Resol PSW Premium Pump User manual

PSW Premium Set
www.resol.com
Manual
en
*11205572* 11205572
Thank you for buying this RESOL product.
Please read this manual carefully to get the best performance from this unit.
Please keep this manual safe.
Mounting
Electrical connection
Adjustment

en
2
Safety advice
Please pay attention to the following safety advice in order to avoid danger and
damage to people and property.
Instructions
Attention must be paid to the valid local standards, regulations and directives!
Target group
These instructions are exclusively addressed to authorised skilled personnel.
Only qualified electricians should carry out electrical works.
Initial installation must be effected by the system owner or qualified personnel
named by the system owner.
Description of symbols
WARNING! Warnings are indicated with a warning triangle!
ÎThey contain information on how to avoid the dan-
ger described.
Signal words describe the danger that may occur, when it is not avoided.
• WARNING means that injury, possibly life-threatening injury, can occur.
• ATTENTION means that damage to the appliance can occur.
ÎArrows indicate instruction steps that should be carried out.
Note
Notes are indicated with an information symbol.
Information about the product
Proper usage
The device is designed for use in standard solar thermal systems and heating sys-
tems in compliance with the technical data specified in this manual.
Improper use excludes all liability claims.
CE Declaration of conformity
The product complies with the relevant directives and is therefore la-
belled with the CE mark. The Declaration of Conformity is available
upon request, please contact the manufacturer.
Note
Strong electromagnetic fields can impair the function of the device.
ÎMake sure the device as well as the system are not exposed to strong
electromagnetic fields.
Disposal
• Dispose of the packaging in an environmentally sound manner.
• Dispose of old appliances in an environmentally sound manner. Upon request
we will take back your old appliances bought from us and guarantee an environ-
mentally sound disposal of the devices.
Subject to technical change. Errors excepted.
© 20170703_11205572_PSW_Premium_Set.monen.indd

en
3
Contents
PSW Premium
1 Overview............................................................................................. 4
2 Installation .......................................................................................... 5
2.1 Mounting.......................................................................................................................5
2.2 Electrical connection..................................................................................................5
2.3 Inversion of the output signal ..................................................................................6
2.4 Overrun function........................................................................................................6
2.5 Application example...................................................................................................6
2.6 LED flashing codes .....................................................................................................6
3 Tips for fault diagnostics ................................................................... 7
Yonos PARA
4 General................................................................................................ 7
5 Safety................................................................................................... 7
5.1 Indication of instructions in the operating manual .............................................8
5.2 Personnel qualifications.............................................................................................8
5.3 Danger in the event of non-observance of the safety instructions.................8
5.4 Safety consciousness on the job..............................................................................8
5.5 Safety instructions for the operator.......................................................................8
5.6 Safety instructions for installation and maintenance work ...............................9
5.7 Unauthorised modification and manufacture of spare parts ............................9
5.8 Improper use ...............................................................................................................9
6 Transport and interim storage ....................................................... 10
7 Intended use ..................................................................................... 10
8 Product Information ........................................................................ 10
8.1 Technical data ........................................................................................................... 10
9 Description and function................................................................. 11
9.1 Description of the pump........................................................................................ 11
9.2 Functions ................................................................................................................... 11
10 Installation and electrical connection............................................ 11
10.1 Installation ................................................................................................................. 11
10.2 Electrical connection............................................................................................... 11
11 Commissioning................................................................................. 12
12 Maintenance ..................................................................................... 12
13 Faults, Causes and Remedies .......................................................... 12
14 Disposal ............................................................................................. 12

