Wilo Stratos User manual

Installation and operating instructions
Notice de montage et de mise en service
Instrucciones de instalación y funcionamiento
Wilo-Stratos, Stratos-D
2085563-Ed.01 / 2007-05-Kothes!

Fig. 1: Fig. 2:
1
1.2 1.3
1.1
2
Fig. 3:

Fig. 4: Fig. 5:
230V~ FC
Achtung
Achtung
Option
IF-Modul Netzspannung
Attention
Mains Voltage
Attention
1 - 230V
!
Fig. 6: Fig. 7:
Fig. 8:

Fig. 9: Fig. 10:
max
min
Off
U[V]
1 2 3 10

5
Installation and operating instructions ..................................................................7
1 General ...................................................................................................................................7
2 Safety .....................................................................................................................................7
3 Transport and interim storage ............................................................................................9
4 Intended use (Application) ..................................................................................................9
5 Specification about the product ......................................................................................10
6 Description and function ...................................................................................................11
7 Installation and electrical connection .............................................................................23
8 Start up ................................................................................................................................28
9 Maintenance/service ..........................................................................................................32
10 Faults, causes and remedies .............................................................................................32
Directives d’installation et d’opération............................................................... 36
1 Généralités ..........................................................................................................................36
2 Sécurité ................................................................................................................................36
3 Transport et entreposage provisoire ...............................................................................38
4 Utilisation prévue (Application) .......................................................................................38
5 Spécifications du produit ..................................................................................................40
6 Description et fonction .....................................................................................................41
7 Installation et raccordement électrique ..........................................................................54
8 Mise en service ....................................................................................................................59
9 Entretien et réparation ......................................................................................................63
10 Défauts, causes et mesures de dépannage ....................................................................63
Instrucciones de instalación y funcionamiento .................................................. 67
1 Información general ...........................................................................................................67
2 Seguridad .............................................................................................................................67
3 Transporte y almacenamiento ..........................................................................................69
4 Uso previsto (empleo) ........................................................................................................69
5 Especificación del producto ..............................................................................................70
6 Descripción y funcionamiento ..........................................................................................71
7 Instalación y conexión eléctricas .....................................................................................84
8 Puesta en funcionamiento ................................................................................................89
9 Mantenimiento y reparación .............................................................................................93
10 Averías, causas y soluciones .............................................................................................93

6

Installation and operating instructions Wilo-Stratos 7
English
Installation and operating instructions
1 General
1.1 About this document
These Installation and Operating Instructions form an integral part of the
product. They must be kept close to the product and in readiness whenever
required. Precise observance of these instructions is a pre-condition for use of
the product for the intended purpose and for its correct operation.
TheseInstallationandOperatingInstructionsconformtotherelevantversionof
theequipmentandtheunderlyingsafetystandardsvalidatthetimeofgoingto
press.
2Safety
Theseinstructionscontainimportantinformationwhichmustbefollowedwhen
installing and operating the pump. It is therefore imperative that they be read
byboththeinstallerandtheoperatorbeforethecirculatorisinstalledorstarted
up.
Both the general safety instructions in the ‘Safety precautions’ section and
those in subsequent sections indicated by danger symbols should be carefully
observed.
2.1 Symbols and signal words used in these operating instructions
Symbols:
NOTE:
General Safety symbol
Hazards from electrical causes

English
8Subject to technical alterations! WILO AG 05/2007
Signal words:
NOTE: Anoticewithusefulinformationfortheuserinrelationtotheproduct.It
attends the user to possible problems.
2.2 Qualified Personnel
Thepersonnelinstallingthe pump musthave the appropriate qualifications for
thiswork.
2.3 Risks incurred by failure to comply with the safety precautions
Failure to comply with the safety precautions could result in personal injury or
damage to the pump or installation. Failure to comply with the safety
precautions could invalidate warranty and/or damage claims.
Inparticular, failuretocomply with thesesafetyprecautionscouldincreasethe
possibility of the following risks:
• the failure of important parts of the pump or installation,
• personal injury due to electrical and mechanical causes,
• material damage.
2.4 Safety precautions for the operator
Existing regulations for the prevention of accidents must be observed.
National Electrical Codes, local codes and regulations must be followed.
2.5 Safety precautions for inspection and installation
Theoperatormustensurethatallinspectionandinstallationworkiscarriedout
by authorized and qualified specialists who have carefully reviewed these
instructions.
Work on the pump/unit must be carried out only with the pump disconnected
(locked out) from the electrical supply and at complete standstill.
2.6 Unauthorized alterations and manufacture of spare parts
Alterations tothe 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
DANGER!
Imminently hazardous situation.
Will result in death or serious injury if not avoided.
WARNING!
Theusercanbe exposedto(severe)injury.'Warning'refersthatharmtothe
user when the user is neglecting the procedure.
CAUTION!
The product is at risk of damage. 'Caution' refers to the product when the
user is neglecting the procedures.

