Wilo PBI-L203MA User manual

INVERTER PUMP
Installation, Operation, and Maintenance Manual
♣ Before installing and operating the pump, the Safety Instructions must be
thoroughly read for the proper use of the pump.
♣Before installation, this manual should be completely studied. / Read this
manual completely before any work on your unit.
♣Keep this manual handy for future reference.
♣Product warranty is attached to this manual.
♣ATTENTION: To keep the pump at top efficiency, this manual
should be thoroughly studied.
BI-L203MA
BI-L205MA
BI-L404MA
BI-L405MA
BI-L802MA
BI-L803MA
Mode s

2
THANK YOU FOR PURCHASING THIS PUMP.
▶ This manual includes installation and operation instructions for PB - Model of WI O Pumps.
▶ To keep the pump at top efficiency, follow the recommended instructions in this manual.
▶ In case of lending the pump, this manual should be attached.
▶
I mproper operation not outlined in this manual may cause defects or physical damage that users are liable for.
▶ The WI O Pumps Customer Service Department is available for customers to ask any questions and to
give an advice on errors on this manual. Call our dealers or headquarter.
▶ Keep this manual handy for future reference.
INVERTER PUMP
FEATURES OF THE PUMP
▶Constant ressure: The inverter equipped with PID Controller and high-speed digital filter guarantee
constant pressure.
▶Energy cost saving: AVR(automatic voltage regulator) embedded in the hybrid inverter allows customers
to save energy cost.
▶Absorption of water hammer shock: The inverter designed to control revolution count absorbs water
hammer shock.
▶User-friendly handling: Optimized input value reduces customer’s input values.
▶Low-noise, low-vibration: The pump makes low-noise and low-vibration.
▶Stainless steel pump: The pump guarantees supply of clean water due to its material, A STS304.
▶Easy installation and maintenance: Package of accessories including piping helps customers easily
install and maintain the pump.
▶Light weight: ighter net weight makes installation and transportation easy.
▶Sophisticated design: The plastic case of the inverter has a sophisticated design.
< BI-L>

3
APPLICATION OF THE PUMP
SPECIFICATIONS OF THE PUMP
▶ The pump is suitable for boosting low water pressure in apartment houses, apartments, weekend
cottages, inns, houses, small sprinklers, school buildings, dormitories, and other buildings,
providingconstant water pressure.
※Water flow rate, water pressure(head), voltage, motor output are referred to on the nameplate.
Basic conditions are:
▶
The embedded converter for constant pressure enables control of the operating pressure depending
on the height of a building.
▶ Pressure gauge is engaged to show pump pressure.
▶ Pressure tank is attached to prevent rapid change of pressure in piping.
▶ The stainless steel pump and brass piping will remain free of rust stains.
FEATURES
▶Adjusting pressure setting
▶Overpressure protection
▶Auto restart after electricity failure
▶Auto restart after correcting errors
▶Dry running protection and zero flow detection
▶Optional operating modes: Pressure regulation mode, Constant speed mode, External signal control
▶Information and alarm signs are indicated on the display, helping easy search
STAINLESS HORIZONTAL MULTI-STAGE PUMP
▶The pump forms block-typed structure and every pump parts in contact with water is corrosion
resistant. (Approved by KTW and WRC)
▶The pump is equipped with Mono-Shaft, general-purpose mechanical seal, and plugs for suction and
discharge.
Ambient temperature
Ambient humidity
Power consumption
0~40°C (32~104°F)ocation Indoors
Pressurized condition
VVVF
Up to 80°C
centrifugal pump (horizontal
multi-stage stainless steel pump)
Suction condition
Inverter control
iquid Temperature
Pump
A relative humidity under
90% (no condensation)
Single phase
220V 60Hz

