Perfecta Pro2 User manual

Pump Pro2 (D)
EN
Installation and operating manual

2
EN: Compliance of the product with EU standards:
Machinery directive (2006/42/EC).
Standard used: EN 809;
Low Voltage (2014/35/EU).
Standard used: EN 60335–1; EN 60335-2-51;
Electromagnetic compatibility (2014/30/EU).
Standard used: EN 55014–1; EN 55014–2; EN 61000-3-2; EN 61000-3-3;
Ecodesign Directive (2009/125/EC).
Standard used: EN 16297–1:2012;
Circulators: Commission regulation No.614/2009.
For EEI see nameplate.
Standard used: EN 16297–1:2012; EN 16297–2:2012;

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English (EN) Installation and operating manual
TABLE OF CONTENTS
1 General information..........................................................................................................................4
1.1 Uses ........................................................................................................................................................4
1.2 Pump labeling .........................................................................................................................................4
1.3 Pump maintenance, spare parts and decommissioning.........................................................................4
2 Safety ................................................................................................................................................5
3 Tehnical specifications ......................................................................................................................5
3.1 Standards and protections .....................................................................................................................5
3.2 Pump medium ........................................................................................................................................5
3.3 Temperatures and ambient humidity.....................................................................................................6
3.4 Electrical specifications...........................................................................................................................6
4 Pump installation ..............................................................................................................................9
4.1 Installation into pipe lines ......................................................................................................................9
4.2 Electrical installation.............................................................................................................................10
4.3 Communication installation....................................................................................................................6
5 Setup and operation ...................................................................................................................... 11
5.1 Control and functions ...........................................................................................................................11
5.2 Operation..............................................................................................................................................17
6 Error and Troubleshooting............................................................................................................. 19
7 Fault finding ................................................................................................................................... 19
7.1 Error codes ...........................................................................................................................................19
8 Images............................................................................................................................................ 21
Symbols used in this manual:
Warning:
Safety precautions which, if ignored could cause personal injury or machinery damage
Notes:
Tips that could ease pump handling.

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1GENERAL INFORMATION
1.1 USES
The Pro2 circulating pumps are used for the transfer of liquid medium within systems for hot-water heating,
air-conditioning and ventilation. They are designed as single or twin variable-speed pumping aggregates where
the speed is regulated by electronic device. The pump constantly measures pressure and flow and adjusts the
speed according to the set pump mode.
The pumps have the option of remote control and monitoring using Ethernet, Modbus, analog inputs and
outputs, and relay control. See communication installation for more information.
The main purpose of the twin pump is uninterrupted operation if one of the pumps fails. Common hydraulic
housing is equipped with a change-over flap and two pump heads, separately connected to the electrical grid.
1.2 PUMP LABELING
Pro2 (Z)(D)40–12/24
Pro2 Pump family
(Z) Sanitary water pump
(D) Twin pump
40 Nominal pipe diameter
12 Maximum head (in 0.1 m of H2O)
24 Maximum flow m³/h
1.3 PUMP MAINTENANCE, SPARE PARTS AND DECOMMISSIONING
Pumps are designed to operate without maintenance for several years.
This product and its components must be disposed of in an environmentally friendly manner.

5
2SAFETY
These instructions should be studied carefully before installing or operating the pump. They are meant to help
you with installation, use and maintenance and to increase your safety. Installation should only be performed
with regards to local standards and directives. Only qualified personnel should maintain and service these
products.
Failure in following these instructions can cause damage to the user or product and can void warranty. Safety
functions are only guaranteed if the pump is installed, used and maintained as described in this manual.
3TEHNICAL SPECIFICATIONS
3.1 STANDARDS AND PROTECTIONS
Pumps are made according to the following standards and protections:
Protection class:
IP44
Insulation class:
180 (H)
Motor protection:
Thermal - built in
3.2 PUMP MEDIUM
Pump medium can be pure water or a mixture of pure water and glycol, which is appropriate for central heating
system. Water must meet water quality standard VDI 2035. The medium must be free from aggressive or
explosive additives, free from mixtures of mineral oils and solid or fibrous particles. The pump should not be used
for pumping flammable, explosive media and in an explosive atmosphere.
Installation specification
Pump type
Nominal pressure
Installation length (mm)
Pro2(Z) 25U–6/9
PN6 and PN10
180
Pro2(Z) 25U-10/12
180
Pro2(Z) 32U–6/9
180
Pro2(Z) 32U-10/12
180
Pro2 32F-6/9
220
Pro2 32F-10/12
220
Pro2 (D)40–8/19
220
Pro2 40-10/12
220
Pro2 (D)40–12/24
250
Pro2 (D) 50–8/32
280
Pro2 50-10/12
240
Pro2 (D) 50–12/37
280

