Biral ModulA RED Series User manual

ModulA …RED, ModulA-D …RED, ModulA …BLUE
40-10 220, 40-12 250, 40-18 250, 50-6 240, 50-12 270, 50-18 270
65-8 270, 65-12 340, 65-15 340, 80-8 360, 80-12 360, 100-12 450
More than pumps
Installation and Operating Instructions, page 5
Instrucciones de instalacion y funcionamiento, página 31
Instrucţiuni de montaj şi exploatare, pagina 57

2
Declaración de conformidad ES
Nosotros Biral AG declaramos bajo nuestra única
responsabilidad que los productos
ModulA … RED
ModulA D … RED
ModulA … BLUE
a los cuales se refiere esta declaración
son conformes con las Directivas del Consejo
relativas a la aproximación de las legislaciones
de los Estados Miembros de la CE sobre
– Máquinas (2006/42/CE)
Norma: EN 12100-1: 20101
– Material eléctrico destinado a utilizarse
con determinadas límites de tensión (2006/95/CE)
Normas: EN 60335-1:2002, EN 60335-2-51:2003
– Compatibilidad electromagnética (2004/108/CE)
Normas: EN 61000-6-2:2005, EN 61000-6-3:2007
– Unicamente a las circuladoras marcadas con el EEI.
(Véase la placa de caracteristicas.):
Diseno ecológico (2009/125/EC)
Bombas circuladoras:
Reglamento de la Comisión no 641/2009
Normas: EN 16297-1, EN16297-2
Declaration of Conformity EN
We Biral AG declare under our sole responsibility
that the products
ModulA … RED
ModulA D … RED
ModulA … BLUE
to which this declaration relates, are in conformity
with the Council Directives on the approximation
of the laws of the EC Member States relating to:
– Machinery (2006/42/EC)
Standard: 12100-1: 2010
– Electrical equipment designed for use
within certain voltage limits (2006/95/EC)
Standards: EN 60335-1:2002, EN 60335-2-51:2003
– Electromagnetic compatibility (2004/108/EC)
Standards: EN 61000-6-2:2005, EN 61000-6-3:2007
– Only for types marked with the EEI.
(See the pump nameplate):
Ecodesign (2009/125/EC)
Circulator Pumps
Commission Regulation No 641/2009
Standards: EN 16297-1:2012, EN16297-2:2012
Biral AG, Südstrasse 10, CH-3110 Münsingen
Phone: [phone], Fax [phone]
Mail: [email protected], www.biral.ch
Münsingen, 1st April 2013
Peter Gyger
Technical Director
Person authorised to compile technical file
and empowered to sign the EC declaration of conformity.
Declaraţie de conformitate RO
Noi, Biral AG, declarăm pe proprie răspundere
că produsele
ModulA … RED
ModulA D … RED
ModulA … BLUE
la care se referă această declaraţie corespund
cu următoarele Directive ale Consiliului
pentru armonizarea prevederilor legale
ale statelor membre CE:
– Mașini (2006/42/CE) Norma: EN 12100-1:2011
– Echipamente electrice pentru utilizarea în cadrul
anumitor limite de tensiune (2006/95/CE) Normele:
EN 60335-1:2002, EN 60335-2-51:2003
– Compatibilitatea electromagnetică (2004/108/CE)
Normele: EN 61000-6-2, EN 61000-6-3
– Directiva Ecodesign (2009/125/CE)
Pompe de recirculare:
Decretul Comisiei Europene Nr. 641/2009 Normele:
EN 16297-1:2012, EN 16297-2:2012
(se aplică numai modelelor marcate cu EEI.
EEI se referă la indicele de eficienţă energetică,
vezi plăcuţa companiei)