CONTENTS
Thank you for
purchasing our pump ........................... 2
Features ................................................... 2
Application ................................................ 3
Contents .................................................... 4
Safety Instructions ................................ 5
Transportation and
Installation instructions ................... 5~9
Operating instructions ................ 10~12
Maintenance .................................. 12~13
Dimension and Parts .......................... 14
Specifications ........................................ 14
Wiring Diagram .................................... 15
Performance Curve ............................ 15
Dimensions ...........................................16
Specifications of the Pump .............. 17
Connecting Sensors with the Pump
........ 17
Changing Operating Mode
................. 18
Reversing the Rotation of the Pump
....... 19
Keypad and Display ........................... 19
Indicators ...............................................20
Set Value ......................................... 21~22
Notifying Errors..................................... 23
Default Value for Inverter .................23
Remote control of the pump
..............24
Trouble shooting
..............................25~27
Thank you for purchasing our pump.
Follow the recommended instructions in this manual.
4

SAFETY INSTRUCTIONS
These instructions contain important information which must be followed when installing and operating the
pump. These operating instructions must therefore be read before assembly and commissioning by the installer
and the responsible operator. Both the general safety instructions in the "Safety precautions" section and those
in subsequent sections indicated with danger symbols should be carefully observed.
Safety precautions in these operating instructions which if not followed could cause personal injury are
indicated by the symbol: electrical warnings are indicated with:
The following symbol is used to indicate that by ignoring the relevant safety instructions, damage could be
caused to the pump/machinery and its functions:
● Indication of instructions in the Operating instructions
The personnel installing the pump must have the appropriate qualifications.
● Staff training
Failure to comply with the safety precautions could result in personal injury, damage to the pump, or damage
to the installation. Failure to comply with the safety precautions could also invalidate any claim for damages.
In particular, lack of care may lead to problems such as:
- Failure of important pump or machinery functions,
-P ersonal injury due to electrical, mechanical and bacteriological causes.
● Risks incurred by failure to comply with the safety precautions
Existing regulations for accident prevention must be followed. Dangers caused by electrical energy
are to be excluded. Directives issued by the VDE German Association of Electrical Engineers and the local
electricity supply companies are to be observed.
● Safety precautions for the operator
The operator must ensure that all inspection and installation work is carried out by authorized and qualified
specialists who have carefully studied these instructions. Work on the pump/machinery should only be
carried out when the machine has been brought to a standstill.
● Safety information for inspection and assembly
Alterations to the pump or installation may only be carried out with the manufacturer's consent. The use of
original spare parts and accessories authorized by the manufacturer will ensure safety. The use of any other
parts may invalidate claims invoking the liabilitty of the manufacturer for any consequences.
● Unauthorized modification and manufacture of spare parts
The operating safety of the pump or installation supplied can only be guaranteed if it is used in accordance
with paragraph 1 of the operating instructions. The limiting values given in the catalogue or data sheet must
neither be exceeded nor allowed to fall below those specified.
● Unauthorized operating methods
ATTENTION!
5

● The power cord must not be
bent, tied, pulled
or twisted by force.
Electric leakage,
electric shock, or fire
can occur.
TRANSPORTATION AND INSTALLATION
● When the power cord is extended, a voltage drop
that keeps the pump from operation may be caused.
Refer to the table for extended power cord.
WARNING!
AC220V
power cord
or plug
● Use a rated outlet with
voltage (220V) fluctuation
of less than
±
10%.
● To prevent electric shock,
never plug in a power
cord under wet
conditions.
● Install the pump where the pump can be
conveniently checked or
repaired after installation.
If the space for the pump
is narrow, make the room
as described on the figure.
● Concrete the foundation with cement to avoid
pump slant.
Concrete
Foundation
over 30cm
over 30cm over 30cm
● When the pump is highly likely to suck in dust
or foreign material, install a sand filter.
Failure to do so may cause a decline
in pressure and quantity
of pumped water, and
malfunction of the inverter.
● Install a stop valve on the suction side and the
discharge side of the pump
for easier pump maintenance.
Stop valve
Stop valve
CAUTION!
ength of power cable
shorter than 10
m
shorter than 200
m
nominal dimension of the cable
larger than 1.5
㎟
larger than 2.0 ㎟
● Before installation, repair or removal
of the pump, the power supply must be
disconnected.
● Install a breaker of electric leakage
of under 30mA of rated sensitivity
to prevent electric shock. Breaker
● Pay special attention to extensions of the power cord.
Any electric leakage or disconnection in the extension
may cause electric shock.
● How to extend the power cord.
① Peel off the rubber/plastic insulation of the cable
as long as the connection terminal is.
②Insulate the connection and cover it with rubber tape.
Then tightly cover it over four times
with friction tape.
● Don’t clasp the power cord in transportation
and installation.
The damaged cord may cause
electric leakage or shock.
Breaker
6
Sand filter

