-SE/SE-TW Circuit diagram G Mains 3~400 V/N/50 Hz Circuit diagram H Mains 3~400 V/N/50 Hz Circuit diagram I Mains 3~400 V/N/50 Hz

1) 3) Wilo-TOP-S/-Z/-SD 1) Wilo-TOP-S/-Z/-SD 1) 2) 3) Wilo-TOP-S/-Z/-SD

Circuit diagram J Mains 3~400 V/N/50 Hz or 1~230 V/N/50 Hz Circuit diagram K Mains 3~400 V/N/50 Hz Circuit diagram L Mains 3~400 V/N/50 Hz 1) 2) 3) Wilo-TOP-E/-ED Wilo-Stratos/-Z/-D/-ZD 1) Wilo-TOP-S/-Z/-SD 1) 2) Wilo-TOP-S/-Z/-SD

1) Automatic restart after power failure

2) After an overload fault trip of the pump (TOP or Stratos), confirm fault first at the pump, then at the switchgear 3) SK 622 additionally with terminals for collective operation and fault signals

Ensure correct grounding when replacing a three-phase pump (3~400 V) with an AC pump (1~230 V).

Consult your Wilo representative prior to installation of Wilo pumps in conjunction with non-listed Wilo switchgears or switchgears not supplied by Wilo.

For circuit diagrams for Wilo circulating pumps, refer to the “Service/Accessories” chapter or to the pump data. 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 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

Connection of Wilo-TOP... and -Stratos ... to Wilo switchgears present on-site

1) Automatic restart after power failure

2) After an overload fault trip of the pump (TOP or Stratos), confirm fault first at the pump, then at the switchgear 3) SK 622 additionally with terminals for collective operation and fault signals

Ensure correct grounding when replacing a three-phase pump (3~400 V) with an AC pump (1~230 V).

Consult your Wilo representative prior to installation of Wilo pumps in conjunction with non-listed Wilo switchgears or switchgears not supplied by Wilo.

For circuit diagrams for Wilo circulating pumps, refer to the “Service/Accessories” chapter or to the pump data. 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 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 L N 15 10 WSK AS 08 N N N L WSK/SSM PE PE L1 U L2 V L3 W PE L1 L2 L3 N 15 L3 L1 L3 SSM 10 WSK AS 08/1,5 AR/DR/CR N N SK 601 TOP-D N L1 PE PE PE L1 N N 2 U1 V1 W1 W2 U2 V2

15

Connection of Wilo-TOP... and -Stratos ... to Wilo switchgears present on-site

Wilo Catalogue A1 - Circulating pumps in glandless design

Heating, Air-condition in g, C oolin g Potabl e wate r cir cul a tion S o la r th er mal Se rvi c e /Accessories , Syst ems Sw itch gear s and C o ntrol De vic es P u mp Ma nag em en t S y st ems

1) Automatic restart after power failure

2) After an overload fault trip of the pump (TOP or Stratos), confirm fault first at the pump, then at the switchgear 3) SK 622 additionally with terminals for collective operation and fault signals

Ensure correct grounding when replacing a three-phase pump (3~400 V) with an AC pump (1~230 V).

Consult your Wilo representative prior to installation of Wilo pumps in conjunction with non-listed Wilo switchgears or switchgears not supplied by Wilo.

For circuit diagrams for Wilo circulating pumps, refer to the “Service/Accessories” chapter or to the pump data. Circuit diagram V Mains 1~230 V/N/50 Hz Circuit diagram W Mains 1~230 V/N/50 Hz Circuit diagram X Mains 1~230 V/N/50 Hz 1) 1) 3) 1) 3) Circuit diagram Y Mains 3~400 V/N/50 Hz Circuit diagram Y1 Mains 3~400 V/N/50 Hz Circuit diagram Z Mains 3~400 V/N/50 Hz 1) 3) 1) 1) 3) Circuit diagram Z1 Mains 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 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

Nameplate designation for Wilo-Stratos Series

Standard version

Series abbreviations for Wilo-Stratos products Type: Wilo-... Design Stratos Stratos-D Stratos-Z Stratos-ZD High-efficiency pumps stepless speed control: Individual pump Twin-head pump

Individual pump for potable water circulation systems Twin-head pump for pota-ble water circulation systems