40-10 220 40-12 250 40-18 250 50-6 240 50-12 270 50-18 270 65-8 270 65-12 340 65-15 340
PN 6-16 PN 6-16 PN 6-16 PN 6-16 PN 6-16 PN 6-16 PN 6-16 PN 6-16 PN 6-16
DN 40 40 40 50 50 50 65 65 65
L1 220 250 250 240 270 270 270 340 340
B1 147.5 153.8 153.8 160.4 166.9 166.9 183.6 184 184
B2 72.3 72.3 72.3 72.1 74.4 74.4 81.6 82 82
B3 163.5 163.5 163.5 163.5 163.5 163.5 163.5 163.5 163.5
B4 105 105 105 105 105 105 120 120 120
D150 150 150 165 165 165 185 185 185
k1 (PN 6) 100 100 100 110 110 110 130 130 130
k2 (PN10/16) 110 110 110 125 125 125 145 145 145
d1 4×14/19 4×14/19 4×14/19 4×14/19 4×14/19 4×14/19 4×14/19 4×14/19 4×14/19
T1 368.4 368.4 368.4 373.5 375 375 391.5 384.9 384.9
T2 59 62 62 64 64 64 62.1 68.7 68.7
T3 303.4 303.4 303.4 303 303 303 317.5 310.9 310.9
T4 86 86 86 97 97 97 90 96 96
3
Dimensions
Dimension
Dimensiuni
Series
Series
Seria
kg 16.3 16.1 16.1 17.6 18.1 18.8 20.6 21.5 24
B3B2
B1
133
B4
1L
T3T2
T1
T4
961564_00
k1
k2
D
d1
DN
ModulA … RED
ModulA … BLUE
80-8 360 80-8 360 80-12 360 80-12 360 100-12 450 100-12 450
PN 6 PN 16 PN 6 PN 16 PN 6 PN 16
DN 80 80 80 80 100 100
L1 360 360 360 360 450 450
B1 219.6 219.6 219.6 219.6 223.2 223.2
B2 97 97 97 97 98.4 98.4
B3 163.5 163.5 163.5 163.5 163.5 163.5
B4 126 126 126 126 126 126
D200 200 200 200 220 220
k1 (PN 6) 150 – 150 – 170 –
k2 (PN10/16) – 160 – 160 – 180
d1 4×19 8×19 4×19 8×19 4×19 8×19
T1 411.9 411.9 411.9 411.9 432.2 432.2
T2 82.7 82.7 82.7 82.7 80.6 80.6
T3 317.9 317.9 317.9 317.9 330.2 330.2
T4 108.6 108.6 108.6 108.6 113.4 113.4
kg 29.1 29.1 29.1 29.1 34.0 34.0

40-12 250 40-18 250 50-6 240 50-12 270 50-18 270 65-8 340 65-12 340 65-15 340
PN6-16 PN6-16 PN6-16 PN6-16 PN6-16 PN6-16 PN6-16 PN6-16
DN 40 40 50 50 50 65 65 65
L1 250 250 240 270 270 340 340 340
B1 512 512 515 517 517 522 522 522
B2 88 88 91 93 93 98 98 98
B3 130 130 130 130 130 130 130 130
B4 164 164 164 164 164 164 164 164
D150 150 165 165 165 185 185 185
k1 (PN 6) 100 100 110 110 110 130 130 130
k2 (PN10/16) 110 110 125 125 125 145 145 145
d1 4×14/19 4×14/19 4×14/19 4×14/19 4×14/19 4×14/19 4×14/19 4×14/19
L2 115 115 125 120 120 140 140 140
L3 133 133 133 133 133 133 133 133
T1 376 376 383 381 381 391 391 391
T2 65 65 71 72 72 74 74 74
T3 304 304 303 303 303 311 311 311
4
Dimensions
Dimension
Dimensiuni
Series
Series
Seria
kg 32 32 35 36 36 42 42 48
B3 B4B3
L3
B2
B1
L2
T3T2
T1
L1
961559_00
k1
k2
D
d1
DN
ModulA-D… RED
80-8 360 80-8 360 80-12 360 80-12 360 100-12 450 100-12 450
PN6 PN10/16 PN6 PN10/16 PN6 PN10/16
DN 80 80 80 80 100 100
L1 360 360 360 360 450 450
B1 538 538 538 538 546 546
B2 114 114 114 114 122 122
B3 130 130 130 130 135 135
B4 164 164 164 164 164 164
D200 200 200 200 220 220
k1 (PN 6) 150 – 150 – 170 –
k2 (PN10/16) – 160 – 160 – 180
d1 4×19 8×19 4×19 8×19 4×19 8×19
L2 160 160 160 160 190 190
L3 133 133 133 133 133 133
T1 418 418 418 418 436 436
T2 94 94 94 94 99 99
T3 318 318 318 318 330 330
kg 58 58 58 58 68 68