Pipe
Pipe
Union
Union
TRANSPORTAION AND INSTALLATION
● Handle the pump with care.
Do not drop.
● The permitted voltage fluctuation is within 10%
of the rated voltage. Otherwise contact a power
company.
● The pump should not be connected directly to
public waterworks. Permission from the authority
should be granted. This could shorten the life of
the pump.
● When the pump is used for
drinking water, a water purifier
must be installed.
※The pump has no
purification ability.
drinking
water
● When installing the pump,
make waterways to prevent
damage caused by water
leakage. Pay special
attention to a
basement, kitchen, and attic. Damage may occur.
waterway
● Set an anti-vibration plate
to absorb the vibration
of the pump.
● Install unions on the
suction side and
discharge side of the
pump for convenient
maintenance and
repair.
CAUTION!
● Connect the earth wire before
operation to prevent electric shock
when the electric insulation is faulty.
● Never get the power plug strained
with water, to prevent electric shock.
embed a cooper plate
or rod deeply in moist ground.
more than 75cm
※ NOTE!
• Disconnect the power supply
before connecting the earth wire.
• Gas pipe must not be connected
with earth wire. Otherwise
an explosion may occur.
more than 75cm
Gas Pipe
Earth wire
● Minimize the number of elbows to prevent water leakages in the piping
and to decrease water resistance.
● Set an alarm system to notify
the malfunction of the pump.
● Don’t expose the pump
to direct sunrays or
to rain, otherwise
faulty parts or an electric
shock may be caused.
7

운반·설치상의 주의사항
INSTALLATION
- The pump should be installed indoors. In case of installing outdoors, set eaves to avoid exposure to wind
and rain, and prevent the pump from freezing.
- The pump should be in pressurized condition. (Recommended suction pressure: 0.2kgf/cm2)
To prevent dry running, the water tank should always be higher than the suction port of
the pump. Keep the minimum suction pressure at all times.
Vent air out from the suction side tank after cleaning it.
Even in a pressurized condition, running the pump with air in the tank or with suction
condition, the mechanical seal may be worn and consequently the rotational part may fall
down upon the stationary part.
-Piping direction can vary depending on circumstances.
-Piping direction can be adjusted by loosening the union on discharge side.
-Tank is separately packed in shipping.
- Even in a pressurized condition, if an elbow is used, the suction piping should never be
of smaller diameter than the pump suction.
- An elbow close to the pump suction flange should be avoided. Abnormal noise and vibration may occur.
- The piping should be adequately supported on both sides to reduce mechanical stress on the pump
- Make the piping run as short as possible and minimize the number of elbows
- Attach a strainer for filtering foreign objects to the end of the suction piping.
- Install a stop valve on the suction side and the discharge side of the pump to make pump maintenance
easier.
- Install the bypass on the discharge side to make pump maintenance easier.
- When the pressure tank is damaged, the discharge pressure can fluctuate or the piping can leak.
- To minimize noise of the pump, install a flexible joint on the suction piping and the discharge piping, and use
an anti-vibration rubber.
Installation process
iping
iping direction
ic.1 ic.2 ic.3 ic.4
ATTENTION!
ATTENTION!
8