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3.3 TEMPERATURES AND AMBIENT HUMIDITY
3.4 ELECTRICAL SPECIFICATIONS
3.4.1 CURRENT, VOLTAGE AND POWER RATINGS
3.4.2 COMMUNICATION SPECIFICATIONS
To see communication functions see chapter 5.1 Control and functions
3.4.3 ANALOG INPUTS AND OUTPUTS
Connections can be used either as inputs or outputs, depending on setup. Pump has 3 connectors: SET1, SET2
and SET3.
Operation outside recommended conditions may shorten pump lifetime and will void the
warranty.
Permitted ambient and media temperature:
Ambient temperature
[°C]
Medium temperature [°C]
Relative ambient humidity
min.
max.
Up to 25
-10
110
<95 %
30
-10
100
35
-10
90
40
-10
80
Electrical ratings
Pump
Rated voltage
Rated power
[W]
Rated current
[A]
Rated
current
(Imax) [A]
Startup
Pro2(Z) xxx–6
230 VAC ± 15 %,
47-63Hz
Pumps operate at
reduced voltage
with limited power
(P=Imax*U)
90
0,75
0,75
Built-in
startup
circuit
Pro2(Z) xxx-10
180
1,5
1,5
Pro2(D) 40–80
270
1,3
4,3
Pro2(D) 40–120
480
2,3
4,3
Pro2(D) 50–80
345
1,6
4,3
Pro2(D) 50–120
560
2,5
4,3
Pro2(D) 65–80
560
2,6
4,3
Electrical properties
Input voltage
–1 - 32 VDC
When used as input.
Output voltage
0 - 12 VDC
When used as an output. Max. 5 mA load on individual output.
Input impedance
~100 kΩ
0,5 mA additional load for most configurations.
Input sink current
0 - 33 mA
Common sink on COM, if used as output
Galvanic isolation
4 kV up to 1 s, 275 V permanent.

7
3.4.4 RELAY OUTPUT
3.4.5 ETHERNET
Electrical properties
Rated current
3 A
Maximum voltage
230 VAC, 32 VDC
Electrical properties
Connector
RJ-45, 10BASE-T, 10 Mbit/s.
Services
- Web server (port 80)
- Software update through web interface.
- Option of Modbus RTU through TCP/IP
Default IP address
192.168.0.245 ( 192.168.0.246 for right pump)
Ethernet visual
diagnostics
LED1
Slowly blinking if module is on. Lights up when the connection is established.
LED2

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3.4.6 MODBUS
Modbus specification
Data protocol
Modbus RTU
Modbus connector
Screwless terminals
2+1 pins. See communication manual.
Modbus connection
type
RS-485
Modbus wire
configuration
Two-wire + common
Conductors: A, B and COM (Common).
See communication manual.
Communication
transceiver
Integrated, 1/8 of
standard load
Connect either via passive taps or daisy chain.
Maximum cable
length
1200 m
See communication manual.
Slave address
1-247
Default is 245, settable over Modbus. See
communication manual.
Line termination
Not present
Line termination is not integrated. For low
speed/short distance, termination can be
omitted. Otherwise, terminate the line externally
on both ends.
Supported
transmission speeds
1200, 2400, 4800, 9600,
19200, 38400 baud
Settable over Modbus register [default=19200].
Start bit
1
Fixed.
Data bits
8
Fixed.
Stop bits
1 or 2
1 stop bit minimum, up to 2 when parity not
enabled [default=1]
Parity bit
Even/odd/none
[default=Even]
Modbus visual
diagnostics
LED2
Flashing yellow when data reception detected.
Combined (OR) with Ethernet ACT function.
Maximum number of
Modbus devices
247
Limited by possible Modbus addresses to 247.
1/8 nominal load enables 256 devices.
Maximum Modbus
packet size
256 bytes
Including address (1) and CRC (2) bytes.
Isolation
Common ground (COM)
with SET1, SET2 and
SET3.
Modbus shares common ground with other
signals.

