Wilo SiClean Comfort Series User manual

Wilo-SiClean Comfort
Pioneering for You
4 196 355-Ed.01 / 2015-05-Wilo
de Einbau- und Betriebsanleitung
en Installation and operating instructions
fr Notice de montage et de mise en service
nl Inbouw- en bedieningsvoorschriften

Fig. 1:
1
10
11
5
6
4B 4A
3
2
8
9
7
Fig. 2:
5
4
1
2
3

Fig. 3:
3
6
2
4
5
1
1

Fig. 4:

English
WILO SE 05/2015
1 General ..................................................................................................................................................27
2 Safety ....................................................................................................................................................27
2.1 Indication of instructions in the operating instructions .................................................................................27
2.2 Personnel qualifications ......................................................................................................................................28
2.3 Danger in the event of non-observance of the safety instructions ..............................................................28
2.4 Safety consciousness on the job ........................................................................................................................28
2.5 Safety instructions for the operator .................................................................................................................28
2.6 Safety instructions for installation and maintenance work ...........................................................................28
2.7 Unauthorised modification and manufacture of spare parts ..........................................................................29
2.8 Improper use ........................................................................................................................................................29
3 Transport and interim storage ...........................................................................................................29
3.1 Transport for installation/removal purposes ....................................................................................................29
4 Intended use .........................................................................................................................................29
5 Product information ............................................................................................................................30
5.1 Type key ................................................................................................................................................................30
5.2 Technical data .....................................................................................................................................................30
5.3 Scope of delivery .................................................................................................................................................30
6 Description and function ....................................................................................................................30
6.1 General description .............................................................................................................................................30
6.2 Description of the product .................................................................................................................................30
6.3 Function of the SiClean Comfort system .........................................................................................................31
7 Switchgear ...........................................................................................................................................32
7.1 Technical data .....................................................................................................................................................32
7.2 Scope of delivery .................................................................................................................................................32
7.3 Options ..................................................................................................................................................................32
7.4 Description ...........................................................................................................................................................32
7.5 Function and operation .......................................................................................................................................33
8 Installation and electrical connection ...............................................................................................44
8.1 Installation ............................................................................................................................................................44
8.2 Hydraulic connection ...........................................................................................................................................44
8.3 Electrical connection ...........................................................................................................................................45
9 Commissioning .....................................................................................................................................46
9.1 General preparation and checking .....................................................................................................................46
9.2 Commissioning the installation ..........................................................................................................................46
10 Maintenance .........................................................................................................................................46
11 Faults, causes and remedies ...............................................................................................................46
11.1 Display and acknowledgement of errors ..........................................................................................................47
11.2 Error history .........................................................................................................................................................47
11.3 Main faults, causes and remedies ......................................................................................................................48
12 Spare parts ...........................................................................................................................................49
13 Disposal .................................................................................................................................................49

English
Installation and operating instructions Wilo-SiClean Comfort 27
Installation and operating instructions
1 General
About this document ThelanguageoftheoriginaloperatinginstructionsisEnglish.Allother
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
preconditionfortheproper useand correctoperation ofthe product.
Theinstallationandoperatinginstructionscorrespondtotherelevant
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 with-
out our agreement or the declarations made in the installation and
operatinginstructionsonthesafetyoftheproduct/personnelarenot
observed, this declaration loses its validity.
2 Safety These operating instructions contain basic information which must
beadheredtoduringinstallation,operationandmaintenance.Forthis
reason,theseoperatinginstructionsmust,withoutfailbereadbythe
service technician and the responsible specialist/operator before
installation and commissioning.
Itis not onlythegeneral safetyinstructionslisted underthemain point
“safety”thatmustbeadheredtobutalsothespecialsafetyinstructions
withdanger symbolsincluded under thefollowing mainpoints .
2.1 Indication of instructions in the
operating instructions
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 (seri-
ous)injuryto persons is probable if thisinformationisdisregarded.
CAUTION!
Thereisariskofdamagetotheproduct/unit.'Caution'impliesthat
damage to the product is likely if this information is disregarded.
NOTE: Usefulinformation onhandlingtheproduct. Itdrawsattention
to possible problems.

