Wilo Comfort Series Manual

Installation, Operation and Maintenance Instructions
For
Comfort Series Pressurisation Units
Models: P135, P235, P160, P260, P180, P280
Date: 07/01/2013

1: Installation
Location
The following should be considered when choosing the position of the pump
set:
The area should be dry and well ventilated.
There must be protection against frost.
There must be adequate drainage facilities.
The area must be secure to prevent unauthorised access / tampering.
Provision for the use of lifting equipment should be made.
There must be at least 1 meter clear area in front of panel and 0.5m at
either side and rear to aid maintenance.
Foundations
Foundations must be ridged and level, a plinth is not essential although it will
assist in keeping the set clear of damp. When fixing care must be taken not to
distort the set by tightening unevenly.
Pipework
Pipework connections to the set should be at least the same size as the
connections on the set, (if you require connections to be smaller contact Wilo
for advice).
Impurities
The water should be clean of all impurities. The sand content should not
exceed 0.01g/l. The size of any suspended bodies should not be such as to
clog or wear the hydraulic components.
On dirty water applications a filter must be installed in the suction pipe.
Electrical Connections
The installer must check that the available supply is compatible with the
voltage and frequency stamped on CE Label. Cable and fuses used for the
incoming electricity supply must be rated to cover all pumps running. Earth
bonding Inline with current IEE regulations is the responsibility of the installer.
Water Connections
Wholesome water supply can be connected directly to the float valve as back
contamination is prevented by the AB airgap within the pressurisation unit, this
unit can be connected to systems up to and including category 5
A quick fill loop by passing the pressurisation unit is not required, the comfort
controller has a system fill feature that allows the unit to fill the system via the
AB air gap over a 24 hour period.

2: Operation
Wilo Pressurisation units sets are available in 1 and 2pump (Duty / Standby)
configurations.
General
Wilo Pressurisation units work on closed loop pressure control via a
transducer and electronic controller. The control philosophy will allow the duty
pump to run ensuring that the CF pressure (Bar) is constantly met. On two
pump systems the duty will rotate between both pumps after each cycle to
ensure even wear. If the duty pump fails the standby pump will automatically
start.
Factory Settings:
Cold Fill Pressure CF 1.0 Bar
Low Pressure Alarm LP 0.6 Bar
High Pressure Alarm HP 2.7 Bar
Excess Starts Alarm ES ON
System Fill SF OFF
Alarm Latching AL OFF
Pump Config PC OFF
These values can be viewed in VIEW mode by pressing the down arrow and
scrolling through the menu. Pump configuration can be altered between Hand-
Off-Auto in this mode.
These values can be altered in USER mode to suit particular site conditions
by entering the password, 1234, and following flow diagram.
Auto Restart
This unit will automatically restart on power up after a mains failure or power
down. The BMS volt free contact 8 can be configured to mains failure if
required.
Low Water
If the water level in the break tank reaches an unacceptably low level, the float
switch is activated which prevents the pumps from running and activates an
audible, visual and volt free alarm
If alarm latching is OFF then the alarm will reset once break tank has been
replenished with water.
Low Pressure (LP)
This parameter can be altered in the User menu.
If the system pressure drops below LP setting an audible, visual and volt free
alarm activates.
If alarm latching is OFF then the alarm will reset once the duty pump has
increased the pressure past the LP setting
High Pressure (HP)
This parameter can be altered in the User menu.