5
Contents
1. Safety information Page 7
1.1 General remarks 7
1.2 Identification of notices 7
1.3 Staff qualification and training 7
1.4 Risk in the event of non-compliance
with the safety information 7
1.5 Safety-conscious work 8
1.6
Safety information for the operator/operating personnel 8
1.7 Safety information for installation,
maintenance and inspection works 8
1.8 Unauthorised reconstruction and production of spares 8
1.9 Improper operating methods 8
2. Symbols used 9
3. General information 10
3.1 Purpose 10
3.2 Requirements of the delivery medium 10
3.3 Operating conditions 11
3.4 Non-return valve 12
3.5 Protection from the effects of frost 12
3.6 Heat insulation 12
3.7 Flow direction 12
4. Installation 13
4.1 General notes 13
4.2 Permissible installation positions 13
4.3 Changing the installation position of the frequency 14
4.3.1 Rotate the pump head 15
4.4 Install the pump in the unit 16
5. Electrical connection 18
5.1 Supply voltage 18
5.2 Connection of the power supply 19
5.3 Connection drawing 20
5.4 SWITCH settings 21
5.5 Power limit 21
6. Start-up 22
6.1 General 22
6.2 Operational control 22
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7. Settings Page 23
7.1 Control panel 23
7.2 Types of control (A1) 24
7.3 Delivery height (A2) 24
7.4 Display of the current delivery height 24
7.5 Summary of maximum delivery height
and delivery amount 24
7.6 Activating / deactivating the control keys 24
7.7 START/STOP pump 24
7.8 Biral impeller 25
7.9 On-site adjustment of the pump 25
8. Fault summary 26
9. Sensor 27
10. Accessories/versions 28
10.1 Biral Remote 28
10.2 Biral interface module, BIM A2 signal module 29
10.3 Biral interface module, BIM B2 control module 29
10.4 Building set for recessed installation of electronics 29
10.5 Cold water pump version 29
11. Technical data 30
12. Disposal 30
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7
1. Safety information
1.1 General remarks
These installation and operating instructions contain items
of information of fundamental importance which must be taken
into account during assembly, operation and maintenance.
They should therefore be read without fail before installation
and commissioning by the fitter and also the responsible
specialist staff/operator. They must always be available
for consultation at the plant’s place of deployment.
Not only are the general safety hints included in this
«Safety Hints» section to be observed, but also the special
items of safety information included in the other sections.
1.2 Identification of notices
Information signs mounted directly on the plant, such as,
for example
– rotating direction arrow
– symbols for fluid connections
must be obeyed without fail and be kept in a fully legible state.
1.3 Staff qualification and training
The staff deployed for assembly, operating, maintenance
and inspection tasks must show that they have the appropriate
qualifications for such work. The field of responsibility,
competence and supervision of the staff must be stipulated
exactly by the operator.
1.4 Risks in the event of non-compliance
with the safety information
Non-compliance with the safety information can result in both
danger for persons and also for the plant and the environment.
Non-compliance with the safety information can lead to the loss
of claims for damages of any kind.
In detail, non-compliance, for example, may result
in the following risks:
– failure of important functions in the plant
– failure of prescribed methods for servicing and maintenance
– danger to persons through electrical and mechanical causes
english
Warning
This product may only be installed and used
by people who have adequate knowledge
and experience. People with limitations
in their physical or mental capacity or sensory
perception, may not use the product, unless
they have been sufficiently trained by a person
who is responsible for their safety.
The product must be kept out of the reach
of children. The product must not be used
by children, e.g. as a toy.