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28 WILO SE 05/2015
Notes applied directly on the product must be strictly complied with
and kept in legible condition. These include:
• Direction of rotation arrow
• Identifiers for connections
• Name plate
• Warning sticker
2.2 Personnel qualifications Theinstallation,operatingandmaintenancepersonnelmusthavethe
appropriate qualifications for this work. Area of responsibility, terms
ofreferenceandmonitoringofthepersonnelaretobeensuredbythe
operator. If the personnel are not in possession of the necessary
knowledge,they are tobe trainedandinstructed. Ifneedbe, thiscan
beaccomplishedbythemanufactureroftheproductattherequestof
the operator.
2.3 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.
Indetail,non-observancecan,forexample,resultinthefollowingrisks:
• 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.
2.4 Safety consciousness on the job The safety instructions included in these installation and operating
instructions,theexistingnationalregulationsforaccidentprevention
togetherwith any internal working, operatingand safetyregulations
of the operator are to be complied with.
2.5 Safety instructions for the operator Thisappliance isnot intendedfor use by persons (including children)
withreducedphysical,sensoryormentalcapabilities,or lackofexpe-
rience and knowledge, unless they have been given supervision or
instruction concerning use of the appliance by a person responsible
for their safety.
Childrenshouldbesupervisedtoensurethattheydonotplaywiththe
appliance.
• If hot or cold components on the product/the unit lead to hazards,
local measures must be taken to guard them against touching.
• Guardsprotectingagainsttouchingmovingcomponents(suchasthe
coupling) must not be removed whilst the product is in operation.
• Leakages (e.g. from a shaft seal) of hazardous fluids (e.g. explosive,
toxicor hot)mustbe conveyedawayso thatno danger topersons or
to the environment arises. National statutory provisions are to be
complied with.
• Highly flammable materials are always to be kept at a safe distance
from the product.
• Dangerfromelectricalcurrentmustbeeliminated.Localdirectivesor
generaldirectives [e.g. IEC,VDE etc.] andlocal energy supplycompa-
nies must be adhered to.
2.6 Safety instructions for installation
and maintenance work Theoperatormustensurethatallinstallationandmaintenanceworkis carriedout byauthorised and qualifiedpersonnel, whoare sufficiently
informedfrom theirown detailed studyof theoperating instructions.
Worktotheproduct/unitmustonlybecarriedoutwhenatastandstill.It
ismandatory thatthe procedure describedin theinstallation andoper-
atinginstructionsforshuttingdowntheproduct/unitbecompliedwith.

English
Installation and operating instructions Wilo-SiClean Comfort 29
Immediately on conclusion of the work, all safety and protective
devices must be put back in position and/or recommissioned.
2.7 Unauthorised modification and
manufacture of spare parts Unauthorisedmodificationandmanufactureofsparepartswillimpair thesafety of theproduct/personneland willmakevoid themanufac-
turer's declarations regarding safety.
Modifications to the product are only permissible after consultation
with the manufacturer. Original spare parts and accessories author-
ised by the manufacturer ensure safety. The use of other parts will
absolve us of liability for consequential events.
2.8 Improper use The operating safety of the supplied product is only guaranteed for
conventional use in accordance with Section 4 of the operating
instructions.Thelimitvaluesmustonnoaccountfallunderorexceed
those specified in the catalogue/data sheet.
3 Transport and interim storage When the product is delivered, check it for any damage in transit. If
anydefect is found,inform thedelivery company (forwardingagent).
The equipment must be transported by means of authorised load
devices.
Beforeinstallation, the productmust be keptdry, frost-free andpro-
tected from mechanical damage.
CAUTION! Risk of property damage!
Improper transport and interim storage can cause damage to the
product.
• The product must not be exposed to temperatures outside the
range between -10°C and +50°C.
Wilo-SiClean Comfort is supplied on a pallet, it is protected from
moisture and dust with a transparent plastic cover.
3.1 Transport for installation/removal
purposes WARNING! Danger of personal injury! Improper transport can lead to personal injury.
• The stability of the load must be ensured.
• The handling should be done by skilled staff and with authorised
equipment.
• Transport straps must be secured to the existing transport lugs.
4 Intended use
Purpose ThebasicfunctionofWilo-SiCleanComfortistoprotectheatingsys-
tems against particles and sludge formation through continuous
removal of suspended matter.
Fields of application It may be used for:
• Hot-water heating systems
• Heating/air-conditioning systems
Restrictions Typical installation locations are technical rooms within the building
withother domesticinstallations. Itis not intendedto installthe sys-
tem directly in rooms used for residential or working purposes.
Outdoor installation is not permitted for this series.