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4PUMP INSTALLATION
4.1 INSTALLATION INTO PIPE LINES
Pump is protected with a double box during transport. It can be lifted from the box with internal handles or by
lifting it by the heat sink.
Pumps are designed to be built in connecting flanges, using all screws. The connecting combined flanges are
designed so the pump can be installed in PN6 or PN10 nominal pressure pipelines. Because of the combined
flange design, washers must be used on the pump side, when installing the pump.
For a pump to operate with minimal vibrations and noise it should be installed into pipe lines with its 1-1 axis in
horizontal position, as showed in figure 1. Pipes should be without curves for at least 5-10 D (D = rated pipe
diameter) from the flanges.
Desired head orientation can be achieved by rotating the pump head (allowed positions shown in figure 2 and
3). Pump head is mounted to hydraulic casting with four screws. By unscrewing those, the pump head can then
be turned (figure 4).
Ambient around the pump should be dry and illuminated as appropriate and the pump should not be in direct
contact with any objects. Pump seals prevents dust and particles from entering as prescribed by IP class. Make
sure that the distribution box cover is mounted and that the cable glands are tightened and are sealing.
Pump will provide the longest lifetime with ambient at room temperature and moderate medium temperature.
Prolonged operation at elevated temperatures could increase wear. Aging is accelerated by high power and high
temperatures.
Misconnection or overload could cause pump shutdown or even permanent damage.
Pumps might be heavy. Provide yourself help if needed,
Pump must not be used in the safety pipelines,
Pump should not be used as a holder during welding!
When reassembling, care should be taken to ensure seal fit. Failing that, water could
cause damage to pumps internal parts,
Drains between pump motor housing and hydraulic housing must be left free (should
not be thermally insulated), as it could interfere with cooling and condense drainage,
Hot medium can cause burns! The motor can also reach temperatures that could cause
injury.

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4.2 ELECTRICAL INSTALLATION
The pump has a built-in over current fuse and protection, temperature protection and basic overvoltage
protection. It doesn’t need an additional thermal protection switch. Connection leads should be capable of
carrying rated power and should be properly fused. Ground lead connection is essential for safety. It should be
connected first. Grounding is only meant for pump safety. Pipes should be grounded separately.
4.3 COMMUNICATION INSTALLATION
4.3.1 ANALOG INPUT/OUTPUT
Detailed description is available in communication module manual.
4.3.2 RELAY OUTPUT
Detailed description is available in communication module manual.
4.3.3 ETHERNET
Detailed description is available in communication module manual.
4.3.4 MODBUS
Detailed description is available in communication module manual.
Connection of the pump must be carried out by qualified personnel,
Connection of the connecting cable must be done in a manner that ensures it is never in
contact with the casing of the device, due to the high temperatures of the casing,
This appliance can be used by children aged from 8 years and above and persons with
reduced physical, sensory or mental capabilities or lack of experience and knowledge if they
have been given supervision or instruction concerning use of the appliance in a safe way
and understand the hazards involved,
Children shall not play with the appliance,
Cleaning and user maintenance shall not be made by children without supervision.

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5SETUP AND OPERATION
5.1 CONTROL AND FUNCTIONS
The pump can be controlled by display panel, 10-step switch, analog inputs, modbus or Ethernet connection.
Display panel controls and overviews pump modes, parameters and on/off status,
10-step switch allows changing of relay output, analog inputs/outputs and resetting the pumps
communication configuration,
Analog inputs gives control over the pump (start, stop, max. curve, min. curve, 0 - 10 V, 4 –20 mA, …),
Analog outputs are used for getting analog information about the pumps performance (errors, speed,
mode, flow, height),
Relay output signalizes pumps status,
Ethernet connections offers control over all pump functions and settings (pumps variables, digital
inputs, error overview),
Modbus connection gives overview of all parameters and settings (pumps variables, analog
inputs/outputs, error overview).
Several signals will influence the pump operation. For this reason, settings have different priorities as shown in
the table below. If two or more functions are active at the same time, the one with highest priority will take
precedence.
Priority
Pump control panel and
Ethernet settings
External signals1
Modbus control
1
Stop (OFF)
2
Active night mode2
3
Max. speed (Hi)
4
Minimal curve
5
Stop (RUN not active)
6
Max. speed (Hi)3
Stop
7
Reference point
8
Reference point
9
Reference point
1
All inputs are not available in every mode of operation.
2
In night mode the external signals and Modbus stop signal become active. Due to the possibility of confusion
it is not recommended using the night mode while using external signals.
3
Not available if using Modbus communication.