운반·설치상의 주의사항
INSTALLATION
Only a qualified electrician should connect cables. Install a circuit breaker and connect
earth wire to prevent any electrical accidents including electric shock.
- The wiring of major parts including the motor and the pressure sensor is already finished. Wiring of earth
and other optional parts should be conducted according to the wiring diagram.
- The power supply should be in accordance with the rated value marked on the nameplate.
- Before supplying power, check the following:
① if the circuit breaker at power is suitable (under 30mA of rated sensitivity).
② if the wiring is correct (connection and wire size).
③ If the connections with motor terminal are tightened (No operation with missing phase).
Wiring
● When the pump remains inactive for a long time at temperatures lower than 0°C, the pump body must
be completely empty through the drain valve to prevent possible cracking of the hydraulic components.
● Bury the horizontal piping at least 30cm under ground.
CAUTION! To prevent a fire, don’t cover the motor or pump with a blanket.
In winter, install protections against cold weather.
over 30cm
summer / not humid winter
lagging
ground
wooden plate
Cover the exposed piping.
waterway
waterway waterway
CAUTION!
ATTENTION!
9

● To prevent a fire, never wrap the motor of the pump head in a blanket or a cloth
to prevent freezing in cold weather.
The customers are liable for any damage caused by improper wrapping.
운반·설치상의 주의사항
USAGE
● Never conduct a shut-off operating under dry running condition
and delivering no water.
The life of the parts may be shortened and explosion may occur.
● In electricity failure, disconnect the pump with the
power supply. Sudden start up may cause
physical damage.
● If water penetrates into the
motor, malfunction or electric
leakage may occur.
● Disconnect the pump if it is unused for a long time.
Otherwise old insulation
may cause electric
shock or fire.
● Never use the pump with liquids other than water. A fire may be caused,
when chemicals or flammable liquids including petroleum, alcohol, or
gasoline are used. In addition, the service life of the pump may be
shortened and malfunctions are highly likely to occur.
● Never touch the pump with
a bare hand when the pump
is operating or just stops
operating.
Oil
Alcohol
Gasoline
● Never alter an automatic item into non-automatic one.
Reconstruction of the pump is prohibited.
● Any physical damage and property losses
cannot be compensated in this case.
● Never use hot water over 80°C in the pump.
Rubber parts and packing may be deformed,
and motor may
be damaged.
● When staring up the pump after a long time of inactivity, check if the rotating
parts turn freely. Turn off the power and insert a screwdriver
in the notch on the motor shaft from the fan side.
Motor
WARNING!
CAUTION!
electricity
failure
10

- Close the discharge valve (3) and open the air vent screw (5).
- Open the suction valve (2) to fill the pump with water.
- Close the suction valve when water comes out from the air vent screw.
- Close the air vent screw.
9
2 4 72 12
12
5
6
3
7
1-phase
220V
60Hz
HC
MIN
10
11
8
운반·설치상의 주의사항
USAGE
The suction pipe should be larger than the discharge pipe.
Make the piping run as short as possible and minimize the number of elbows.
The piping should be adequately supported on both sides to reduce mechanical stress on the pump.
* Install a stop valve on the suction side and the discharge side of the pump.
①riming the pump: The pump must not be run dry.
1. Make sure the pump has been primed and open the discharge valve.
2.
Switch on the power and verify that the motor rotates in right direction. Then turn on the power to pump up water.
3. If water is not primed up, power off and reprime the pump.
4.
Make sure that the pump operates without any problem. Then open and close the water tap to verify no leakage.
● Check the pressure gauge to confirm stable suction and discharge pressure. If the pressure fluctuates,
Reprime the pump.
● Verify the electronic current flow doesn’t exceed the rated value marked on the nameplate.
②Start-up of the pump
iping
Test running
※ Recommended suction pressure : 0.2kgf/cm2
※ Maximum suction pressure : 6kgf/cm2
1. Foot valve, strainer
2. Stop valve on the
suction side
3. Stop valve on the
discharge side
4. Check valve
5. Air vent screw
6. Drain cap
7. Pipe support
8. Strainer
9. Water tank
10. Piping
11. Monitor protector
12. Union
art Description
11

