Wilo Control Booster CC User manual

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2 552 577-Ed.01 / 2020-12-Wilo
Wilo-Control CC-Booster (CC, CC-FC, CCe)
en Installation and operating instructions

Fig. 1a:
Comfort Control
6
1
7
8
2
3
1
Fig. 1b:
Comfort Control
6
1
7
8
2
3
1

Fig. 1c:
Comfort Control
4
1
6
8
2
3
1
6
7
5
Fig. 1d:
Comfort Control
4
18
2
3
1
6
7
5

Fig. 1e:
Comfort Control
8
1
2
3
6
1
Fig. 2:
Fig. 3:

Fig. 4a:
Fig. 4b:
Fig. 4c:

English
2WILO SE 12/2020
1 General information ..............................................................................................................................3
2 Safety ......................................................................................................................................................3
2.1 Symbols and signal words in the operating instructions .................................................................................. 3
2.2 Personnel qualifications ........................................................................................................................................ 3
2.3 Danger in the event of non-observance of the safety instructions ................................................................ 3
2.4 Safety consciousness on the job .......................................................................................................................... 3
2.5 Safety instructions for the operator ................................................................................................................... 4
2.6 Safety instructions for installation and maintenance work ............................................................................. 4
2.7 Unauthorised modification and manufacture of spare parts ............................................................................ 4
2.8 Improper use .......................................................................................................................................................... 4
3 Transport and temporary storage .......................................................................................................4
4 Application (Intended use) ................................................................................................................... 4
5 Product information .............................................................................................................................. 5
5.1 Type key ................................................................................................................................................................ 5
5.2 Technical data ........................................................................................................................................................ 5
5.3 Scope of delivery ................................................................................................................................................... 5
5.4 Accessories ............................................................................................................................................................. 6
6 Description and function ...................................................................................................................... 6
6.1 Description of the product (Fig. 1) ....................................................................................................................... 6
6.1.1 Function description .............................................................................................................................................. 6
6.1.2 Set-up of the switchgear ...................................................................................................................................... 6
6.2 Function and operation ......................................................................................................................................... 6
6.2.1 Switchgear operating modes ................................................................................................................................ 7
6.2.2 Motor protection ................................................................................................................................................... 8
6.2.3 Operation of the switchgear ................................................................................................................................ 9
7 Installation and electrical connection ...............................................................................................10
7.1 Installation ............................................................................................................................................................10
7.2 Electrical connection ...........................................................................................................................................10
8 Commissioning .....................................................................................................................................14
8.1 Factory setting .....................................................................................................................................................14
8.2 Checking the motor direction of rotation .........................................................................................................14
8.3 Setting the motor protection .............................................................................................................................15
8.4 Signal transmitters and optional modules ........................................................................................................15
9 Maintenance .........................................................................................................................................15
10 Faults, causes and remedies ...............................................................................................................15
10.1 Fault display and acknowledgement .................................................................................................................15
10.2 History memory for the faults ............................................................................................................................15
11 Appendix ..............................................................................................................................................17
11.1 ModBus: Data types .............................................................................................................................................17
11.2 ModBus: Parameter overview .............................................................................................................................17

English
Installation and operating instructions Wilo-Control CC-Booster 3
Installation and operating instructions
1 General information
About this document
The language of the original operating instruc-
tions is German. All other languages of these
instructions are translations of the original oper-
ating 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 intended use and correct
operation of the product.
These installation and operating instructions cor-
respond to the relevant version of the product and
the underlying safety standards valid at the time
of going to print.
EC-Declaration of conformity:
A copy of the EC-Declaration of conformity is an
integral part of these installation and operating
instructions.
If a technical modification is made to the designs
named in the declaration without our prior agree-
ment, or the declarations made in the installation
and operating instructions on product/personnel
safety are not observed, this declaration is no
longer valid.
2Safety
These installation and operating instructions con-
tain basic information which must be adhered to
during installation, operation and maintenance.
For this reason, it is mandatory that these installa-
tion and operating instructions are read by the
service technician and the responsible qualified
personnel/operator before installation and com-
missioning.
Not only must the general safety instructions
listed under this main "Safety" section be adhered
to, but also the special safety instructions that are
marked by danger symbols and included under the
following main sections.
2.1 Symbols and signal words in the operating
instructions
Symbols:
General danger symbol
Danger due to electrical voltage
NOTICE
Signal words:
DANGER!
Acutely dangerous situation.
Non-observance will result in death or
extremely serious injuries.
WARNING!
The user could suffer (serious) injuries.
"Warning" implies that (serious) injury to
persons is probable if this information is disre-
garded.
CAUTION!
There is a risk of damaging the product/unit.
"Caution" implies that damage to the product is
likely if this information is disregarded.
NOTICE:
Useful information on handling the product. It
draws attention to possible problems.
Information that appears directly on the product,
such as
•direction of rotation arrow,
• identifiers for connections,
• rating plate,
• warning stickers,
must be strictly complied with and kept in a fully
legible condition.
2.2 Personnel qualifications
The installation, operation and maintenance per-
sonnel must have the appropriate qualifications
for this work. The area of responsibility, responsi-
bility and monitoring of the personnel are to be
ensured by the operator. If the personnel do not
possess the necessary knowledge, they are to be
trained and instructed. This can be carried out, if
necessary, by the product manufacturer at the
operator’s request.
2.3 Danger in the event of non-observance of the
safety instructions
Non-observance of the safety instructions can
result in the risk of injury to persons and damage
to the environment and the product/unit. Non-
observance of the safety instructions will render
any claims for damages null and void.
In particular, non-observance can, for example,
result in the following risks:
• danger to persons due to electrical, mechanical
and bacteriological factors,
• damage to the environment due to leakage of
hazardous materials,
•material damage,
• failure of important product/unit functions,
• failure of required maintenance and repair
procedures.
2.4 Safety consciousness on the job
The safety instructions included in these installa-
tion and operating instructions, the existing
national regulations for accident prevention,
together with any operator’s internal working,
operating and safety regulations are to be com-
plied with.