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30 WILO SE 05/2015
CAUTION! Risk of material damage!
Impermissible substances in the fluid can destroy the pump. Abra-
sive solids (e.g. sand) increase pump wear.
Pumps without an Ex-rating are not suitable for use in potentially
explosive areas.
• The correct use of the pump/system also includes following these
instructions.
• Any other use is considered to be incorrect use.
5 Product information
5.1 Type key The type key consists of the following elements:
5.2 Technical data
When ordering spare parts, make sure to state all the information
given on the pump and motor rating plates.
5.3 Scope of delivery • Wilo-SiClean Comfort
• Installation and operating instructions: Wilo-SiClean Comfort
including SC switchgear description
• Installation and operating instructions: Wilo-VeroLine-IPL...
6 Description and function
6.1 General description SiClean Comfort is a compact pre-assembled unit delivered com-
pletely piped-up and ready to be connected. The only connections
that have to be made are:
• Suction pipe
• Delivery pipe
• Sludge disposal
• Power mains
6.2 Description of the product Mechanic and hydraulic installation components (Fig. 1)
The compact unit is mounted on a steel base frame with vibration
absorbers.Itconsistsofanin-linepump(pos.1)andaseparator(pos.
2).An automatic sludgeevacuation system (pos.4A, 4B, 6)is located
in the lower part. The device is equipped with a degasser (pos. 7) in
the upper part to the outlet of the separator.
Example: SiClean Comfort 12
SiClean
Comfort Standard version, automatically operated, with in-line pump in glanded technology
12 Nominal diameter of separator inlet/outlet
Property Value Remarks
Maximum permissible operating pressure 10 bar -
Maximum permissible fluid temperature 0 °C to +100 °C -
Ambient temperature min./max. 0 °C to +40 °C -
Storage temperature min./max. -10 °C to +50 °C -
Approved fluids Heating water according to VDI 2035 Other fluids on request
Electrical connection 3~400 V ± 10%, 50 Hz -

English
Installation and operating instructions Wilo-SiClean Comfort 31
NOTE
When pump is running, the shut-off valve (pos. 8) should be open.
The switchgear (pos. 5) is mounted on the base frame. All electric
components are delivered ready-wired. This installation and operat-
ing instructions describe the complete installation of SiClean Com-
fort.
In-line pump (pos. 1)
The pump is sized to compensate the pressure losses of the system
and create the needed flow conditions inside the separator. The
attached installation and operating instructions provides further
information on the pump.
Separator (pos. 2)
Theseparatorisanon-movingpartwithaparticleseparationcylinder
including magnetic elements in it in order to create a magnetic field
and a sludge collection chamber.
Switchgear (pos. 5)
The SC switchgear is used to automatically control hydraulic compo-
nents (pump, valves) of the particle separator system. Please read
chapter 7 for further information about the switchgear.
SiClean Comfort inlet and outlet connections dimensions
PleasefindhereafterflangedimensionsaccordingtoSiCleanComfort
model:
6.3 Function of the SiClean Comfort
system SiCleanComfort merelyapplies natural,physical processesfor physi- calseparation ofparticles andsludge, microbubbles and gas removal
from water.
Fluidfromthesystementeringthemoduleisacceleratedbythepump
and introduced into the separator which makes it swirl. The created
powerful centrifugal effect, together with the multipolar magnetic
field,sucksparticlessuspendedinthewaterdowninto thecollection
chamber.The cleanedwaterflows backup to thecentre ofthe sepa-
rator and goes back into the system.
Acontinuousprocessremovesgasattheseparatoroutlet.Ironoxides
are converted into magnetite or black sludge and removed through
the motorised drain valve.
The process is fully automated and can be monitored via the switch-
gear.
SiClean
Comfort... Inlet flange Outlet flange Sludge disposal
12 DN 32 DN 32 1”
15 DN 32 DN 32 1”
20 DN 32 DN 32 1”
25 DN 40 DN 50 1”
30 DN 40 DN 65 1”
40 DN 40 DN 80 1”
50 DN 50 DN 80 1”
65 DN 65 DN 100 1”