en
4
130
45
Drill hole positions
113 mm
130
45
Technical data
Inputs: On / Off, bursts / wave packets, phase cutting
Outputs: 1 semiconductor relay, 1 PWM, 1 0-10 V
PWM frequency: 625 Hz +-2,5 %
PWM voltage: 11 V
Power supply: 220 … 240 V~ (50 Hz)
Supply connection: type Y attachment
Power consumption max. 1.7 VA
Mode of operation: type 1.Y
Rated impulse voltage: 2.5 kV~
Functions: signal converter, converting a speed-controlled 230 V signal into a
PWM or 0-10 V signal.
Housing: plastic
Mounting: wall mounting
Protection type: IP 20 / DIN EN 60529
Protection class: II
Ambient temperature: 0 … 40 °C
Degree of pollution: 2
Dimensions: Ø 130 mm
PSW Premium
1 Overview
The PSW Premium Pump signal converter is used for connecting speed-controlled
high-efficiency pumps with a PWM or 0-10V control input to a controller without
a corresponding output. Thus, when replacing the pump, speed control can be
enabled without replacing the controller.
The PSW Premium pump signal converter converts the 230 V signal of the con-
troller to which a standard pump had previously been connected, into a signal that
enables speed control of a HE pump.
The PSW Premium is equipped with a relay output for the power supply of the
pump. Moreover, it has an overrun function to reduce the number of switching
processes for high-efficiency pumps.
• For solar and heating pumps
• PWM or 0-10 V output signal
• Inversion of the output signal possible
• Integrated power supply of the pump
• Overrun
• Pump status indication
1 HE pump per signal converter connectable.
The following signal conversions are possible:
Output signal
Input signal
PWM PWM
inv.
0-10V 0-10V
inv.
On / Off xxxx
Burst / wave packet xxxx
Leading-edge phase control x x x x
Trailing-edge phase control x x x x
Not suitable for heat pumps and DHW exchange controllers

en
5
1 Installation
1.1 Mounting
WARNING! Electric shock!
Upon opening the housing, live parts are exposed!
ÎAlways disconnect the controller from power supply
before opening the housing!
The unit must only be located in dry interior rooms.
The controller must additionally be supplied from a double pole switch with con-
tact gap of at least 3 mm.
Please pay attention to separate routing of sensor cables and mains cables.
In order to mount the device to the wall, carry out the following steps:
ÎChoose a mounting location.
ÎDrill 2 holes (Ø 6 mm, centres 113mm) and insert the wall plugs.
ÎFasten the base part of the housing by means of the enclosed screws
(4 x 40 mm, (1)).
(1)
Spare fuse
(interior part of cover)
1.2 Electrical connection
WARNING! Electric shock!
Upon opening the housing, live parts are exposed!
ÎAlways disconnect the controller from power supply
before opening the housing!
ATTENTION! ESD damage!
Electrostatic discharge can lead to damage to electronic com-
ponents!
ÎTake care to discharge properly before touching the
inside of the device!To do so, touch a grounded sur-
face such as a radiator or tap!
Note:
Strong electromagnetic fields can impair the function of the device.
ÎMake sure the device as well as the system are not exposed to strong
electromagnetic fields.
Do not use the device if it is visibly damaged!
Connecting the device to the power supply must always be the last step of the
installation!
Depending on the product version, mains cables and signal cables are already con-
nected to the device.
If that is not the case, please proceed as follows:
The device is supplied with power via a mains cable.The mains voltage must be
220 … 240 V~ (50 Hz).
Connect the signal cable from the controller to the low voltage input of the device:
R In (1 / 2) = 230 V control signal from the controller (conductor L)
Depending on the desired signal type, connect the output cable to (4) and one
of the following outputs:
ATTENTION! Malfunction!
Pumps with line break detection run with minimum speed if the
control signal is 0V.
ÎDo not operate pumps with line break detection by
a 0-10 V signal!
10V (3) = 0-10 V control signal for the HE pump
PWM (5) = PWM control signal for the HE pump
The mains connection of the device is at the following terminals:

en
6
N (8) = neutral conductor N
L (9) = conductor L
Ground conductor ⌯(common terminal block)
Power supply for the pump, connect the cable to the R Out relay output:
N (6) = neutral conductor N pump
R Out (7)= 230 V power supply of the pump via the relay output
Ground conductor ⌯(common terminal block)
1.3 Inversion of the output signal
By means of the lower two-pole jumper on the left-hand side above the output
terminals, the output signal can be issued inverted or not inverted.
Jumper open: not inverted (solar pump)
Jumper connected: inverted (heating pump)
Input
100 %
Heating Solar
PWM /
0-10 V
output
100%0%
1.4 Overrun function
By means of the upper two-pole jumper the overrun function can be activated or
deactivated.
The overrun function can be used to reduce the number of switching processes
for high-efficiency pump. Power supply for the pump will remain switched on for
another 30 minutes after the input signal has signalled a switch-off.
Jumper open: Overrun function on
Jumper connected: Overrun function off
1.1 Application example
1.2 LED flashing codes
Flashing code Description
Green: Output on standby
Green flashing: Output active
Power supply 230V~
230 V~ via relay output
PWM
pump signal
Input signal: 230
V control signal
from the controller
(On / Off, burst / wave
packet, phase cutting)
Controller

en
7
2 Tips for fault diagnostics
If the device does not work perfectly, please check the following items:
If the device does not switch on when the power supply is connected, please check
the fuse.The device is protected by a T1A fuse, which can be replaced after having
removed the housing and the cover. A spare fuse is enclosed on the backside of
the cover.
Spare fuse
(interior part of cover)
Yonos PARA
3 General
About this document
The language of the original operating instructions is English.All other languages of
these instructions are translations of the original operating instructions.
These installation and operating instructions are an integral part of the product.
They must be kept readily available at the place where the product is installed.
Strict adherence to these instructions is a precondition for the proper use and
correct operation of the product.
The installation and operating instructions correspond to the relevant version of
the product and the underlying safety regulations and standards valid at the time
of going to print.
EC declaration of conformity:
A copy of the EC declaration of conformity is a component of these operating
instructions.
If a technical modification is made on the designs named there without our agree-
ment or the declarations made in the installation and operating instructions on
product/personnel safety are not observed, this declaration loses its validity.
4 Safety
These operating instructions contain basic information which must be adhered to
during installation, operation and maintenance. For this reason, these operating in-
structions must, without fail, be read by the service technician and the responsible
specialist/operator before installation and operation.
It is not only the general safety instructions listed under the main point “safety”
that must be adhered to but also the special safety instructions with danger sym-
bols included under the following main points.

en
8
4.1 Indication of instructions in the operating manual
Symbols:
General danger symbol
Danger due to electrical voltage
NOTE:
Signal words:
DANGER!
Acutely dangerous situation.
Non-observance results in death or the most serious of injuries.
WARNING!
The user can suffer (serious) injuries. ‚Warning‘ implies that (serious) injury to
persons is probable if this information is disregarded.
CAUTION!
There is a risk of damaging the product/unit. ‚Caution‘ implies that damage to the
product is possible if this information is disregarded.
NOTE:
Useful information on handling the product. It draws attention to possible prob-
lems.
Information applied directly to the product, such as:
• Direction of rotation arrow,
• Identifiers for connections,
• Name plate,
• warning sticker,
must be strictly compliant with and kept in a fully legible condition.
4.2 Personnel qualifications
The installation, operating and maintenance personnel must have the appropriate
qualifications for this work.Area of responsibility, terms of reference and monitor-
ing of the personnel have to be ensured by the operator. If the personnel are not
in possession of the necessary knowledge, they have to be trained and instructed.
This can be accomplished if necessary by the manufacturer of the product at the
request of the operator.
4.3 Danger in the event of non-observance of the safety instructions
Non-observance of the safety instructions can result in risk of injury to persons
and damage to the environment and the product/unit. Non-observance of the
safety instructions results in the loss of any claims to damages.
In detail, non-observance can, for example, result in the following risks:
• Danger to persons from electrical, mechanical and bacteriological influences,
• Damage to the environment due to leakage of hazardous materials,
• Property damage,
• Failure of important product/unit functions,
• Failure of required maintenance and repair procedures.
4.4 Safety consciousness on the job
The safety instructions included in this installation and operating instructions, the
existing national regulations for accident prevention together with any internal
working,operating and safety regulations of the operator are to be compliant with.
4.5 Safety instructions for the operator
This appliance is not intended for use by persons (including children) with reduced
physical, sensory or mental capabilities, or lack of experience and knowledge, un-
less they have been given supervision or instruction concerning use of the appli-
ance by a person responsible for their safety.
Children should be supervised to ensure that they do not play with the appliance.
• If hot or cold components on the product/the unit lead to hazards, local meas-
ures must be taken to guard them against touching.
• Guards protecting against touching moving components (such as the coupling)
must not be removed whilst the product is in operation.