Nameplate designation for Wilo-TOP-Programme series

Standard version

Series abbreviations for Wilo-TOP products

Type: Wilo-... Design TOP-E TOP-ED Energy-saving pumps, stepless speed control: Single-head pump Twin-head pump TOP-S/-RL, SE TOP-SD, SE-TW Standard pumps 2 or 3 speed stages: Single-head pump Twin-head pump TOP-D Standard pumps 1 speed stage: Single-head pump TOP-Z

Circulating pumps for potable water circulation systems 3 speed stages: Single-head pump Typ Stratos 40/1-8 Art.-No.2030570/0601 1~230 V 50 Hz Class F IP 44 PN 6/10 Tmax.110°C SW 3.06 Made by WILO WILO AG Nortkirchenstr.100 44263 Dortmund Germany S/N70000100008

310

1,37

18

0,17

PN = nominal pressure d. Pump Tmax = max. fluid temperature SW = Software Version Voltage

Frequency

Maximum power consumption Maximum current I

Series/Pump type

Art. No./Date of Manufacture 06 01 Month Year Sequential numbering Typ TOP-E50/1-6 Art.-No.-2039649/0601 1~230 V 50 Hz SW 4.00 Made by WILO

WILO AG Nortkirchenstr.100 44263 Dortmund Germany

Class F IP 43 S/N20000100004 PN 6/10 Tmax 110°C 390 1,70 70 0,35 Insulation class Protection class IP PN = nominal pressure of the pump max. fluids temperature Tmax Voltage Frequency Three-phase current 3~400V or 3~230V with switching plug 230V SW = Software Version Maximum current I Maximum power consumption Series/Pump type

Art. No./Date of Manufacture 06 01 Month Year Sequential numbering

17 Wilo Catalogue A1 - Circulating pumps in glandless design

Heating, Air-condition in g, C oolin g Potabl e wate r cir cul a tion S o la r th er mal Se rvi c e /Accessories , Syst ems Sw itch gear s and C o ntrol De vic es P u mp Ma nag em en t S y st ems Non-standard versions

Several pumps can be supplied in the following non-standard versions at additional charge, if desired (the type of the special version is marked on the name plate):

-PN 10 Maximum permitted pump operating pressure

-RG Red bronze version

Example:

Star-RS 25/4 RG = Star-RS 25/4 with red-bronze housing

Nameplate designation Wilo-Star, Wilo-Stratos ECO

Standard version

Series abbreviations for Wilo-Star and Wilo-Stratos ECO products.

Type: Wilo-...

Design

Star-E

Energy-saving pumps Stepless speed control: Single-head pump Star-RS Star-RSD Star-RSL Standard pumps 3 speed stages: Single-head pump Twin-head pump Venting pump

Potable water circulators:

Star-Z Single-head pumps,

1 or 3 speed stages

Stratos ECO Individual pump in high-effi-ciency design

Stratos ECO-Z

Individual pump in high-effi-ciency design for potable water circulation systems Art.-No. Star-RS 25/4 4032954/0503 1 ~ 230 V 50 Hz 27-68 W Imax 0,28 A PN 10 TF 110 IP 44 WILO AG Nortkirchenstr.100 44263 Dortmund Germany Voltage Frequency Power consumption Maximum current I Pressure stage PN

Maximum fluid temperature Tmax Protection class

Series/Pump type

Art. No./Date of Manufacture 05 03

Month

Type key High-efficiency pumps Example: Wilo-Stratos 30/1-12 Energy-saving pumps Example: Wilo-Star-E 25/1-5 SSM, Wilo-TOP-E 50/1-6

Standard pumps, max. 2800 1/min

Example: Wilo-Star-RS 25/6 Wilo-TOP-S 50/4

Standard pumps, max. 1400/1 min

Example: Wilo-RP 25/80 r,

Wilo-TOP-D 40

Stratos Screw-end or flange-end pump stepless

elec-tronic control

Stratos-D Flange twin-head pump stepless

elec-tronic control

Stratos-Z Screw-end or flange-end pump for

potable water circulation systems

stepless elec-tronic control

Stratos-ZD

Flange twin-head pump for potable water circulation systems

stepless elec-tronic control

Stratos ECO

Screw-end pump in Economy ver-sion, specially for

1-6-family houses

stepless elec-tronic control

Stratos ECO-Z

Screw-end pump in Economy ver-sion for potable water circulation systems

30/ Nominal connection diameter

1-12 Nominal delivery head range (m)