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5.1.1 DISPLAY PANEL
With the use of the display panel, you can control and overview pump modes, on/off control, pump
parameters and errors. To see how pump modes work, see chapter 5.2 Operation.
1. Bar graph display of pump parameters
2. Numerical display of values
3. Unit display
4. Display of the currently selected mode
5. Night mode
6. key
7. key
8. key
5.1.1.1 KEY FUNCTIONS
Key
Short press:
Scrolling through parameters downwards when not changing parameter values,
Scrolling through modes downwards when mode selection is selected,
Changing parameters downwards when setting parameter values.
Long press:
3 seconds together with turns on night mode,
3 seconds together with locks pumps current operation,
5 seconds to turn off pump,
5 seconds together with and keys to restore pump to factory settings.
Key
Short press:
To confirm currently selected values of both mode and parameter.
Long press:
3 seconds to trigger mode selection,
3 seconds together with locks pumps current operation,
5 seconds together with long press on and keys to restore pump to factory settings.

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Key
Short press:
Scrolling through parameters upwards when not changing parameter values,
Scrolling through modes upwards when mode selection is selected,
Changing parameters upwards when setting parameter values.
Long press:
3 seconds together with puts us in night mode,
5 seconds together with and keys to restore pump to factory settings.
5.1.1.2 TURNING ON AND OFF
On first start up the pump will operate with factory settings in automatic mode.
With subsequent start-ups, the pump will operate with the last settings that were set prior to its shut-down.
To switch the pump off, press and hold the key for 5 seconds, until OFF is shown on the display. When the
pump is switched off, the numerical display shows OFF.
To turn the pump on, press the key briefly.
5.1.1.3 PUMP MODES AND PARAMETERS
For transition between modes, we hold the key for 3 seconds and then select the mode in which we wish the
pump to operate with or keys. We confirm the selection with the key.
After confirming the mode, the parameter, which can be set, will automatically be displayed and blink (except
for auto mode). If necessary, we set the parameter value with and keys, then confirm the setting with the
key or just press the key to accept the given parameter.
We can scroll through the parameters within a mode with and keys. We select the parameter that can be
adjusted (see individual mode) in the mode with the key and set the desired value with and keys. We
confirm the selected value with the key.
5.1.1.4 PUMP OPERATION LOCK
For locking and unlocking pump current pump mode and parameters, hold and keys for 3 seconds. When
the pump is locked, it is possible to turn the pump on and off, view parameters and reset the pump to factory
settings that also unlocks the pump.

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5.1.2 10-STEP SWITCH
There is a mode selection rotary switch in the terminal box. It can be rotated by gently inserting a screwdriver
into the arrow mark on top and rotating the switch to desired value.
Switch setting is read when the pump turns on! More details about different modes can be found in
communications manual.
Mode
switch
position
Function
Description
0
Free configuration
Terminal functions are configured over Ethernet interface.
1
Mode 1
SET1 = RUN input
SET2 = MAX input
SET3 = FB (10.5 V) output, used to supply RUN and MAX inputs.
External voltage source can also be used.
RS-485 = Modbus interface.
2
Mode 2
SET1 = RUN input
SET2 = SPEED input
SET3 = FB (10.5 V) output, used to supply RUN and MAX inputs.
External 5-24 V voltage source can also be used.
RS-485 = Modbus interface
3..5
Reserved
Reserved for future or customer specific use.
6
Show relay
configuration
LED1 and LED2 will show relay configuration.
7
Change relay
configuration
Relay configuration will be increased (0->1, 1->2, 2->0) when power is
turned on.
LED1 and LED2 will show current relay configuration.
8
Twin reset to factory
Same as Mode 9, with exception of:
module IP address is set to 192.168.0.246
Twin IP address is set to 192.168.0.245
9
Reset to factory
This mode will set communication interface to default values. Main
purpose is to restore default settings.
NOTE:
Disconnect any SET1, SET2 and SET3 connections when using
this mode to prevent possible harm to controller. SET1, SET2,
SET3 will output test voltages of 10 V, 7 V and 5 V
respectively. RS-485 port is actively driven. Relay will cycle.
This is used for testing purposes.
It is recommended that all module wires are disconnected to
prevent possible harm to external controllers.