en
9
• Leakages (e.g. from a shaft seal) of hazardous fluids (e.g. explosive, toxic or hot)
must be led away so that no danger to persons or to the environment arises.
National statutory provisions are to be complied with.
• Danger from electrical current must be eliminated. Local directives or general
directives [e.g. IEC, VDE etc.] and local energy supply companies must be ad-
hered to.
• Faults of electronic devices due to electromagnetic fields Electromagnet-
ic fields are created during the operation of pumps with frequency convert-
er. Interference of electronic devices may be the result. The result may be a
device malfunction, which can result in damage to the health or even death,
e.g. of persons carrying implanted active or passive medical devices.
Therefore, during operation the presence of any persons e.g. with cardiac pace-
makers in the vicinity of the unit/pump should be prohibited.With magnetic or
electronic data media, the loss of data is possible.
WARNING! Danger due to strong magnetic field!
Inside the machine there is always a strong magnetic field that can cause
injury and damage to property in the event of incorrect dismantling.
• It is only permitted to have the rotor removed from the motor housing by
qualified personnel!
• There is a crushing hazard! When pulling the rotor out of the motor, it may be
suddenly pulled back into its initial position by the strong magnetic field.
• If the unit consisting of impeller, bearing shield and rotor is pulled out of the
motor, persons with medical aids, such as cardiac pacemakers, insulin pumps,
hearing aids, implants or similar are at risk. Death, severe injury and damage to
property may be the result. For such persons, a professional medical assess-
ment is always necessary.
• Electronic devices may be impaired functionally or damaged by the strong
magnetic field of the rotor.
• If the rotor is outside the motor, magnetic objects may be attracted very
suddenly.That can result in injury and damage to property.
In assembled condition, the rotor‘s magnetic field is guided in the motor‘s iron
core.There is therefore no harmful magnetic field outside the machine.
4.6 Safety instructions for installation and maintenance work
The operator must ensure that all installation and maintenance work is carried
out by authorized and qualified personnel, who are sufficiently informed from their
own detailed study of the operating instructions.
Work to the product/unit must only be carried out when at a standstill. It is man-
datory that the procedure described in the installation and operating instructions
for shutting down the product/unit be complied with.
Immediately on conclusion of the work, all safety and protective devices must be
put back in position and / or re-commissioned.
4.7 Unauthorised modification and manufacture of spare parts
Unauthorised modification and manufacture of spare parts will impair the safety
of the product/personnel and will make void the manufacturer‘s declarations re-
garding safety.
Modifications to the product are only permissible after consultation with the man-
ufacturer. Original spare parts and accessories authorised by the manufacturer
ensure safety. The use of other parts will absolve us of liability for consequential
events.
4.8 Improper use
The operating safety of the supplied product is only guaranteed for conventional
use in accordance with Section 7 of the operating instructions. The limit values
must on no account fall under or exceed those specified in the catalogue / data
sheet.