BMS Version with Building Management

System

ST

Version with special hydraulics for utilisation in solar thermal installa-tions

L Venting pump

Star-E Screw-end pump stepless

elec-tronic control

Star-EP Screw-end pump with RG housing

for floor heating

stepless elec-tronic control

Star-EL Screw-end pump with connection

for automatic ventilation

stepless elec-tronic control

Star-ZE Screw-end pump for potable water

circulation systems

stepless elec-tronic control

TOP-E Screw-end or flange-end pump stepless

elec-tronic control

TOP-ED

Flange twin-head pump stepless

electronic control

50/ Nominal connection diameter

1-6 Nominal delivery head range (m)

SSM Version with collective fault signal

Star-RS

Screw-end pump 3 speed stages,

manually reversi-ble

Star-RSD

Screw-end twin-head pump 3 speed stages,

manually reversi-ble

Star-Z

Screw-end pump for potable water circulation systems

1/3Speed stages, manually reversi-ble

Star ST

Screw-end pump for solar thermal 3 speed stages, manually reversi-ble

Star-AC

Screw-end pump for air-condition-ing/cooling

3 speed stages, manually reversi-ble

TOP-S

Screw-end or flange-end pump 2 or 3 speed stages, manually reversible

TOP-RL SE

Screw-end or flange-end pump 3 speed stages, manually reversi-ble

TOP-Z

Screw-end or flange-end pump for potable water circulation systems

3 speed stages, manually reversi-ble

TOP-SD

Flange twin-head pump 2 or 3 speed

stages, manually reversible

SE-TW

Flange twin-head pump 3 speed stages,

manually reversi-ble

25/ Nominal connection diameter

6 Nominal delivery head (m) at

Q = 0 m3_/h

EM Version with single-phase AC motor

DM Version with three-phase AC motor

L Venting pump RP Screw-end pump 3_/ 4Speed stages, manually reversi-ble P

Flange-end pump 4 speed stages,

manually reversi-ble

TOP-D Screw-end or flange-end pump 1 speed stage

DOP

Flange twin-head pump 4 speed stages,

manually reversi-ble

25 Nominal connection diameter

/80 Nominal impeller diameter

19 Wilo Catalogue A1 - Circulating pumps in glandless design

Heating, Air-condition in g, C oolin g Potabl e wate r cir cul a tion S o la r th er mal Se rvi c e /Accessories , Syst ems Sw itch gear s and C o ntrol De vic es P u mp Ma nag em en t S y st ems

Energy efficiency classification

Within the framework of the Kyoto Convention, European govern-ments in particular are pursuing the goal of drastically reducing CO2 emissions. Energy-specific designations, particularly for high-con-sumption household devices such as washing machines and refriger-ators, is prescribed as an important control element for providing the end consumer with an aid for making decisions in favour of energy-saving appliances.

Because of the fact that heating circulating pumps are numbered among the biggest energy consumers in household use because of their long running times, leading European heating pump manufac-turers have voluntarily declared their intention of henceforth attach-ing energy consumption labels to their heatattach-ing pumps. This makes it possible for users and end consumers to recognise, on the basis of an already familiar classification system, to recognise whether a heating circulating pump being utilised is especially energy-efficient. The energy efficiency classification of heating pumps is carried out through the application of a measurement technology procedure that provides the Energy Efficiency Index (EEI). The smaller the EEI, the less electrical energy the pump consumes and the better the energy classification.

Tab.: Breakdown of the Energy Efficiency Index into 7 different Energy Classes The following tables identify the associated Energy Class for all of the heating pumps to be labelled, which can be seen to be incorporated into the energy label on the packaging. In accordance with the letter-ing system familiar from household appliances, A is the best possible and G is the worst possible of the Energy Classes.

When comparing hydraulically similar pumps with different Energy Classes, it should be recognised that adjacent Energy Classes differ by approximately 22 percentage points in energy expenditure. A pump of Energy Class A requires accordingly on average only around 33% of the electrical energy used by a Class D pump.

Even though the energy requirements of a Class A pump are them-selves very high, high-efficiency Energy Class A pumps are neverthe-less available for the entire performance spectrum ranging from single-family houses to large buildings.