MAINTENANCE
● At first running, if you notice abnormal vibration, noise, or strange smell, turn off and disconnect the
pump from its source and contact the dealer or service center. Continuous operating in this case may
cause fire or electric shock.
● Don’t ever disassemble or alter the product.
- Fire, electric shock, or physical injury may occur.
- The pump must not be dismantled and repaired except by qualified skilled personnel.
- Contact our service center or dealer to have the pump repaired.
● When the power cord is broken, the replacement should be carried out by our dealer or other qualified
personnel.
● After assembled, the pump should be put to test running.
Incorrect assembly may cause malfunction, electric leakage, or water leakage.
WARNING!
CAUTION!
12

- The pressure in the tank must not exceed the rated maximum.
- Regularly check pre-charged gas pressure in the pressure tank.
When checking the pressure, stop the pump and drain the tank. Otherwise the pre-charged gas pressure
cannot be accurately measured.
- Check the pre-charged gas pressure every six months when using proper tank. When refilling the tank,
follow the instructions below:
Completely drain the tank and open the cap. Refill the tank with an injector or a compressor.
The injected pressure should be 90% of operating pressure or lower by 0.5 kgf/cm2than the pressure.
If it is difficult to drain the tank, stop the pump and start refilling the pressure when pre-charged gas pressure
is far less than needed.
- If the refilled pressure is much lower than operating pressure, the pressure tank may work abnormally.
-
If the refilled pressure is much higher than operating pressure, the pump may shutdown and restart frequently.
The timetable below shows how often a part should be replaced.
The wiring and setting of the inverter is already finished before delivery.
Never change any setting except data related to the operation.
The inverter is a semiconductor device that can be damaged by ambient temperature, humidity, and vibration.
To prevent malfunctions, pay attention to following:
① If there is any problem in wiring connections ② If there is abnormal vibrations or noise
③ If there is overheating, discoloration, or abnormal smell
- To prerent destruction of IC components, do not preform a voltage test or insulation resistance(mega test).
-
The electronic circuit is embedded in the inverter, so any contact with the inverter may cause static electricity
that can damage parts of the inverter.
Never touch the electronic circuit when repairing and checking the inverter. Otherwise use a ground
connection and earth Chassis when touching it.
- If the bolts and nuts are loosened or rusted, disconnect the power supply, and tighten or replace them.
- If there is a connection defect in the electromagnetic switch or abnormal noise, replace the part.
What to replace How often replace Whenever
Every one year it leaks
-
it is checked
Every three years abnormal noise occurs.
Every three years
discrepancy between pressure values
occurs, or value is uncertain.
Every three years operation is not certain.
Every three years connection is critically damaged
or malfunction occurs.
Every three years operation is not certain.
Mechanical seal
O-ring/ Casket
Motor bearing
Input transmitter
Pressure tank
Relays
PCBs
Pump/ Motor
Machinery
Control
panel
NOTE: The timetable is based on the assumption that
after startup, the unit has been operated at
rated load. So the schedule can be adjusted in
accordance with circumstance and operating
conditions.
Disposal of PCB or electronic parts must be carried
out in accordance with related laws and regulations.
This product includes PCB, so never dispose it in a
general waste collection.
운반·설치상의 주의사항
MAINTENANCE
Refilling ressure Tank
Maintenance time table
WARNING!
WARNING!
Checking Inverter
13

운반·설치상의 주의사항
SPECIFICATIONS
DIMENSION AND PARTS
Power Cord
Display
Inverter Cover
Inverter Base
Fan Cover
Motor
Base Plate
Pressure Gauge
※Pressure transmitter (pressure sensor): rated pressure 16bar, input voltage 5 VDc, output 0~5VCD(Voltage)
※ The volume of pressure tank : 2l
PBI Model Pump Impeller
stage
Motor
output
Inverter specifications
Rating output
Suction Discharge
Rating capacity
Pipe demension
14
Pressure Sensor
Check Valve
Union
Drain Plug
Pressure Tank
Cross Nipple
Priming Plug
Casing
PBI- 203MA MHI203i 25A 25A
25A 25A
32A 25A
32A 25A
40A
40A
32A
32A
0.75kW
1.1kW
1.85kW
1.1kW
1.85kW
1.85kW
1.85kW
3.0KVA
3.0KVA
4.5KVA
4.5KVA
4.5KVA
4.5KVA
1.1kW
1.85kW
1.5kW
1.85kW
1.5kW
Operation
Pressure
2㎏f/㎠4㎏f/㎠4㎏f/㎠2㎏f/㎠
2㎏f/㎠
4㎏f/㎠
MHI205i
MHI404i
MHI405i
MHI802i
MHI803i
PBI- 205MA
PBI- 404MA
PBI- 405MA
PBI- 802MA
PBI-803MA
3
5
4
5
2
3