Installation and operating instructions Wilo-Stratos 9
English
may invalidate claims involving the liability of the manufacturer for any
consequences.
2.7 Improper use
The operational safety of the pump or installation supplied can only be
guaranteed if it is used in accordance with paragraph 4 of the operating
instructions. The limits given inthe catalogue or data sheet must under no
circumstances be exceeded.
3 Transport and interim storage
When receiving the material, check that there has been no damage during the
transport. If shipping damage has occurred, take all necessary steps with the
carrier within the allowed time.
Handle the pump carefully so as not to damage the unitprior to installation.
4 Intended use (Application)
The circulating pumps are used to circulate liquids in
• Warm and hot water heating systems,
• Cooling and cold water circuits,
• Closed circulation systems.
Permissible liquids and requirements:
• Heating water according the requirements of accepted standards of water
quality in heating systems.
• Water and water/glycol mixtures in a maximum ratio up to 1:1. High glycol
concentrationandlowtemperaturesystemsmayrequireareassessmentofthe
hydraulic data to compensate for the increased viscosity (please contact your
WILO representatives for more information). Use of additives (corrosion
inhibitors, oxygen scavengers etc.) must be in compliance with the
manufacturer instructions.
• If other fluids or additives are used, please contact WILO for proper
authorization.
CAUTION! Outside influences may cause damages
If the delivered material is to be installed later on, store it in a dry place and
protect it from impacts and any outside influences ( humidity, frost etc.).
CAUTION! Possible damage of the pump
This pump is intended for use with water and water/glycol only.
WARNING! Health hazard
The materials are not designed for drinking water supply.

English
10 Subject to technical alterations! WILO AG 05/2007
5 Specification about the product
5.1 Model identification
Min. pump inlet pressure [psi] at the suction side during operation by Wilo-
Stratos model:
The values apply up to 984 ft above sea level, add-on for higheraltitudes:
0.15 psi/328 ft increase in height
5.3 Scope of Supply
• Complete pump
• Installation and operating instructions
• 2 flange gaskets (only for 1.25, 1.5 and 2 inch flange pumps)
5.4 Accessories
• Accessories such as companion flanges must be ordered separately.
• Companionflanges(included bolts,nutsand gaskets)for flange-pipeconnection.
• IR (infra-red) module for special setup and diagnostics.
• IF (interface) Module Stratos Ext. Off/SBM, Ext.Min
Example: Stratos 1.5x3-40
Stratos High-efficiency pump
Wet-rotor circulating pump
1.5 Pipe connection [inch]
3-40 Infinitely variable nominal pump head 3 to 40 [ft]
Hmin: 3.3 ft, Hmax: 39.4 ft
5.2 Technical Data
Power supply 1~230 V ± 10%
Frequency 60 Hz
Degree of protection Enclosure 2
Insulation class H
Motor protection Standard built-in full motor protection
Maximum sound pressure level 54 dB(A)
Liquid temperature 14°F (-10°C) to 230°F (+110°C)
Max. ambient temperature 104°F (40°C)
Max.working pressure atthe pump 145 psi
At these liquid temps TMed
14°F...122°F
(- 10°C...+50°C) 203°F (+95°C) 230°F (+110°C)
1.25 inch 4.4 (psi) 14.5 (psi) 23.2 (psi)
1.5 and 2 inch 7.3 (psi) 17.4 (psi) 26.1 (psi)
3 inch 10.2 (psi) 21.8 (psi) 33.4 (psi)