Fig.: Comparison of the energy consumptions of pumps with the same hydraulic output

Fig.: Energy label for heating circulating pumps, Example: Energy Class A

Energy Class Energy Efficiency Index

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

EEI Classification – Single-head pumps/ twin-head pumps (area of application: single- and two-family houses) Nominal diameter Wilo-Stratos ECO... EEI Class Wilo-Star-E... (EasyStar) EEI Class Wilo-Smart... EEI Class Wilo-Star-RS... (ClassicStar) EEI Class Wilo-Star-RSD... (ClassicStar) EEI Class DN 15 (Rp ½) – – 15/1-3 – – – 15/4 B – – – – 15/1-5 – – – 15/6 C – – DN 25 (Rp 1) 25/1-3 A 25/1-3 B 25/4 B 25/2 C – – 25/1-5 A 25/1-5 B 25/6 B 25/4 B – – – – – – – – 25/6 C – – DN 30 (Rp 1 ¼) 30/1-3 A 30/1-3 B 30/4 B 30/2 C 30/4 D 30/1-5 A 30/1-5 B 30/6 B 30/4 B 30/6 D

EEI Classification – Single-head pumps (area of application: multifamily houses, commercial applications)

Nominal diameter Wilo-Stratos... EEI

Class Wilo-TOP-E... EEI Class Wilo-TOP-S... EEI Class Wilo-RP/P... EEI Class DN 25 (Rp 1) 25/1-6 A 25/1-7 C 25/5 EM/DM D/D RP 25/80 r EM/DM G/G

25/1-8 A – – 25/7 EM/DM D/D RP 25/100 r EM/DM F/E

– – – – 25/10 EM/DM D/D – – DN 30 (Rp 1 ¼) 30/1-6 A 30/1-7 C 30/4 EM/DM D/D RP 30/80 r EM/DM G/F 30/1-8 A 30/1-10 C 30/5 EM/DM D/D RP 30/100 r EM/DM F/F 30/1-12 A – – 30/7 EM/DM D/D – – – – – 30/10 EM/DM D/D – – DN 32 32/1-12 A – – – – – – DN 40 40/1-4 A 40/1-4 C 40/4 EM/DM D/D P 40/100 r EM/DM F/D 40/1-8 A 40/1-10 B 40/7 EM/DM D/C P 40/160 r E 40/1-12 A – – 40/10 EM/DM D/C – – – – – – 40/15 EM/DM D/D – – DN 50 50/1-8 A 50/1-6 C 50/4EM/DM D/D P 50/125 r D 50/1-9 A 50/1-7 B 50/7EM/DM E/D P 50/160 r E 50/1-12 A 50/1-10 B 50/10 EM/DM D/C P 50/250 r E – – – – 50/15 C – – DN 65 65/1-9 A 65/1-10 B 65/7 EM/DM F/D P 65/125 r D 65/1-12 A – – 65/10 EM/DM F/D P 65/160 r D – – – – 65/13 C P 65/250 r E – – – – 65/15 C – – DN 80 80/1-12 A 80/1-10 B 80/7 EM/DM F/D P 80/125 r D – – – – 80/10 D P 80/160 r C – – – – – – P 80/250 r E DN 100 100/1-12 A 100/1-10 B 100/10 D P 100/160 r E – – – – – – P 100/200 r E

21 Wilo Catalogue A1 - Circulating pumps in glandless design

Heating, Air-condition in g, C oolin g Potabl e wate r cir cul a tion S o la r th er mal Se rvi c e /Accessories , Syst ems Sw itch gear s and C o ntrol De vic es P u mp Ma nag em en t S y st ems

EEI Classification – Single-head pumps (range of applications: multifamily houses, commercial applications) (Continued)

Nominal diameter Wilo-TOP-D... EEI Class Wilo-TOP-RL... EEI Class Wilo-AXL... EEI Class Wilo-SE... EEI Class

DN 25 (Rp 1) – – 25/7.5 E 80-25-130 D 125-N D DN 30 (Rp 1 ¼) 30 EM/DM G/F 30/4 D – – 110-N D – – 30/6.5 E – – – – – – 30/7.5 E – – – – DN 32 – – – – – – – – – – – – – – – – DN 40 40 EM/DM E/E 40/4 D 150-N D – – – – – – 200-N D DN 50 50 EM/DM E/E – – – – – – – – – – – – – DN 65 65 EM/DM E/E – – – – – – DN 80 80 EM/DM E/E – – – – – – DN 100 100 EM/DM E/E – – – – – – DN 125 125 D – – – – – –