운반·설치상의 주의사항
WIRING DIAGRAM
운반·설치상의 주의사항
PERFORMANCE CURVE
15
Pump
(Red, Green, Black)
RS232(Black, Blue, Yellow)

DIMENSIONS
16
Model
PBI- 203MA
Dimension(mm) Weight
(kg)
H
580
580
580
H1H2H312ØD1ØD2
90
90
90
120
120
120
435
435
435
360
425
425
204
252
252
109.5
157.5
157.5
1”
1”
1 1/4”
1”
1”
1”
13
14
19.5
PBI- 205MA
PBI- 404MA
580
580
90
90
120
120
435
435
425
360
252
204
157.5
109.5
1 1/4 ”
1 1/2 ”
1”
1 1/4”
20
18
PBI- 405MA
PBI- 802MA
580 90 120 435 360 204
109.5
1 1/2 ”
1 1/4”
19 PBI- 803MA
Unit(mm)

운반·설치상의 주의사항
INVERTER DISPLAY
운반·설치상의 주의사항
SENSOR CONNECTION OF INVERTER PUMP
17
For avoiding electric accidents by high voltage and hazards caused by the leakage of
inverter and condensers, please pull-out the power cord and wait more than 5 minutes.
Every connections (include with potential-free connections) check the poles.
1. Display
Easy display for user
2. Control Button
Use to change the system information
or check.
Keep the power off before connection
- Sensor connection
Pressure auto control mode : Should connect sensor for pressure control
Pressure manual control mode : Sensor is assist function of checking pressure and display
1. Sensor input
Need the qualified person’s help to install the relative pressure for measure the pressure of suction and discharge pipes
Sensor input

18
pump stop
운운·운운운운 운운운운
INVERTER CONTROL BUTTEN EXPLANATION
운운·운운운운 운운운운
STATUS DISPLAY EXPLANATION
Status display when pump stop
Status display when pump running
Set the pressure in a auto control mode, change the motor
frequency in a manual mode
Pump run, parameter save in a setting mode
Pump stop, parameter cancel in a setting mode
parameter increase in a setting mode, change the status in a
status display menu
parameter decrease in a setting mode, change the status in a
status display menu
Current pressure display setting pressure display
Current mode display
Current pressure display setting pressure display
Current frequency display
saved error check

19
운운·운운운운 운운운운
AUTO CONTROL MODE PRESSURE SETTING
운운·운운운운 운운운운
PARAMETER SETTING
Warning!
Stop the pump before pressure setting
Press the stop button and pump stop
Press the “P” button, display will change the pressure setting
menu.
Press the + or - , change the setting.
Press the + or – move “Mode”,
and press the auto button.
Press the Auto button and save.
Press the + or – move
“Manu”, and press the
auto button.
Press the + or – change
the frequency and press
auto button(save).
Press the stop button, display
will change initial screen.
Press the stop button and display will change initial screen.
Ex) How to change setting pressure 2.0 to 3.0 bar
- Open the cover and press the “menu” button in a back of
PCB when change the parameter setting

20
운운·운운운운 운운운운
PARAMETER MENU
※ MENU button is not in front
interface. Open the inverter cover,
menu button is located in back of
interface PCB.
Press the “stop”
button, move to stop
status in each menu
Pump power
Rotation of motor
Move the
menu by + or -
Warming up time
Sensor offset
Dry run pressure setting
Running mode setting
Stop flow time setting
Hi-pressure setting