en
10
5 Transport and interim storage
Immediately after receiving check the product for damage in transit.
CAUTION! Risk of damage to property!
Incorrect transport and interim storage can cause damage to the product.
The pump must be protected from moisture, frost and mechanical damage due to
impact during transport and interim storage.
Transport conditions
The device must not be exposed to temperatures outside the range of -40 °C up
to +85 °C The transport conditions must be applied max. three months.
Storage conditions
The device must not be exposed to temperatures outside the range 0 °C up to
+40 °C.The storage time can be up to two years.The remaining water, in case of
customer production tests, cannot lead to frost damages.
6 Intended use
The circulation pumps of the Wilo-Yonos PARA series are designed for hotwater
heating systems and other similar systems with constantly changing volume flows.
Approved fluids are heating water in accordance withVDI 2035, water/glycol mix-
ture at a mixing ratio of max. 1:1. If glycol is added, the delivery data of the pump
must be corrected according to the higher viscosity, depending on the mixing ratio
percentage.
Intended use also includes following these instructions.
Any other use is regarded as incorrect use.
7 Product Information
7.1 Technical data
Approved fluids
(other fluids on request)
Heating water
(in accordance withVDI 2035)
Water-glycol mixtures (max. 1:1;
above 20% admixture, the pumping
data must be checked)
Power
Max. delivery head (Hmax) 6,2 m (6 m model) 7,3 m (7 m model)
Max. volume flow (Qmax) 3,3 m3/h
Permitted field of application
Temperature range for applications in
heating and air-conditioning systems
at max. ambient temperature. See
nameplate for “TF” indication
Ambient 52 °C = TF 0 to 110 °C
of 57 °C = 0 to 95 °C
of 60 °C = 0 to 90 °C
of 67 °C = 0 to 70 °C
Max. operating pressure According information on the
nameplate
Electrical connection
Mains connection 1~230 V +10 % / -15 %, 50 / 60 Hz
(acc. IEC 60038)
Motor/Electronics
Electromagnetic compatibility EN 61800-3
Emitted interference EN 61000-6-3 / EN 61000-6-4
Interference resistance EN 61000-6-1 / EN 61000-6-2
Protection class IP X4D
Insulation class F
RoHS conform
Minimum suction head at suction port for avoiding cavitation at
water pumping temperature
Minimum suction head at 50/95/110°C 0,5 / 4,5 / 11 m

en
11
8 Description and function
8.1 Description of the pump
The pump (Fig. 1) consists of a hydraulic system, a glandless pump motor with a
permanent magnet rotor, and an electronic control module with an integrated fre-
quency converter.The control module receives an external PWM signal for speed
control.This version is equipped with an LED for displaying the operating status of
the pump (see chap. 12, p. 12).
8.2 Functions
External control via a PWM signal
The actual/setpoint level assessment required for control is referred to a remote
controller.The remote controller sends a PWM signal as an actuating variable to
the Pump.
The PWM signal generator gives a periodic order of pulses to the pump (the duty
cycle), according to DIN IEC 60469-1.The actuating variable is determined by the
ratio between pulse duration and the pulse period.The duty cycle is defined as a
ratio without dimension, with a value of 0 … 1 % or 0 … 100 %. See PWM signal
logic 1 (heating) Fig. 2a and PWM signal logic 2 (solar) Fig. 2b.
9 Installation and electrical connection
DANGER! Danger of death!
Incorrect installation and electrical connection can result in fatal injury.
• Installation and electrical connection may only be carried out by qualified
personnel and in accordance with the applicable regulations!
• Adhere to regulations for accident prevention!
9.1 Installation
• Only install the pump after all welding and soldering work has been completed
and, if necessary, the pipe system has been flushed through.
• Install the pump in a readily accessible place for easy inspection and dismantling.
• When installing in the feed of open systems, the safety supply must branch off
upstream of the pump (DIN EN 12828).
• Install check valves upstream and downstream of the pump to facilitate a
possible pump replacement.
• Perform installation so that any leaking water cannot drip onto the control
module,
• To do this, aline the upper gate valve laterally.
• In thermal insulation work, make sure that the pump motor and the module
are not insulated.The condensate-drain openings must remain uncovered.
• Install the pump with the power switched off and the pump motor in a hori-
zontal position see Fig. 3 for installation positions of the pump.
• Direction arrows on the pump housing indicate the direction of the flow.
9.2 Electrical connection
DANGER! Danger of death!
A fatal shock may occur if the electrical connection is not made correctly.
• Only allow the electrical connection to be made by an electrician approved
by the local electricity supplier and in accordance with the local regulations in
force.
• Disconnect the power supply before any work.
• The current type and voltage must correspond to the details on the name plate.
• Maximum back-up fuse: 10 A, slow bow.
• Earth the pump according to the regulations.
• Mains connection: L, N, PE
Note:
For information on connecting the mains and signal cables see chap. 2.5,
p. 6.