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32 WILO SE 05/2015
7 Switchgear
7.1 Technical data
7.2 Scope of delivery • Switchgear SC-Clean
• Circuit diagram
• Installation and operating instructions: Wilo-SiClean Comfort
including SC switchgear description
• Test protocol acc. EN60204-1
7.3 Options Options have to be ordered separately:
7.4 Description General description
TheSCswitchgeariscontrolledbyamicrocontroller.Itisusedtocon-
trola SiCleanComfort particle separatorsystem mainlycomposed of
the following items:
• a pump (pos. 1),
• a flushing/drain valve (pos. 4A),
• a safety valve (pos. 4B).
Dependingonthenumberofflushingperdayoftherespectivemonth
andflushingduration, the pumpandvalveswill beswitchedoffor on
automatically. The parameters are available through the menu. If a
leakageofdrainingvalveisdetected,analarmappearsandthesafety
valvewillbeclosed. Alarms arerecordedinthealarmhistory memory.
ThecurrentoperationalstateandthevalvesareindicatedviatheHMI
and LEDs at the front side of the panel. User input is accepted by a
turn-and-push button at the front side of the panel.
Construction of the switchgear (Fig. 3)
The switchgear consists of the following main components:
• Main switch: Power on/off of the whole switchgear (pos. 1).
• Human-Machine-Interface (HMI): LCD-Display to show operating
data (see menus), LEDs to indicate the general status (run/failure),
rotary button for menu navigation and parameter setting (Pos. 2).
• Base board: PCB with micro-controller; (pos. 3).
• Motor protection breaker (pos. 4).
• Contactors: contactors to start pumps. (pos. 5).
• Electrode relays: for leakage detection (pos. 6).
Property Value Remarks
Power supply voltage 3~400 V (L1, L2, L3) -
Frequency 50/60 Hz -
Control voltage 24 V AC -
Rated current See rating plate -
Protection class IP 54 -
Max. fuse protection on mains side See circuit diagram -
Ambient temperature min./max. 0 °C to +40 °C -
Electrical safety Pollution degree: II -
Option Description
BACnet MSTP Communication BACnet MS/TP (RS485)
Modbus RTU Communication Modbus RTU (RS485)