Installation and operating instructions Wilo-Stratos 11
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6 Description and function
6.1 Pump description (fig. 1)
The Wilo-Stratos high efficiency pump (fig. 1) is a series of glandless pumps
with Electronic Commutated Motor (ECM) technology and built-in differential
pressure control.
On the motor housing there is in axial mounting form a control module (fig. 1,
pos. 1) which sets the pump's differential pressure to a set value that can be
varied withinthe control range.Dependingon the control system involved, the
differential pressureis subject to different criteria. However, regardless of the
control system the pump constantly adapts to changing system power
requirements, as it is especially the case when using thermostatic valves or
mixers.
The main benefits of electronic control are:
• it saves energy while reducing operating costs,
• it reduces noise caused by the excess flow,
• it does not require pressure bypass valves.
This wet rotor pump is designed to have all rotating parts surrounded by the
liquid being pumped. The pump is maintenance free and requires no further
maintenance after the air bleeding procedure during the initial start-up
(no after start-up maintenance).
6.1.1 Differential-pressure control systems
The control systems which can be selected are:
•Δp-v:(Factorydefaultsetting) Theelectronicsincreasethepump's differential
pressure set point in a straight line between ½ Hs and Hs. The differential
pressure set point Hs increases or decreases in accordance with the required
flow rate (fig. 6).
•Δp-c: The electronics keep the differential pressure generated by the pump at
a constant differential pressure set point Hs over the entire operation range of
the pump (fig. 7).
•Δp-T: The electronics alter the nominal differential pressure set point
dependantonthe fluidtemperaturemeasured.This controlsystem canonly be
adjusted with the IR module. There are two possible settings (fig. 8):
• Positive control: As the system temperature rises, the nominal differential
pressuresetpointisincreasedlinearlybetweenHsminandHsmax.(settingon
IR module: Hsmax > Hsmin).
Used e.g. with standard boilers with sliding flow temperature.
• Negative control: As the system temperature rises, the nominal differential
pressuresetpointisdecreasedlinearlybetweenHsminandHsmax(settingon
IR module: Hsmax < Hsmin).
Used e.g. with condensing boilers where a specific maxium return water
temperature must be maintained to achieve as much condensing as possible
to insure maxium boiler effeciency. To do this, the pump must be installed in
the system's return flow section.

English
12 Subject to technical alterations! WILO AG 05/2007
6.1.2 Other energy-saving operating modes
• Speed regulation mode operation: The speed of the pumpis kept at an
externallysetconstantspeed between minimumand maximum speeds(fig. 9).
The speed regulation mode deactivates the differential pressure control.
• In the "auto" operating mode (factory default setting) the pump is able to
recognize a minimum systemheat output requirement due toa sustained drop
in the system temperature and then automitically switch to "Autopilot" night
setback mode. If the heat output requirement rises, the pump automatically
switches to standard mode. This setting ensures that the pump's energy
consumptionisreducedtoaminimumandinmostcasesistheoptimumsetting.
6.1.3 General pump functions
• The pumps are fitted with an electronic overload protection system which
switches the pump off should it become overloaded.
• The control module is equipped with a non-volatile memory for data storage.
What this means is that data is saved, even during long periods of down time.
Once the voltage returns the pump starts operating again with the values set
before the power outage.
•Pump kick: If the pump has been switched off externally by the IF (interface)
device (Ext.Off, 0…10 V) or IR module it will automatically run for a short time
once every 24 hours to exercise the pump.
Connections to the building management system (BMS)
•FC: A collective fault contact FC (potential-free closed contact) can be
connected to a control point (building management system) as standard. The
internal contact is closed if the pump is turned off, or there are no problems or
failures on the part of the control module. The faults are described in detail in
chapter 10.
•IF(Interface) modules (accessory):
Analoginterfacesareavailableintheformofadd-onIFmodulesforconnecting
to external control system (e.g. DDC/BMS).
6.1.4 Double pump mode
Two corresponding single pumps in a parallel pump installation can be fitted
with built-in double-pump management.
•Stratos IF module: Two IF modules connected via the DP (double pump)
interfacearerequiredforcommunicationbetweenpumps.Inadditiontodouble
pump management, the IF modules provide other interfaces for the double
pump.
This double pump management has the following functions:
•Master/Slave: Both pumps are controlled by the master. All settings are made
by the master.