EEI Classification – Twin-head pumps (area of application: multifamily houses, commercial applications)

Nominal diameter

Wilo-Stratos-D.... EEI Class Wilo-TOP-ED... EEI Class Wilo-TOP-SD... EEI Class Wilo-DOP... EEI Class Wilo-SE-TW... EEI Class DN 25 (Rp 1) – – – – – – – – – – DN 30 (Rp 1 ¼) – – – – 30/5 EM/DM D/D – – 125-N-TW D DN 32 32/1-8 A 32/1-7 C 32/7 EM/DM E/D – – – – 32/1-12 A – – – – – – – – DN 40

40/1-8 A 40/1-7 C 40/3 EM/DM E/D 40/100 r EM/DM F/E 150-N-TW E

40/1-12 A 40/1-10 B 40/7 EM/DM D/D 40/160 r F 200-N-TW E – – – – 40/10 EM/DM E/C – – – – – – – – 40/15 EM/DM E/D – – – – DN 50 50/1-8 A 50/1-6 C 50/7 EM/DM F/C DOP 50/100 r D – – 50/1-12 A 50/1-7 B 50/10 EM/DM E/D 50/160 r E – – – 50/1-10 C 50/15 D – – – DN 65 65/1-12 A 65/1-10 B 65/10 EM/DM F/D 65/125 r D – – – – – – 65/13 D 65/160 r D – – – – – – 65/15 D – – – – DN 80 80/1-12 A 80/1-10 B 80/7 EM F 80/125 r D – – – – – – 80/10 D 80/160 r E – – DN 100 – – – – – – 100/160 r D – – DN 125 – – – – – – – – – –

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

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

Wilo-Stratos is the first high-efficiency pump of glandless design world-wide to feature the following advantages:

- up to 80 % energy savings compared to standard pumps

- for all heating, air-conditioning and cooling systems in the tempera-ture range of -10 °C to +110 °C

- automatic adjustment of pump performance to the continually changing hydraulic system load conditions

- preventing flow noise

- reliability and comfort during installation and operation

Fields Of application

The Wilo-Stratos series features high-efficiency pumps used in cir-culation systems for the heating, ventilating, air conditioning of commercial residential and functional buildings:

- Large residential buildings - Apartment blocks - Residential complexes - Hospitals

- Schools

- Administrative office buildings - Real-estate developments

Temperature range

Fluid temperature range of -10 °C to +110 °C without restrictions at ambient temperatures of 0 °C to a max. of + 40 °C.

Heating application

In nearly all circulation systems, correctly sized controlled glandless pumps ensure adequate heat supply at all times at significantly reduced energy costs, while at the same time preventing noise gen-eration.

Since the introduction of the German energy-saving ordinance (EnEV) of 01.01.2002, heating circulating pumps with nominal thermal outputs of 25 kW or more are required to include control units.

On account of its corrosion-resistant red bronze pump housing, Wilo-Stratos-Z are particularly suitable for systems subject to the possible ingress of oxygen, such as e.g. floor heating systems made of plastic piping.

Thermal insulation for heating

In order to prevent thermal losses through the pump housing, Wilo-Stratos/-Stratos-Z series single-head pumps are standard-equipped with thermal insulation shells. The PP material used, foamed polypro-pylene, has the following properties:

- Environmental compatibility: easily recyclable - Heat resistance: up to 120 °C

- Transmission coefficient: 0.04 W/mK according to DIN 52612 - Flammability: Class B2 4102in accordance with DIN (normal

flamma-bility)

In Germany, normally flammable materials can, in accordance with fire protection regulations, be used in boiler rooms as long as a mini-mum distance of 20 cm from the burner is maintained.

Air-conditioning/cooling application

Wilo-Stratos pumps are not subject to the usual restrictions on con-ventional speed-controlled pumps regarding the dependency of fluid temperature on ambient temperature.

Condensation takes place on cold surfaces if the fluid temperature is lower than the ambient air temperature. Wilo-Stratos pumps can nonetheless be used in such cases. They are constructed in such a way that damage to electrical parts caused by condensation water is prevented.