If the system pressure rises above HP setting the pump stops and an audible,
visual and volt free alarm activates. This parameter can be changed by
following flow diagram.
If alarm latching is OFF then the alarm will reset once the system pressure
has fallen below the HP setting.
Excess Starts (ES)
If ON the alarm will activate and stop the pumps if the pump has started too
many times within a set period of time, this will activate an audible, visual and
volt free alarm.
The excess starts variables can be altered at time of commissioning
System Fill (SF)
If ON will overide System Leak alarm and allow pump to run for 24 hours or
until the CF pressure has been met, then the controller returns back to normal
operation.
To be used for initial System Fill during commissioning.
Pump Trip
The FLC of the pump is monitored by the controller whilst running and if
exceeded will stop the pump and activate an audible, visual and volt free
alarm. On a 1 pump unit or if both pumps are stopped via a trip alarm the
boiler interlock volt free alarm is also activated.
Pump Fail
The FLC of the pump is monitored by the controller whilst running and if no
current is drawn it will stop the pump and activate an audible, visual and volt
free alarm. On a 1 pump unit or if both pumps are stopped via a fail alarm the
boiler interlock volt free alarm is also activated.
Pump Check
All Wilo pressurisation units will automatically check the operation of the pump
by running them for a short period of time if they have been inactive for a long
period of time
The pump check variables can be altered at time of commissioning
Alarm Latching
If OFF then all alarms will reset once alarm condition has deactivated
If ON then alarms will have to be manually reset via reset button on the front
panel.
Alarm Log
The alarm log, logs the last 30 alarm events and these can be viewed from
the view or user mode.
Volt free contacts
This unit has the facility for 10 volt free alarms for remote monitoring, please
note all contacts are rated at 230V 5 Amp max.
Pump no. 1 fail/trip normally closed / common / normally open
Pump no. 1 run normally closed / common / normally open

Pump no. 2 fail/trip normally closed / common / normally open (If fitted)
Pump no. 2 run normally closed / common / normally open (If fitted)
Low Pressure normally closed / common / normally open
High Pressure normally closed / common / normally open
Excess Starts normally closed / common / normally open
Low Water normally closed / common / normally open
Boiler Interlock normally closed
The unit also has one off volt free contact that is rated for 230V 10Amp max,
which can be programmed at time of commissioning between
Common pressure alarms normally closed / common / normally open
Mains failure normally closed / common / normally open
Common alarm normally closed / common / normally open
3A: Pre-Commissioning checks
The pressurisation unit is piped up to system and water is available.
The unit is wired up correctly in accordance with wiring diagram, that
all connections are tight and the installation has been earth bonded to
current regulations.
System has been filled by the system fill function or quick fill loop
3B: Commissioning
Calculate the Cold Fill Pressure (CF):
CF= (A + 2.5)/10.2 Bar
Where A is the height of the building above the pressurisation unit in meters.
In cases of Roof Top plant rooms the minimum CF = 0.8 Bar.
Check air pressure in vessel whilst empty of water, air pressure should be
equal to CF pressure, use nitrogen to increase pressure if necessary.
Turn switch to OFF position.
Close all isolating valves.
Open any inlet valves to unit and allow break tank to fill ensuring ball float
valve closes before water level is 25mm below overflow. If water does reach
over flow adjust height of ball float.
Prime each pump in turn, by opening the vent plug on each pump.
Ensure common main discharge isolating valve is closed.
Turn switch to ON position.

Key in password, 1234, to enter the Main Menu and scroll through windows
entering settings to suit the installation, CF as above, LP should be at least
0.2 bar below CF and HP which should be 0.5 bar below the setting on
system safety valve.
If the system has not been filled by a quick fill loop the System Fill function
can be utilised by selecting ON. This will allow the pump to run for 24 hours or
until the CF pressure has been met.
Switch pumps(s) into Auto
Test High Pressure alarm by reducing the HP setting to 0.5 bar above the CF
and running one pump in Hand.
Test Low Pressure alarm by switching the pumps OFF, close main discharge
valve and slowly drain water from the system via drain cock until the LP
setting has been reached.
Ensure all settings are returned to normal and all valves are open
Check the units and system pipework for any leaks and flooding.
Warning
When running the unit in System Fill mode the system leak alarm is switched
OFF and the pump will continue to run if there is a leak on the system
4: Maintenance
Wilo pressurisation units are designed to ensure minimum maintenance is
required. However routine inspection is necessary and can be carried out by
Wilo, please contact our service department for details.
Every 6 months:
Check unit for leaks.
Check for corrosion especially on vessel and ensure water is not present
when Schrader valve (on top of vessel) is pressed down.
Every 12 months:
Check pump set for leaks.
Check for corrosion especially on vessel and ensure water is not present
when Schrader valve (on top of vessel) is pressed down.
Isolate vessel, drain down, check and recharge vessel with nitrogen.
Check motor / pump shafts are free to rotate.
Check operation of all valves to ensure they have not seized and or letting by.
Check operation of pressurisation to ensure it is still working within design
parameters.
Warning
Wilo would advise that power to the unit be isolated before any of the above is
undertaken, as the pump will start automatically.