Installation and operating instructions Wilo-Stratos 13
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•Optimum-efficiency peak-load operation: Two corresponding single pumps
can be run in a low/high flow application where if the lead pump can not keep
up with the flow demand the lag pump will operate automatically. At partial
load, the hydraulic capacity is provided by one pump only. The second pump is
switchedonatoptimumefficiency,whenthesumofpowerconsumptionsP1of
both pumps is less than the power consumptions P1of one pump. Both pumps
arethenadjustedupwardssimultaneouslytomax.speedifnecessary.Inrelation
to the conventional peak load operation(load controlled switch on and off) a
further energy saving is reached by this mode of operation.
•Duty/Standbymode:Eachofthetwopumpsproducesthedesigndeliveryrate.
The other pump can be used in the event of the first pump malfunctioning or
following a pump swap. Only one pump operates at a time.
• Intheeventthatonepumpexperiencesa failure/problem,the otherwillrun as
a single pump in standard mode as instructed by the master.
• In the event of a break in communication: The slave pump runs at the last set
value of the master prior to the interruption.
•Pump swap: If only one pump is operational (duty/standby, peak- or low-load
operation),the pumpsare swappedafter every24hrs’ ofactual operatingtime.
•FC:Thecollectivefaultcontact(FC)ofthemastercanbeconnectedtoacentral
control point. In this case, contact is only established with the master. The
reading is valid for both pumps.
As an option, the error message contacts of master and slave can be
programmed as single fault signal with the IR module. For the single fault
signals, contact must be established with each pump.
6.2 Operating the pump
The electronic module (fig. 1, pos. 1) houses the IR window (infraredwindow,
pos. 1.1) for communication with an IR module and the LC display (pos. 1.2)
with the tuning button (pos. 1.3) for operating the pump. The IR receiver and
sendersurfacemustbelocatedinsuchawayastobeabletocommunicatewith
theIRmodule.IftheconnectiontotheIRmodulehasbeenmade,thegreen LED
lights up in the IR window to confirm the IR communication of all pumps that
were connected to the IR module at the same time. The LED on the pump with
whichtheIRmodulecommunicatesblinks. It stopsblinking 5 minutes afterthe
connection to the IR module has been interrupted. A red Error LED in the IR
windowlights up whena fault isregistered. Information onhow tooperate the
IR module can be obtained in its installation and operating instructions.
LC display:TheLCdisplay showsthepump’s settingparametersusing symbols
and numerical values. The display can be selected according to the position of
the module, i.e. horizontal or vertical, at a readable angle (face to face).
Thedisplayis constantlylit up.The table belowexplainsthe meaning ofthe LC
display's symbols:

English
14 Subject to technical alterations! WILO AG 05/2007
Symbol Description of possible operating conditions
auto Standard mode; automatic switch-over to night setback mode is
enabled. Night-time mode is activated at minimum heat output
requirement (default).
auto Pump runs in night-time mode (night setback operation) at min. speed.
(no symb.) Automaticswitch-overtonightsetbackmode blocked, i.e. pump runs in
standard mode only.
Night setback mode activated via interface Ext.Min, regardless of the
system temperature.
Pump switched on (default).
Pump switched off.
Differential pressure set value set to H = 18.0 ft. (example)
Control system Δp-v, regulated to variable differential pressureset
value (fig. 6) (default).
Control system Δp-c, regulated to constant differential pressure set
value (fig. 7).
The regulator mode control system deactivates the module pressure
variations.Thespeedofthepumpis keptataconstantlevel.The speed
is set internally using the tuning button (fig. 9).
Pump set to a constant speed (2.600 rpm example shown) - regulator
mode.
10 V In regulator mode, the speed or nominal lift of operating mode Δp-c or
Δp-v of the pump is set via input 0...10 V of the Stratos IF module
Ext.Min. The button then has no set value input function. (fig. 10)
Control system Δp-T, regulated to temperature dependent differential
pressure set value (fig. 8). The maximum set value Hsmax is displayed.
This control system can only be activated via the IR module.
All settings on module except "acknowledge error" blocked. Settings
locked out by IR module. Settings can only be altered using IR .
Pump runs as slave pump. No changes can be made to the position
setting of the display.
Twosinglepumpsasdoublepumprunninginpeakloadmode(master+
slave)
Two single pumps as double pump running in duty / standby mode
(master or slave)

Installation and operating instructions Wilo-Stratos 15
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Operating the tuning button: (fig. 1, pos. 1.3) Starting from the basic setting,
the setting menus are selected one after the other in a fixed order by pressing
the button (in 1st menu: press for more than 1 second). The relevant symbol
blinks. By turning the button to the left or to the right the parameters onthe
display can be altered up or down. The symbol which has just been set blinks.
The new setting is stored by pressing the button. At the sametime the system
advances to the next setting option.
Thesetvalue (differentialpressure orspeed) inthe basic settingcanbe altered
byturningthetuningbutton.Thenewvalueblinks.Thenewsettingisstoredby
pressing the button.
If the new setting is not confirmed, after 30 seconds the old value is restored
and the display returns to the basic setting.
Settingsof the displayposition:Forthe layoutofthe controlmodule,whether
installed horizontally or vertically, the position of the display can be rotated
through 90°. The position setting can be entered in menu point 3. The display
positionspecifiedby thebasic settingflashesby“ON“ (forhorizontalposition).
The display can be rotated by turning the selector button. “ON“ flashes for the
vertical position. The setting is confirmed by pressing the selector button.
Display position:
Position setting
in menu point 3