English
Installation and operating instructions Wilo-SiClean Comfort 33
7.5 Function and operation DANGER! Risk of fatal injury!
Incorrect installation and improper electrical connections can
resultinfatal injury.Whenworkingon anopenswitchgear,thereis
risk of electric shock through contact with live parts.
• Have the electrical connections established by approved electri-
cians only, in compliance with the applicable regulations.
• Observe the accident prevention regulations!
NOTE
Afterconnectingtheswitchgeartothesupplyvoltageaswellasafter
every power failure, the controller returns back into the mode that
was set before power interruption.
7.5.1 Operating modes In the automatic mode the control of the pump and the valves
dependsontheoperationsettings.Thenumberofflushingperdayof
the respective month (menu 1.2.1.1, flushings/24h) determines the
remaining duration of pump running before the next flush.
The minutes (/day) or hours (/month) left until the next flushing are
indicated on the main screen.
If “External Off” and any alarms are inactive, the pump is always run-
ning except during a flushing phase.
At the beginning of the flushing process:
• The pump will switch off
• Thedrainvalveopens.Duringtheperiodspecifiedinmenu1.2.7.1the
valve stays open to flush out the water, after that time delay has
elapsed
• The valve closes according to the delay specified in menu 1.2.7.1
• The pump will start running again unless a leakage alarm occurs
If a leakage has been detected:
• (1) an alarm occurs
• (2)thesafetyvalvecloses and systemwaitsuntilthetimespan spec-
ified in menu 1.2.7.2. The drain valve starts an “open/close cycle” in
ordertoremovetheblockingpoint.Infact,thedrainvalveopensdur-
ingacertainduration(specifiedinmenu1.2.7.1)andclosesthen.The
safety valve stays closed during that unlock attempt.
• A manual reset is required in order to allow the next step.
• The safety valve reopens.
• Leakage detection:
• still active: Jump to the (1) and then (2) step.
• passive: The system goes back to its automatic mode and run.
NOTE
The leakage monitor is active while the pump is running.
External Off
The control system can be deactivated by an external NC contact. If
the pump runs in automatic mode, it will stop and the timer to the
next flush is interrupted.
Operating modes of pump and valves
In the menus 3.2.1.1, 3.2.3.1 and 3.2.4.1 the operation mode of the
pump and the valves can be selected (Hand, Off, Auto).
Logic of collective failure signal (SSM)
In menu 5.5.2.0 the logic of SSM can be selected between negative
logic (falling slope in case of a failure = “fall“) or positive logic (rising
slope in case of a failure = “raise“).
Function of collective run signal (SBM)
Inmenu5.5.1.0thefunctionofSBMcanbeselectedbetween„Ready“
(switchgear is ready to run) and „Run“ (at least one pump is running).

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34 WILO SE 05/2015
7.5.2 Motor protection Excess current protection
Themotoris protectedbyaprotection switchwiththermaland elec-
tromagnetic tripping. The trip current must be adjusted directly on
these breaker.
Pump failures lead directly to stopping the command for the pump
andgenerate a collective fault signal(SSM). Afterrectification of the
fault’scause,anacknowledgementisrequestedbeforerestartingthe
pump.
All motor protection functions are active in the hand mode.
7.5.3 Operation of the switchgear Operating devices
• Main switch On/Off (lockable in position "off")
• TheLC-displayshowsthestatusofthepump,thevalvesandthecon-
troller.Using therotaryknob onecan select menusand enterparam-
eters. To change values and to scroll through menus the rotary knob
(Fig.5)hastobeturnedandithastobepressedinordertoselectand
to acknowledge.
The display of information occurs as follows (Fig. 6):
Fig. 5: Rotary knob
Fig. 6: Information display
Pos. Description
1 Pump and valve state or menu number
2 Value
3 Unit of the value
4 Standard symbols
5 Graphic symbols

English
Installation and operating instructions Wilo-SiClean Comfort 35
The following graphic symbols are used:
Symbol Function/description
Stepback(pressthe button shortly:onemenulevel
back;pressthebuttonforalongertime:backtothe
main screen)
EASY menu
EXPERT menu
Service logged in
1st meaning: Service not logged in
2nd meaning:
Displayvalue–noentry possible
Pump status symbol: Pump available but switched
off
Pump status symbol: Pump running
Valve open
Valve closed
Flushing
Opening and closing time of flushing valve
Service
Parameter
Information
Fault
Fault acknowledgement
Alarm settings
Pump
Pump 1 or valve 1

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36 WILO SE 05/2015
Valve 2
Setpoint
Time settings
Control mode (only /day)
Drive mode
Control mode of the pump respective valve
Stand-by
Switchgear data
Controller type, ID number, software/firmware
Operating hours
Operating hours pump 1
Starts
Starts pump 1/valve 1
Starts valve 2
Symbol Function/description