5: Written Scheme of Examination
Accumulator vessels are classed as a pressure system under the Health and
Safety Executive ‘Pressure system safety regulations 2000’. This regulation
imposes a legal requirement on the user/maintainer to have the equipment
inspected by a competent company on a regular basis as a mandatory duty
under parts 7 & 8 of the regulations.
A supplier / installer may not fall under the category of user / maintainer,
however they are still obliged to inform the user / maintainer of their legal and
mandatory duties under the HSE Regulation.
Wilo recommend that any vessel over 250 bar / litres should have a working
test every 6 months and a thorough examination every 24 months.
Bar/Litre = Maximum Working Pressure (Bar) x Volume of vessel (Litres)
6: Warranty
This equipment is covered against manufacturing defects for 12 months from
date of purchase.
This warranty covers the replacement of parts or products, verified as
having a manufacturing defect, when inspected in the factory.
WILO reserve the right to inspect an installation to verify that the equipment
has been installed in accordance with the written instructions.
Any modifications to the supplied equipment must be approved in writing;
failure to do so will invalidate the warranty
Site Visit
Before requesting a site visit, the following information must be available to
the service team:
Article number of the equipment
A purchase order to cover the work in the event that no manufacturing
defect is found.
A site contact name and number
A FULL description of the alleged fault

7: Fault Finding Chart
Indication
Possible Reason
Action
Pump/s Don’t Run
Power Fail, Pressure not below CF-
Differential pressure. Pump Drive fault.
Check: Power to the Unit; Discharge valve is
open; Pressure settings; Electrical connections.
Boiler Not Running.
Power Failure, Low Pressure Alarm.
Check: for Low Pressure Alarm; Electrical
connections.
LCD is blank; Power
LED & Backlighting OK
Contrast fault. Connection fault, firmware
lock-up error.
Reset the Display by pressing Reset Key for 5-
seconds. Check ribbon cable connectors. Reset
the Control PCB by Power-down & Restart.
LCD Blank, No Power
LED or backlighting.
Power failure. PCB Failure.
Check: Mains feed to Unit; PCB fuse F3; Ribbon
cable connectors; Electrical connections .
Pump Trip Alarm
Pump draws excessive current.
Reset Alarm. Pump may require servicing. Check:
Pump rotates freely; Water flow.
Pump Fail Alarm
Pump draws zero current.
Check: Fuse (replace if required); Wiring; Pump.
Low Pressure Alarm
System Pressure is below Low Pressure
Alarm setting.
Check: Pumps operate correctly; System for
leaks/flooding; Alarm Latching is OFF.
High Pressure Alarm
System Pressure is above High Pressure
Alarm setting.
Check: Pumps operate correctly; ‘Pump Check’
settings (adjust frequency if required); Discharge
Isolation valve; Alarm Latching is OFF.
System Fill Alarm
Pump has run for 24-hours, with System Fill
active, & not yet reached CFP.
Check: System Pressure. Reset audible alarm.
Press Rest Key again to clear Alarm. Switch
System Fill ON if required.
Service Due Alarm
Service Period expired.
Ensure that the Pressurisation unit is serviced.
Low Water Alarm
Water Level in break tank low.
Check mains water inlet. Check ball valve
operation. Check Float switch operation.
High Water Alarm
Water level in break tank high.
Check ball valve operation. Check float switch
operation.
Pump Hunting
Settings incorrect for system. Pressure
Vessel/connection faulty
Check: Settings for Minimum Run & Start Delay;
Discharge valve; NRVs; Pressure vessel
operation & Connection; Transducer wiring
Pumps running
continuously
System Pressure not reaching CF.
Check: System for leaks; NRVs; Pumps;
Transducer & wiring. Check/Adjust System Leak
timer.
Transducer Fail
Excessive pressure rise or fall; Pressure not
changing with Pump running
Check: Discharge valve open; Transducer Wiring;
Reading Rises & Falls with pressure changes.

8: PARAMETER CHART & WIRING DIAGRAM