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1.5 Safety-conscious work
The safety information contained in these installation and
operating instructions, the existing national regulations
for the prevention of accidents, as well as any internal working,
operating and safety regulations stipulated by the operator
must be observed.
1.6 Safety information for the operator/operating personnel
Any risks from electric power must be eliminated (For details see,
for example, the regulations published by NIN (CENELEC)
and the I.E.E.).
1.7 Safety information for installation, maintenance
and inspection works
The operator has to ensure that all installation, maintenance
and inspection works are carried out by authorised and qualified
specialist personnel who have informed themselves adequately
about the requirements by a thorough study of the installation
and operating instructions.
Basically, any works on the plant should only be carried out
when it is at a standstill and not carrying any electrical current.
Directly after completion of the works, all safety and protective
installations must be mounted or activated again.
Before re-commissioning, the points listed in the section
«Electrical connection» must be observed.
1.8 Unauthorised reconstruction and production of spares
Reconstruction of or changes to pumps are only permissible
after consultation with the manufacturer. Genuine spare parts
and accessories authorised by the manufacturer serve
the cause of safety.
The use of other parts can cancel any liability for the resultant
consequences of this.
1.9 Improper operating methods
The operating reliability of the pumps supplied is only guaranteed
with appropriate application of the section «Intended application»
of the Installation and Operating Instructions. The limit values
given in the technical data must not be exceeded on any account.

9
2. Symbols used
english
Warning
Serious personal injury may result
from not adhering to these safety notes.
Warning
Warning
Danger from dangerous electrical voltage.
If these safety instructions are not adhered to,
there is a risk of electric shock, which may
lead to serious injury or death.
Warning
Risk of injury or burns from hot surfaces!
Warning
Risk of injury from falling objects!
Warning
Risk of injury from escaping steam!
Not adhering to these safety notes may cause
malfunctioning or material damage.
Note This contains advice or notes that facilitate work
and ensure safe operation.

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3. General information
The Biral series, ModulA consists of a complete range
of circulation pumps with integrated frequency converter,
which enable independent or controlled adaptation of output
to the actual requirement of each system. Therefore, in many
systems, energy consumption will be reduced and the control
behaviour of the system improved.
Besides this, current noise from control cabinets can be
reduced effectively.
All necessary settings can be adjusted using the control panel
for the pump.
3.1 Purpose
Biral circulation pumps of the ModulA series are intended
for the circulation of liquids in the following systems:
−ModulA RED in heating units
−ModulA GREEN in air-conditioning units and cooling systems
−ModulA BLUE in domestic hot water systems.
The pumps can also be used in the following systems:
– Geothermal heat pumps
– Thermal solar equipment
The pumps are suitable for use in systems with variable
and constant delivery volumes.
3.2 Requirements of the delivery medium
The pump is suitable for delivery of pure, thin, non-explosive
and non-aggressive media without fixed or long-fibred elements,
which do not affect the pump either mechanically or chemically.
− Heating water:
Requirements according to current standards that apply
to water quality in heating systems: (e.g. VDI 2035)
− Glycol:
The pump can be used for delivering water-glycol mixes.
Maximum permissible viscosity: 50 mm²/s (cSt).
This corresponds to a water-ethylene-glycol mix
with a glycol content of around 50% at –10°C.
The pump is controlled via an output-limiting function
that protects against overload.
The delivery of glycol mixes affects the MAX characteristic
curve because the delivery capacity is reduced accordingly,
based on the glycol content and temperature of the media.
So that the effect of the glycol is not reduced, temperatures
above the nominal temperature given for the medium should
be avoided.
Generally, the operating duration with high media temperatures
should be minimised.
Before adding the glycol mix, it is vital that the system
is cleaned and rinsed.
To avoid corrosion or precipitations, the glycol mix should
be checked regularly and changed if necessary.
If the glycol mix has to be further thinned, the specifications
from the glycol manufacturer should be adhered to.

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Note For the delivery of a liquid with density that
differs from water and/or kinematic viscosity,
the delivery output is reduced.
– Domestic hot water:
Permissible water hardness: max. 35°fH (20 °dH)
(water temperature below 65°C)
max. 25 °fH (14°dH)
(water temperature below 85°C)
To counter the risk of lime deposits, for domestic
hot water systems we recommend:
Hardness level max. 25°fH (14 °dH)
Medium temperature <65°C
Warning
The pump may not be used to deliver
combustible media such as diesel and fuel.
Warning
The pump may not be used to deliver
aggressive liquids such as acids or seawater.
Single pump Dual pump
ModulA… ModulA-D …
At 75 °C water temperature 0,10 bar 0,90 bar
At 95 °C water temperature 0,35 bar 1,20 bar
At 110 °C water temperature 0,65 bar 1,50 bar
Per ±100 m height ±0,01 bar ±0,01 bar
3.3 Operating conditions
– Medium temperature:
ModulA RED +15 °C to +110 °C
ModulA GREEN –10 °C to +110 °C
ModulA BLUE +15°C to +85 °C
(recommended for domestic
hot water systems: max 65 °C)
– Operating pressure:
The maximum permissible operating pressure is indicated
on the nameplate. (6 bar, 10 bar or 16 bar)
Minimum operating pressure at the pump intake ports
(intake pressure ) at 500 m above sea level:
– Ambient temperature:
0 °C to 40 °C