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16 Subject to technical alterations! WILO AG 05/2007
The following menus appear in succession on the pump display:
(horizontal representation of display)
Single pump mode: Setting when first used / Menu order during standard use
LC display Setting
Afterswitchingon themodule, all symbols appear
on the display for 2 seconds. The current setting
thenengages.
Current (basic) setting (factory default):
auto • automatic night setback
enabled,
Pump runs in standard mode
e.g. H 18.0 ft • present differential pressure
setpoint HS= 18.0 ft at same
time ½ Hsmax (factorysetting
depending on pump type)
• Control system Δp-v
The differential pressure set point can
bealteredbyturningthetuningbutton.
The new differential pressure set point
blinks.
The new settingis stored by pressing
the button briefly.
If no button is pressed, the previously
set blinking differential pressure set
pointreturnstothepreviousvalueafter
30 seconds.
Press tuning button for > 1 second.
The next menu point appears.
If no setting is made in the subsequent menus for 30s,
the basic setting re-appears in the display.

Installation and operating instructions Wilo-Stratos 17
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Position setting of display vertical / horizontal
The set position of the display is shown by the
flashing “ON“.
By turning the tuning button the other
position can beselected.
Setting stored.
The currently set control system blinks.
By turning the tuning button other
control systems can beselected. The
new selected control system blinks.
Pressing the button stores the new
controlsystemandswitchestothenext
menu.
Menupoint onlyappearsifaStratosIFmodule
was inserted with input 0...10 V.
Switch input 0...10 V on/off
Activate input 0...10 V: “ON” and the “module
motor symbol” appears in the display.
The setting can be altered by turning
the tuning button.
Deactivate input 0...10 V: “OFF” appears in the
display and the “motor symbol” disappears.
Setting stored.
If the input was switched on, the menu manager
jumps to menu point .
LC display Setting

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18 Subject to technical alterations! WILO AG 05/2007
Switch pump on/off.
Switch on pump, "ON" and the “module motor
symbol” appear in the display
The setting can be altered by turning
the tuning button.
Switch off pump, "OFF"appearsinthe displayand
the “motor symbol” disappears.
Setting stored.
Menu point is skipped if regulator mode was
selected
Either flash
auto • automatic night setback
Pump runs in standard mode
Menupoint thenshows"auto
" during autom. standard
mode or "auto " during
automatic night-setback
• normal standard mode,
automatic night-setback
disabled.
Menupoint doesnotcontain
any symbol.
call up one of the two settings
and store.
Display jumps to the next menu.
Menu point is skipped if:
• regulator mode was selected,
• the input 0...10 V was activated
In single-pump mode the display returns to basic
setting .
In the event of an error the error menu
appears before the basic setting .
In double pump mode (two single pumps) the
display jumps to menu .
LC display Setting

Installation and operating instructions Wilo-Stratos 19
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Doublepumpmode (as two singlepump mode): Setting whenstarting up for
the first time
(vertical display)
LC display Setting
When the module is switched on all symbols
appear in the display for 2 seconds. Menu then
appears.
The symbol MA = Master blinks on the display of
both pumps.
Shouldthesettingsnotbealtered,bothpumpswill
run at a constantspeed (HS=½H
max. where
Q = 0).
By on the master pump tuning button the
setting mode menu appears on the display.
SL = Slave appears automatically on the slave
pump display.
The configuration: left pump Master, right pump
Slave is thus selected. The tuning button on the
slavepumpisdeactivated.Nomoresettingscanbe
made here.
A position setting for the display cannot be made
on the slave pump. Position setting on the slave
pumpistakenoverfromthesettingsofthemaster
pump.

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20 Subject to technical alterations! WILO AG 05/2007
Double pump mode: Menu order during normaluse:
After switching on the module, all symbols appear on the display for 2
seconds. The current setting then sets itself. When "scrolling" in the MA
displaythe same menuorder ... appears as for the single pump. Thenthe
MA menu appears and remains on the screen permanently.
LC display Setting
ATTENTION! Use to confirm MA at the left
pump.Nochangemustbemadeinthismenuitem.
It is always: MA = left pump, SL = right pump.
Setting Peak load and duty / standby mode
The other setting blinks.
Setting stored.
Display returns to basic setting .