1 drain labyrinth for condensation water

Thermal insulation for air-conditioning/cooling

If vapour-proof insulation is installed on-site, care must be taken that the drain labyrinth between pump housing and motor is left free to ensure that any condensate having possibly accumulated in the motor can drain off freely through the condensate drain openings in the motor housing.

The Wilo-ClimaForm vapour-proof insulation that is obtainable as an accessory for the Wilo-Stratos series for insulating pump housings in cold water applications guarantees this automatically, thanks to its specific construction.

Corrosion-proof pump design

Corrosion-proof designs are required for e.g. radiant cooling or heat-ing ceilheat-ing panels. For these applications, the pump housheat-ing is coated. Alternatively, the Wilo-Stratos-Z can be used as the ultimate design with a corrosion-resistant red bronze pump housing.

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

Wilo Catalogue A1 - Circulating pumps in glandless design

Heating, Air-condition in g, C oolin g Potabl e wate r cir cul a tion S o la r th er mal Se rvi c e /Accessories , Syst ems Sw itch gear s and C o ntrol De vic es P u mp Ma nag em en t S y st ems

Utilisation of potable water circulation (Wilo-Stratos-Z/Stratos-ZD)

Pumps used in potable water circulation systems are subject to specific requirements which are satisfied by the Wilo-Stratos-Z/ Stratos-ZD series:

- The fluids involved are potable water and water for food businesses in accordance with the TrinkwV 2001 (German Potable Water Ordi-nance). The design of the pumps take into account calcification in such a way as to permit total carbonate hardness of 20°d at a max. fluid temperature of +80 °C.

- All plastic parts that come into contact with the conveyed media conform to the KTW recommendations.

- The differential-pressure control modes 'p-c and 'p-v allow auto-matic adjustment of pump performance in variable volumetric-flow potable water circulation systems with thermostatically controlled line shutoff valves.

- The manual control mode allows optimum manual adjustment of pump performance to the constant volumetric-flow circulation sys-tem. This can be performed for example with the Wilo-IR-Monitor. The criterion for this is the temperature of the potable water in the circulation pipe which upon entry into the potable water accumulator is permitted to be a max. of 5 K below the accumulator temperature

High-Efficiency Pumps

The pump overall efficiency is determined by the hydraulic and motor efficiencies. Both components have been doubled in the Wilo-Stratos in comparison with the glandless pump previously used in building engineering and thus significantly improved.

The applied ECM technology drastically reduces the annual power consumption, achieving significant cost savings in comparison to conventional pumps.

ECM technology

The new ECM technology is the basis for the outstanding efficiency of the Wilo-Stratos. It consists of:

EC motor

EC stands for electronically commutated motor. Its basis is a syn-chronous motor with a permanent magnet rotor. The rotating stator flux is generated by electronic commutation, meaning that the stator windings are specifically activated for the reciprocal action of the electrical and magnetic poles.

Advantage: The magnetic field required in the rotor does not first have to be generated with losses.

Advantage: Particularly in the partial-load range (up to 98% of the operating time), the difference in efficiency in compari-son with an asynchronous motor will be even greater than it already is anyway in the full-load range. Advantage: This motor can be operated at higher speeds than with

an asynchronous motor. This leads to a reduction in size and weight of the pump with comparable hydraulics.

Wet rotor encapsulation

The rotor of the glandless pump motor runs in the pumping medium. This fluid serves to lubricate the bearings and cool the motor. The current-carrying stator is separated from the pumping medium by a can, this being known as the wet rotor encapsulation. This wet rotor encapsulation directly influences efficiency - through the size of the necessary gap between stator and rotor, - through the magnetic resistance of the selected can material. - In this respect the efficiency improvement on the Wilo-Stratos

results from:

- reduction of the air gap and

- utilisation of an innovative can material with smaller losses to the magnetic flux between stator and rotor.

Hydraulic optimisation

Optimised hydraulic conditions are provided by a 3D spiral housing, an 3D impeller and a smooth surface in the pump housing (cata-phoretic painting).

The suction throat seal between impeller and pump housing reduces radial gap losses. Axial losses are reduced by the lip seal at the front of the impeller. Planning Guide High-Efficiency Pumps Wilo-Stratos/ Stratos- Z/Stra-tos-D/ Stratos-ZD

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

Wilo-Stratos with EC motor Wilo-TOP-E with AC motor