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3.4 Non-return valve
If a non-return valve is fitted, the pump must be adjusted (see 7.2),
so that the discharge pressure of the pump exceeds the closing
pressure of the valve at all times.
This must be adhered to in particular for the proportional pressure
control (reduced delivery height for decreasing delivery flow).
3.5 Protection from the effects of frost
Heat losses can be reduced by insulating the pump casing
and pipes. For ModulA RED, heat insulation shells are included
in the delivery. Heat insulation shells can only be supplied
for single pumps.
3.7 Flow direction
The arrow on the pump casing indicates the flow direction.
3.6 Heat insulation
961604_00
961572_00
Warning Where there is a risk of frost during downtime
periods, measures required to avoid frost
damage must be taken.
Note Heat is lost via the pump casing and pipes.
These heat losses should be limited
to a minimum.
Warning ➀Never cover the frequency converter
or the control panel with insulation.
➁Keep the drainage outlet at the motor free.
➀
➁

4. Installation
4.1 General notes
ModulA is only intended for installation indoors.
The pumps must be mounted voltage-free so that no energy
can be transferred from the pipes to the pump casing.
The pumps can be installed directly in the pipe, provided
the pipes are designed for the weight of the pump.
Installation is only possible after completion of all welding
and soldering work on the system. Avoid drops of water
on the pump motor, especially the frequency converter.
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Warning
The local regulations for the lifting
and carrying of loads must be adhered to.
The weight of the pump is given
on the packaging.
4.2 Permissible installation positions
− The installation position of the rotor shaft must always
be horizontal.
961569_00

961581_00
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– To guarantee adequate cooling, the frequency converter
must always be in a horizontal position. (A, B, C, D)
It is delivered in position A.
AB
CD
E
I
M
J
F
N
G
K
O
H
L
P
961570_00
4.3 Changing the installation position
of the frequency converter
To ensure the correct installation position of the frequency
converter, for installation positions E to P (see 4.2)
the pump head must be rotated 90°, 180° or 270°.
The sensor cable must be separated from the frequency converter
in advance!
961592_00
Warning − Unplug the sensor cable ➀
− Unscrew the cable screws ➁
➀
➁

961578_00
961579_00
961580_00
BA
4.3.1 Rotate the pump head
➀Remove the three Torx
screws
➁Carefully pull out
the electronics
➂Remove the four inner
hexagonal screws
➃Turn the pump head
carefully in the desired
position.
(If the pump head is firmly
connected with the pump
casing, loosen the pump
head via light blows
from a rubber hammer.)
➄Put in four inner hexagonal
screws and tighten. (XNm)
➅Carefully push
in the electronics:
«A»: connector plug
«B»: Holder
➆Put in three Torx screws
and tighten (XNm)
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Warning
Do not drop
the disassem-
bled pump
parts!
➀
➁
➃
➄
➅
➆
➂
90°/180°/270°

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961575_00
90°
961605_00
90°
1
1
2
961587_00
For pumps of a smaller design (P1 small 750 W)
it is not necessary to take out the frequency converter,
the pump head can be turned fully.
The sensor cable must also be separated in advance
from the frequency converter!
Turning the pump head
without taking out the frequency
converter:
ModulA type:
40-10 220, 40-12 250, 40-18 250
50-6 240, 50-12 270, 50-18 270
65-8 270, 65-12 340, 80-8 360
Turning the pump head with
removal of the frequency
converter:
ModulA type:
65-15 340
80-12 360
100-12 450
Warning
Do not drop the disassembled pump parts!
Warning
Risk of injury from escaping steam!
4.4 Install the pump in the unit
➀Close the shut-off valves and ensure that the system
is without pressure when fitting the pump.
➁Install the pump in the pipe with seals.