English
4WILO SE 12/2020
2.5 Safety instructions for the operator
This appliance is not intended for use by persons
(including children) with reduced physical, sensory
or mental capabilities, or who lack experience and
knowledge, unless they have been given supervi-
sion or instruction concerning the use of the
device by a person responsible for their safety.
Children should be supervised to ensure that they
do not play with the device.
• If hot or cold components on the product/the unit
lead to hazards, measures must be taken on-site
to prevent them from being touched.
• Guards for moving components (such as the cou-
pling) must not be removed whilst the product is
in operation.
• Leakages (e.g. from the shaft seals) of hazardous
fluids (which are explosive, toxic or hot) must be
discharged so that no danger to persons or to the
environment arises. National statutory provisions
are to be complied with.
• Highly flammable materials should always be kept
a safe distance from the product.
• Danger due to electrical current must be elimi-
nated. Local directives or general directives [e.g.
IEC, VDE etc.] and instructions from local energy
supply companies must be adhered to.
2.6 Safety instructions for installation and
maintenance work
The operator must ensure that all installation and
maintenance work is carried out by authorised and
qualified personnel who have sufficiently familiar-
ised themselves with the installation and operat-
ing instructions by studying them in detail.
Work on the product/unit must only be carried out
when at a standstill. The procedure described in
the installation and operating instructions for
shutting down the product/unit must be strictly
observed.
Immediately after completing work, all safety and
protective devices must be put back in position
and/or recommissioned.
2.7 Unauthorised modification and manufacture of
spare parts
Unauthorised modification and manufacture of
spare parts will impair the safety of the product/
personnel and void the manufacturer’s declara-
tions regarding safety.
Modifications to the product are only permissible
following consultation with the manufacturer.
Original spare parts and accessories authorised by
the manufacturer ensure safety. The use of other
parts will absolve the manufacturer of liability for
any consequences arising therefrom.
2.8 Improper use
The operational reliability of the supplied product
is only guaranteed if used as intended and in
accordance with section 4 of the installation and
operating instructions. The limit values must on
no account fall under or exceed those values
specified in the catalogue/data sheet.
3 Transport and temporary storage
Immediately after receiving the product:
• Check product for transport damage,
• In the event of damage in transit, take the neces-
sary steps with the forwarding agent within the
respective time limits.
CAUTION! Risk of property damage!
Incorrect transport and temporary storage can
cause damage to the product.
• The switchgear is to be protected against mois-
ture and mechanical damage.
• It must not be exposed to temperatures outside
the range of -10 °C to +50 °C.
4 Application (Intended use)
The CC switchgear is used for automatic, conven-
ient control of pressure-boosting systems (single
and multi-pump systems).
The field of application is water supply in residen-
tial towers, hotels, hospitals, offices and industrial
buildings.
When used in conjunction with suitable signal
transmitters, the pumps offer low-noise and
energy-saving operation. The performance of the
pumps is adapted to the constantly changing
requirements in the heating / water-supply
system.
Intended use also includes compliance with this
manual.
Any other use is regarded as non-intended use.

