Wilo SiFlux Series User manual

Wilo-SiFlux
Pioneering for You
4 188 939-Ed.01 / 2014-05-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: SiFlux

Fig. 2:
9
2
1
3
5 6 12 76 4

Fig. 3:
56 127
Fig. 4:
81011

English
WILO SE 05/2014
1 General ..................................................................................................................................................15
2 Safety ....................................................................................................................................................15
2.1 Indication of instructions in the operating instructions .................................................................................15
2.2 Personnel qualifications ......................................................................................................................................16
2.3 Danger in the event of non-observance of the safety instructions ..............................................................16
2.4 Safety consciousness on the job ........................................................................................................................16
2.5 Safety instructions for the operator .................................................................................................................16
2.6 Safety instructions for installation and maintenance work ...........................................................................16
2.7 Unauthorised modification and manufacture of spare parts ..........................................................................17
2.8 Improper use ........................................................................................................................................................17
3 Transport and interim storage ...........................................................................................................17
3.1 Attachment ..........................................................................................................................................................17
4 Intended use .........................................................................................................................................17
5 Product information ............................................................................................................................18
5.1 Type key ................................................................................................................................................................18
5.2 Technical data .....................................................................................................................................................18
5.3 Scope of delivery .................................................................................................................................................18
6 Description and function ....................................................................................................................18
6.1 General description .............................................................................................................................................18
6.2 Description of the product .................................................................................................................................18
6.3 Function of the SiFlux system ............................................................................................................................20
7 Installation and electrical connection ...............................................................................................21
7.1 Installation ............................................................................................................................................................21
7.2 Hydraulic connection ...........................................................................................................................................21
7.3 Electrical connection ...........................................................................................................................................21
8 Commissioning .....................................................................................................................................22
8.1 General preparation and checking .....................................................................................................................22
8.2 Commissioning the installation ..........................................................................................................................22
9 Maintenance .........................................................................................................................................22
10 Faults, causes and remedies ...............................................................................................................22
11 Spare parts ...........................................................................................................................................24
12 Disposal ................................................................................................................................................24

English
Installation and operating instructions Wilo-SiFlux 15
Installation and operating instructions
1 General
About this document The language of the original operating instructions is English. 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 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 with-
out our agreement or the declarations made in the installation and
operating instructions on the safety of the product/personnel are not
observed, this declaration loses its validity.
2Safety These operating instructions contain basic information which must
be adhered to during installation, operation and maintenance. For this
reason, these operating instructions must, without fail be read by the
service technician and the responsible specialist/operator before
installation and commissioning.
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 symbols included under the following main points .
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) injury to persons is probable if this information is disregarded.
CAUTION!
There is a risk of damage to the product/unit. 'Caution' implies that
damage to the product is likely if this information is disregarded.
NOTE: Useful information on handlingthe product. It draws attention
to possible problems.

English
16 WILO SE 05/2014
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 The installation, operating and maintenance personnel must have the
appropriate qualifications for this work. Area of responsibility, terms
of reference and monitoring of the personnel are to be ensured by the
operator. If the personnel are not in possession of the necessary
knowledge, they are to be trained and instructed. If need be, this can
be accomplished by the manufacturer of the product at the request of
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.
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.
2.4 Safety consciousness on the job The safety instructions included in these 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 complied with.
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 lack of expe-
rience and knowledge, unless they have been given supervision or
instruction concerning use of the appliance 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 measures 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.
• Leakages (e.g. from a shaft seal) of hazardous fluids (e.g. explosive,
toxic or hot) must be conveyed away so that no danger to persons 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.
• Danger from electrical current must be eliminated. Local directives or
general directives [e.g. IEC, VDE etc.] and local energy supply compa-
nies 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 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 mandatory that the procedure described in the installation and oper-
ating instructions for shutting down the product/unit be complied with.