English
Installation and operating instructions Wilo-SiClean Comfort 37
Menu structure
The menu structure of the switchgear consists of 4 levels.
IntheexampleshowninFig.4,thenavigationthroughmenusandthe
change of parameters can be seen.
A description of all menus can be found in the following table:
Error counter
Factory settings
Restore of factory settings
Communication
Communication parameters
Parameters of output
Parameter SBM
(collective run signal)
Parameter SSM
(collective fault signal)
ModBus
BACnet
Symbol Function/description

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38 WILO SE 05/2015
Menu no./
notes Display Description Parameter range Factory setting
0The main screen shows the status of
the system, pump and valves – –
1.0.0.0 TheEASY menuoffers thepossibility
toselectthesetpointvalueandshow
the control mode
– –
1.0.0.0 All parameters of the system can be
set in the EXPERT menu. That
includes changes of control mode
and valve timings.
– –
1.1.0.0 Menu to select the control mode – –
1.1.1.0 Display of control mode which is in:
“flushings per day” or “flushings per
month”fortheSC-Clean.IntheEASY
menumodeisnotchangeablebutitis
in EXPERT menu.
.../day
.../month 24/day 2/month
1.2.0.0 Menu controller parameter – –
1.2.1.0 Menuofsetpoints,adjustmentofthe
value for the set point. – –
1.2.1.1 Adjustment for the number of
cleanings per day. Only visible if con-
trol mode is “/day”.
1... 24 24

English
Installation and operating instructions Wilo-SiClean Comfort 39
1.2.1.2 Adjustment for the number of clean-
ingspermonth.Onlyvisibleifcontrol
mode is “/month”
1…2…30 2
1.2.1.3 Possibility for manual flushing. Set-
ting this item to “Now Flush” starts
the flushing procedure immediately
and sets item back to Auto Flush.
Only works if drives are enabled.
Auto Flush/
Now Flush Auto Flush
1.2.7.0 Valve timing (only visible in EXPERT
menu) – –
1.2.7.1 Opening and closing time of valve 1
(only visible in EXPERT menu) 1…90…120 [s] 90 s
1.2.7.2 Opening and closing time of valve 2
(only visible in EXPERT menu) 1…90…120 [s] 90 s
2.0.0.0 Menu Communication – –
2.1.0.0 Display of currently activated
field bus No Modbus
BACnet
No
3.0.0.0 Menu pump management – –
3.1.0.0 System management
Drive On/Off OFF ON OFF
Menu no./
notes Display Description Parameter range Factory setting

English
40 WILO SE 05/2015
3.2.0.0 Menu pump – –
3.2.1.0 Call up pump 1 – –
3.2.1.1 Selection of the operating mode of
the pump OFF HAND
AUTO
AUTO
3.2.3.0
to
3.2.4.0
Call up valve 1 or 2 – –
3.2.3.1
to
3.2.4.1
Select the mode of operation for
valve 1 and 2 SHUT OPEN
AUTO
AUTO
4.0.0.0 Menu information – –
4.2.0.0 Call up operating hours – –
4.2.1.0 Display total operating hours of the
system – –
4.2.2.0 Call up operating hours of the pumps – –
Menu no./
notes Display Description Parameter range Factory setting

English
Installation and operating instructions Wilo-SiClean Comfort 41
4.2.2.1 Display total operating hours of
pump 1 – –
4.2.3.0 Display total switching operations of
the system – –
4.2.4.0 Call up switching operations of the
pumps – –
4.2.4.1 Display total switching operations of
pump – –
4.2.4.3 Display total switching operations of
valve 1 or 2 – –
4.3.0.0 Menu system info – –
4.3.1.0 Display controller type SC SC
4.3.2.0 Display identification number as
ticker – –
4.3.3.0 Software version – –
Menu no./
notes Display Description Parameter range Factory setting