English
Installation and operating instructions Wilo-Control CC-Booster 5
5Product information
5.1 Type key
5.3 Scope of delivery
• CC-Booster switchgear
• Circuit diagram
• CC-Booster installation and operating
instructions
• Frequency converter installation and operating
instructions (only for CC... FC version)
• Factory test report
e.g.: Wilo-Control CC-B 3x10A T34 DOL FC WM
CC
CCe
Comfort Control switchgear for fixed
speed pumps
Comfort Control switchgear for electronic
pumps
Pressure boosting application
4 x Number of pumps 1 – 6
10 Max. rated current per pump in amperes
[A]
T Mains connection:
M = alternating current (1~)
T = three-phase current (3~)
34 Rated voltage:
2 = 220 – 230 V
34 = 380 – 400 V
DOL Pump activation type:
DOL = direct
SD = star-delta
FC With Frequency Converter
WM Installation type:
WM = Switchgear is mounted on a
mounting bracket (wall mounted)
BM = Floor model (base mounted)
5.2 Technical data
Mains supply voltage [V]: See rating plate
Frequency [Hz]: 50/60 Hz
Control voltage [V]: 24 VDC; 230 VAC
Max. current consumption [A]: See rating plate
Protection class: IP54
Max. fuse protection on mains side [A]: See circuit diagram
Ambient temperature [°C]: 0 to +40 °C
Electrical safety: Pollution degree II

English
6WILO SE 12/2020
5.4 Accessories
Accessories must be ordered separately:
(see also Wilo-Select)
6 Description and function
6.1 Description of the product (Fig. 1)
6.1.1 Function description
The Comfort switchgear, controlled by a program-
mable logic controller (PLC), is used to control
pressure-boosting systems with up to 6 single
pumps. The pressure of a system is controlled as a
function of the load with appropriate signal trans-
mitters. The controller acts on a frequency con-
verter (CC-FC version), which in turn influences
the speed of the base-load pump. A modification
of the speed changes the volume flow and thus
the rated power of the pressure-boosting system.
Only the base-load pump is speed-controlled.
Uncontrolled peak-load pumps are switched on
and off automatically according to load require-
ments, while the base-load pump handles
fine-tuning to the pre-set setpoint.
In the CCe version, each pump has an (integrated)
frequency converter.
6.1.2 Set-up of the switchgear
The set-up of the switchgear is dependent on the
performance of the pumps that are to be con-
nected, and the version (CC, CC-FC, CCe) (see:
Fig. 1a CC direct starting; Fig. 1b CC star-delta
starting, Fig. 1c CC-FC direct starting; Fig. 1d
CC-FC star-delta starting, Fig. 1e CCe). It consists
of the following main components:
• Main switch: Switches the switchgear on/off
(item 1).
• Touch display: Display of operating data (see
menus) and the operating status. Menu selection
and parameter input possible via touch sensitive
surface (item 2).
• Programmable logic controller: Modular design
PLC with power supply unit. The configuration
depends on the system (item 3).
• Frequency converter: Frequency converter for
load-sensitive speed control of base-load pump -
only available for CC-FC version (item 4).
• Motor filter: Filter for ensuring a sinusoidal motor
voltage and for suppressing voltage peaks - only
in the CC-FC version (item 5).
• Fuse protection for drives and frequency con-
verter: Fuse protection for the pump motors and
the frequency converter. For devices with
P2 ≤ 4.0 kW: Motor protection switch. On the CCe
version: Circuit breaker for the fuse for the pump
mains supply cable (item 6).
• Contactors/contactor combinations: Contactors
for switching on the pumps. In devices with
P2 ≥ 5.5 kW, including the thermal tripping
devices for excess current protection (default
value: 0.58 * IN) and the time relay for the star-
delta switchover (item 7).
• Manual-0-Automatic switch: Switch for selecting
the pump operating modes "manual" (emergency/
test operation on the mains; motor protection
available), "0" (pump switched off – no activation
possible via PLC) and "auto" (automatic mode
enabled via PLC) (item 8).
The speed of every pump (0 – 100 %) can be set
in manual mode with the manual control in the
CCe version.
6.2 Function and operation
DANGER! Risk of fatal injury!
When working on the open switchgear, there is
a danger of electric shock from touching the live
components.
The work must only be carried out by qualified
personnel!
Option Description
Signal module Relay output module for outputting individual operation
signals and fault signals
DDC and control module Input terminal assembly for switching potential-free control
contacts
GSM module Mobile radio module for dialling into GSM networks
GPRS module Mobile radio module for dialling into GPRS networks
WebServer Controller module for connection to Internet or Ethernet data
transmission
Communication module "ProfiBus DP" Bus communication module for "Profibus DP" networks
Communication module "CanOpen" Bus communication module for "CanOpen" networks
Communication module "LON" Bus communication module for "LON" networks
Communication module "ModBus RTU" Bus communication module for "ModBus" networks
Communication module "BACnet" Bus communication module for "BACnet" networks
Mains switching External auxiliary device for switching to redundant supply
network
Other options on request