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5.1.3 ANALOG INPUT/OUTPUT
The pump has three analog inputs/outputs with different functions. They can be configured through the web
interface (page “pump”) or through Modbus.
5.1.4 RELAY OUTPUT
5.1.5 ETHERNET
The pump has a built in web server which allows you to access your pump directly via an existing Ethernet
connection. The default address for access to the pump is "perfectapro" or 192.168.0.245
The web server uses HTML pages to set/view:
Regulation mode settings
Regulation parameters (power, RPM, head, flow)
Relay settings
External control inputs settings
Current and previews error
Pump statistics (power consumption, run time and other)
5.1.6 MODBUS
Pump has built in Modbus client, through which we can access pump information using the RS 485 standard.
Modbus allows to set and view:
Regulation mode settings,
Regulation parameters (power, RPM, head, flow),
Relay settings,
External control inputs settings,
Current and previews error,
Pump statistics (power consumption, run time and other).
Input/Output
Function
Function description
SET1
Run [Default - Mode 1]
Turning the pump on/off. By default activating with connection to
SET3.
SET2
Max/Min [Default - Mode 1]
Set the pump to max. settings when SET1 is active and to min.
settings when SET1 is inactive.
SET3
FB [Default - Mode 1]
10 V voltage output used for activating SET 1 and SET2 by
connecting them to SET3.
Configuration
Description
Run
Shows when pump is running.
Operate
Shows when pump is standby.
Error[Default]
Shows when pump has an error.
No function
Relay output doesn’t show anything.
Always on
Relay always closed.

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5.1.7 RESETTING PUMP TO FACTORY SETTINGS
For resetting the pump to factory settings all three buttons must be held for 5 seconds. This way the pump will
set itself to automatic mode, delete previous height and power settings and unlock setting pump operation (if
locked).
Resetting of communications module needs following steps:
1. Disconnecting power from pump,
2. Set the 10-step switch to number 9
4
(or 8 for right twin pump),
3. Turning the pump on and off again,
4. Setting the 10-step switch to number 1,
5. Turning the pump on.
Communications module should now be set to factory settings.
4
This also sets up the right twin pump.

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5.2 OPERATION
The pump can operate in 5 different modes. We can set the pump in the most appropriate mode, depending
on the system where the pump operates.
The pump modes:
Automatic mode (factory default),
Proportional pressure,
Constant pressure,
Constant speed,
Combined mode (all mode indicators are off)
Automatic mode
In automatic mode the pump automatically sets the operating pressure, depending on the hydraulic
system. By doing so, the pump finds the optimal operating position.
This mode is recommended in most systems.
The parameters cannot be set; they can only be scrolled through.
Proportional pressure
The pump maintains the pressure with relation to the current flow. The
pressure is equal to the set pressure (Hset on the drawing) at maximum power; at
0 flow it is equal to HQ % (default 50%, HQ % can be set on the pump webpage) of
the set pressure. In between, the pressure changes linearly, relative to the flow.
In regulated mode we can only set the pump pressure (Hset on the drawing). We
can only scroll through the other parameters.
Constant pressure
The pump maintains the currently set pressure (Hset on the drawing), from 0 flow
to maximum power, where the pressure begins to drop.
At constant pressure, we can only set the pressure (Hset on the drawing) which the pump
will maintain. We can only scroll through the other parameters.
Constant speed
The pump operates with the currently set speed (RPMset on the drawing).
In the unregulated mode, we can only set the speed at which the pump will operate. We
can only scroll through the other parameters.
Combined mode
Multiple limits can be set only over the web interface. None of the other modes are on.
Night mode
When the pump is operating in night mode, it automaticly switches between the current mode and
night mode. Switch occurs based on the temperature of the medium.
While in night mode its icon is turned on and the pump operates in chosen mode. If the pump senses drop in
temperature of the medium for 15 -20 °C (in time frame of 2 hours), icon starts to blink and the pump switches
to night mode. When the temperature of the medium rises, blinking stops and the pump goes back to
previously chosen operation mode.
Night mode can only work in compliment to other modes and is not a mode that can run by itself.
Max.
Min.
Hset
H
Q
Max.
H
Q
Min.
RPMset
Max
Min
H
Q
Hset*HQ%
Hset