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DN
961588_00
A
B
The pump flanges are drilled with mounting holes, PN6/PN10/PN16.
For safe screwing of the flanges, the shims supplied (B)
must be fitted.
Warning Safety elements (e.g. snap rings)
are not permissible.
Warning For PN 10/16, special seals and screws
must be used.
Warning
Use the relevant screws
for nominal pressure PN.
After installation is completed, put on the heat insulation shells
and secure with cable bands.
Recommended screw tightening torque
for M 12 <40 Nm
for M 16 <95 Nm
Installation of combined flange with combined flange
is not permissible.
PN 6 PN 10 / PN 16 PN 6 PN 10 / PN 16
DN 40
DN 50 M 12 M 16 Ø 14 Ø 18
DN 65
DN 80
DN 100 M 16 M 16 – –
AB

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5. Electrical connection
Electrical connection should be carried out in accordance
with the local regulations.
It is vital to ensure that the voltage and frequency indicated
on the nameplate are compatible with the mains supply available.
Warning
Before carrying out any electrical connection
work, the voltage supply must be switched off.
The pump must be connected to an external
network switch with a contact opening
on all poles of minimum 3 mm.
The protection against indirect contact can be
achieved by earthing or potential equalisation.
If the pump is connected to an electrical
installation, which has an FI circuit breaker
for additional protection, the FI circuit breaker
must trigger with a pulsing direct current
component if earthing fault currents arise.
The FI circuit breaker must be marked
with the following symbol:
The pump does not require any external motor protection.
The motor has integrated over-temperature protection,
which offers safeguarding against overloading that appears
slowly and against blocking according to IEC 34-11: TP 211.
5.1 Supply voltage
1×230 V ±10%, 50/60 Hz, PE
The voltage tolerances are set for equalising voltage fluctuations
on the mains. They are not for operating pumps with voltages
other than those shown on the nameplate.
Note With direct mains connection, the pump may
not be switched on and off at the mains more
than four times an hour.
If the pump is switched on directly via the mains,
it only starts after a 5-second delay.

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5.2 Connection of the power supply
The pump must be protected on-site (min. 10 A, slow)
and must be connected to an external mains switch.
All cables used must have a heat resistance of up to 85°C.
They must not be in contact with the pipe or the pump
and motor casing.
All cables must be connected in accordance with EN 60204-1
and EN 50174-2: 2000.
The electrical connection must be made as indicated
on the nameplate. For simpler subsequent replacement,
we recommend strapping the cable.
Nominal Output P1
current
ModulA…RED, ModulA BLUE [A] [W]
ModulA 40-10 220 0.19 – 1.54 18 – 341
ModulA 40-12 250, ModulA-D 40-12 250 0.18 – 1.91 17 – 421
ModulA 40-18 250, ModulA-D 40-18 250 0.18 – 2.63 16 – 594
ModulA 50-6 240, ModulA-D 50-6 240 0.21 – 1.09 21 – 236
ModulA 50-12 270, ModulA-D 50-12 270 0.21 – 2.32 20 – 516
ModulA 50-18 270, ModulA-D 50-18 270 0.21 – 3.34 22 – 742
ModulA 65-8 270, ModulA-D 65-8 340 0.24 – 2.10 22 – 464
ModulA 65-12 340, ModulA-D 65-12 340 0.22 – 3.32 21 – 736
ModulA 65-15 340, ModulA-D 65-15 340 0.28 – 5.68 30 – 1254
ModulA 80-8 360, ModulA-D 80-8 360 0.29 – 3.08 29 – 704
ModulA 80-12 360, ModulA-D 80-12 360 0.32 – 5.56 32 – 1282
ModulA 100-12 450, ModulA-D 100-12 450 0.32 – 6.78 35 – 1563
FI
N
L
L
N
961613_00
Example of a typical mains connection, 1×230 V ±10%, 50/60 Hz
External switch
Protection
(min. 10 A, slow)

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DC out
24V
max. 20mA
961566_00
max. 250V AC
2A
min. 5V DC
20mA
AC in
~1x230V
±
10%
50/60 Hz
N 51 L54521011 4- +2
Switch
91 92 9291
961598_00
5.3 Connection drawing
Clamp description
+24-
24 V DC out
11, 10
External OFF or external ON
(can be switched over)
52, 54, 51
Fault or operating signal
L, PE, N
Power supply
Twin design
91, 92
Twin pump function