English
Installation and operating instructions Wilo-SiFlux 17
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
Unauthorised modification and manufacture of spare parts will impair
the safety of the product/personnel and will make void the manufac-
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. The limit values must on no account fall under or exceed
those specified in the catalogue/data sheet.
3 Transport and interim storage The SiFlux is delivered on a pallet and is protected from moisture and
dust with a transparent plastic cover.
The equipment must be transported by means of authorised load
devices.
On arrival, inspect the pump immediately for any transport damage. If
damage is found, the necessary procedure involving the forwarding
agent must be taken within the specified period.
Before installation, the product must be kept dry, frost-free and pro-
tected from mechanical damage.
3.1 Attachment 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 or
placed around the base frame.
• The pipes will not withstand loads and should not be used to secure
loads in transit.
Labels on manifolds refer to these warnings (Fig. 5).
CAUTION! Risk of damage due to incorrect handling!
Loading the pipes in transit can result in leaks.
4Intendeduse
Purpose The SiFlux is designed to ensure the flow in function of the pressure
difference on a HVAC installation (hot and cold water).
Fields of application They may be used for:
•Hot-waterheating systems
• Cooling and cold water circulation systems
• Industrial circulation systems
• Heat carrier circuits
Restrictions Typical installation locations are technical rooms within the building
with other domestic installations. Installing the device directly in
other used rooms (residential and work rooms) is not intended.
Outdoor installation is not permitted for this series.
Fig. 5: Warning labels on manifold

English
18 WILO SE 05/2014
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/installation 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 •SiFlux
•Switchgear
• Installation instructions: system, pump and switchgear
• Safety instructions
6Descriptionandfunction
6.1 General description The system is a compact installation which is supplied completely
piped and ready-for-connection. The only connections that have to
be made are for suction and discharge and also the power mains.
6.2 Description of the product Mechanic and hydraulic installation components (Fig. 2, 3 and 4)
The compact installation is mounted on a steel base frame with vibra-
tion absorbers (pos. 3). It consists of a group of 3 or 4 in-line pumps
with electronics (pos. 1), which are combined by means of a supply
manifold pipe (pos. 4) and a delivery manifold pipe (pos. 5).
Example: SiFlux-21-IL-E 65/160-7,5/2-SC-16-T4
SiFlux Multi-pump system for closed HVAC installations
21 2 operating pumps + 1 standby pump
IL-E
65/160-7,5/2
Pump type
(see Installation and operating instructions of th
pump)
SC Type of switchgear
16 Maximum operating pressure
T4 Three-phase supply voltage 400V
Property Value Remarks
Maximum permissible operating pressure 16 bar
Maximum permissible fluid temperature +120 °C
Ambient temperature min./max. 0 °C to +40 °C
Electrical connection 3~230 V, 50 Hz
3~400 V, 50 Hz

English
Installation and operating instructions Wilo-SiFlux 19
A shut-off valve (pos. 6) is mounted on the suction and delivery side
of each pump, and a non-return valve (pos. 7) on the delivery side of
the pump.
A flanged nipple (pos. 12) is a fitting between the shut-off valve and
the non-return valve (Fig. 3).
A unit composed of a differential pressure sensor (Fig. 4, pos. 10),
2 manometers (Fig. 4, pos. 8) and 2 shut-off valves (Fig. 4, pos. 11 )
is mounted between the manifolds and on the brackets of the
switchgear.
NOTE
When the pumps are running, the shut-off valve (pos. 6) must be
open.
The switchgear (pos. 2) is mounted on the base frame by means of
one or two brackets (pos. 9). All electronic components are prewired
upon delivery.
These Installation and operating instructions describe the complete
installation of the SiFlux.
In-line pumps (pos. 1)
Different types of pumps are installed in the SiFlux depending on the
intended use and the performance parameters required. The number
of these pumps can vary between 3 and 4. The enclosed Installation
and operating instructions provide further information about the
pumps.
Switchgear (pos. 2)
Switchgears and control devices of different constructions can be
integrated and delivered to activate and control the SiFlux. The
enclosed Installation and operating instructions provide further infor-
mation about the switchgear.
Suction (pos. 4) and discharge (pos. 5) manifolds
Please find hereafter manifold diameters according to flows and
number of pumps that compose the system.