18
5.2.1 TWIN PUMP OPERATION
Twin pump has double hydraulic housing with integrated check valve, which automaticly turns based on
medium flow, and two separated motors. Pumps communicate with each other through Ethernet connection.
Night mode is not recommended in this mode of operation.
Pumps can operate in several different modes, switching betweend the pumps is done by the communications
module:
-Alternating operation [default setting] –One pump is operating while the other one is on standby.
Pumps switch their role every 24 hours or when an error occurs on one pump.
-Backup operation –One pump operates constantly and the other one is on standby. If an error occurs
on the operating pump the one on standby will automaticly start working. This mode can be set up by
turning off the pump that we wish to be on standby. That is done by holding the button for 5
seconds.
-Parallel operation –Both pumps work at the same time with the same settings of constant pressure.
This mode is used when greater flow than one single pump can output is needed. When the first pump
hits its flow limit the second one turns on and compliments the first to reach desired flow.
This mode is activated when we set both pumps to constant pressure mode.

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6ERROR AND TROUBLESHOOTING
If pump failure occurs, the error causing the failure will appear in the display screen.
Errors on the screen are identified as:
E X Y
EError marking
XError group
YService code
Error group
Error description
Possible cause and solution
1
Low load detected
There is no medium in the pump. Check if there is medium in the system.
2
Motor overload
Excessive current load or blocked rotor. If the issue persists, check if the
rotor is spinning freely.
3
Motor too hot
Motor has exceeded allowed temperature and is now stopped to cool
down. Once cooled, it will automatically restart.
4
Electronics error
An electronics error was detected. The pump can still operate, but needs
servicing.
5
Motor/stator failure
There could be an interruption in the motor winding. Pump needs servicing.
The service code (Y) is intended for service personal.
If the pump is unresponsive, disconnect and connect it back to the electrical grid.
7FAULT FINDING
7.1 ERROR CODES
The following codes will show up on display panel and on the appropriate Modbus registers to help you
diagnose the cause of improper operation.

20
Error code
Description
Probable cause
E1x
Load errors
E10 (drY)
Low motor load
Low load detected. Pump is running dry.
E11
High motor load
Motor might be faulty or viscous medium is
present.
E2x
Protection active
E22 (hot)
Converter temperature limit
Circuit is too hot and power was reduced to
less than 2/3 of rated power.
E23
Converter temperature protection
Circuit is too hot to run, pump stopped
E24
Converter overcurrent
Hardware overcurrent protection triggered.
E25
Overvoltage
Line voltage is too high
E26
Undervoltage
Line voltage is too low for proper operation.
E27
PFC Overcurrent
Power correction circuit current cannot be
controlled
E3x
Pump errors
E31
Software motor protection active.
Average motor current was too high, pump
load is much higher than expected
E4x
Device specific error codes
E40
General frequency converter error
Electrical circuitry did not pass self‐test.
E42 (LEd)
LED faulty
One of the display segment diodes is faulty
(open/short)
E43 (con)
Communications failed
Display board does not detect proper
connection to main board, but power supply
is present
E44
DC link current offset
Voltage on DC link shunt (R34) not in
expected range
E45
Motor temperature outside limits
During MFG. TEST, this is 10 kΩ, 1% resistor
for 10 °C..30 °C During operation, expected
values are ‐55 °C..150 °C
E46
Circuit temperature outside limits
During MFG. TEST, this is 0 °C..50 °C. During
operation, expected values are ‐55 °C..150
°C
E47
Voltage reference outside limits.
Comparison between internal references
does not match
E48
15V outside limits
15V supply is not 15V.
E49
Test load does not match
No test load detected or current
measurement does not work properly (MFG.
TEST)
E5x
Motor error codes
E51
Motor parameters out of range
Motor does not behave as expected
E52
Thermal protection active
Motor temperature is too hot to operate.
E53
Invalid model selected
Pump model not valid or out of reach