en
12
10 Commissioning
WARNING! Risk of injury and damage to property!
Incorrect commissioning can lead to injuries to persons and damage to property.
• Commissioning by qualified personnel only!
• Depending on the operating status of the pump or system (fluid temperature),
the entire pump can become very hot.
Touching the pump can cause burns!
11 Maintenance
DANGER! Danger of death!
A fatal shock may occur when working on electrical equipment.
• The pump must be electrically isolated and secured against unauthorised
switch-on during any maintenance or repair work.
• Any damage to the connecting cable must always be rectified by a qualified
electrician only.
After successful maintenance and repair work, install and connect the pump ac-
cording to the “Installation and electrical connection” chapter. Switch on the pump
according to the “Commissioning” chapter.
12 Faults, Causes and Remedies
LED Meaning Diagnostic Cause Remedy
lights green Pump in operation Pump runs according its setting Normal operation
blinks quick green Pump in standby Normal operation
blinks red / green Pump in function but stopped Pump restarts by itself after the fault is
disappeared
1. Undervoltage U<160 V or
Overvoltage U>253 V
1. Check voltage supply 195
V < U < 253 V
2. Modul overheating: temperatur inside
motor too high
2. Check water and ambient
temperature
blinks red Pump out of function Pump stopped (blocked) Pump does not restart by itself due to a
permanent failure
Change pump
LED off No power supply No voltage on electronics 1. Pump is not connected to power supply 1. Check cable connection
2. LED is damaged 2. Check if pump is running
3. Electronics are damaged 3. Cange pump
If the fault cannot be remedied, please consult the specialist technician or the Wilo factory after-sales service.
13 Disposal
Damage to the environment and risks to personal health are avoided by the prop-
er disposal and appropriate recycling of this product.
1. Use public or private disposal organisations when disposing of all or part of the
product.
2. For more information on proper disposal, please contact your local council or
waste disposal office or the supplier from whom you obtained the product.
Technical information subject to change without prior notice!

en
13
Fig. 1:
Fig. 2b:Fig. 2a:
Fig. 3:
max
min
0712 15 95 100 PWM %
n/¹/min
max
n/¹/min
min
05 85 88 93 100 PWM %

en
14

en
15

Distributed by: RESOL – Elektronische Regelungen GmbH
Heiskampstraße 10
45527 Hattingen / Germany
Tel.: [phone] / 96 48 - 0
Fax: [phone] / 96 48 - 755
www.resol.com
[email protected]
Important note
The texts and drawings in this manual are correct to the best of our knowledge.As
faults can never be excluded, please note:
Your own calculations and plans, under consideration of the current standards and
directions should only be basis for your projects.We do not offer a guarantee for
the completeness of the drawings and texts of this manual - they only represent
some examples.They can only be used at your own risk. No liability is assumed for
incorrect, incomplete or false information and / or the resulting damages.
Note
The design and the specifications can be changed without notice.
The illustrations may differ from the original product.
Imprint
This mounting and operation manual including all parts is copyrighted.Any other
use outside the copyright requires the approval of RESOL – Elektronische Rege-
lungen GmbH. This especially applies to copies, translations, micro films and the
storage into electronic systems.
©RESOL – Elektronische Regelungen GmbH