Wilo Stratos User manual

Installation and operating instructions
Notice de montage et de mise en service
Instrucciones de instalación y funcionamiento
Wilo-Stratos /-D/-Z
2 095 796-Ed.01 / 2011-02-Wilo

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

Fig. 4: Fig. 5:
230V~ FC
Achtung
Achtung
Option
IF-Modul
Netzspannung
Attention
Mains Voltage
Attention
1 - 230V
!
Fig. 6: Fig. 7:
Q
H
Hs
H max
H
Q
H
s
½Hs
H
min
H s
1
1
2
2
Q
1
2
Hs
H max
H
Hs
Hmin
Hs
1
2
Fig. 8:
Hs Hs
Hs var.
Q min Q max Q
Hs max
Hs min
T min T max T med

Fig. 9: Fig. 10:
Q
Hs
H
n
s
= const n
max
= const
H
s
10U[V]1 23
Off / Aus
H min / n min
H max / n max
H/n

1
Installation and operating instructions ..................................................................3
1 General ................................................................................................................................... 3
2 Safety ..................................................................................................................................... 3
3Transport and interim storage ............................................................................................ 5
4 Intended use (Application) .................................................................................................. 5
5 Product details...................................................................................................................... 6
6 Description and function ..................................................................................................... 7
7 Installation and electrical connection .............................................................................13
8 Commissioning ...................................................................................................................18
9 Maintenance/service ..........................................................................................................29
10 Faults, causesand remedies.............................................................................................30
11 Spare parts...........................................................................................................................34
12 Disposal ................................................................................................................................34
Notice de montage et de mise en service ........................................................... 35
1 Généralités..........................................................................................................................35
2 Sécurité ................................................................................................................................35
3Transport et entreposage provisoire ...............................................................................37
4 Utilisation (application) prévue ........................................................................................37
5 Détailsproduit ....................................................................................................................39
6 Description et fonctionnement ........................................................................................40
7 Installation et raccordement électrique ..........................................................................46
8 Mise en service ....................................................................................................................51
9 Entretien/Service ................................................................................................................62
10 Défauts, causeset mesuresde dépannage ....................................................................63
11 Piècesde rechange .............................................................................................................67
12 Élimination ...........................................................................................................................67
Instrucciones de instalación y operación ............................................................ 69
1 Información general ...........................................................................................................69
2 Seguridad .............................................................................................................................69
3Transporte y almacenamiento ..........................................................................................71
4 Uso previsto (aplicación) ...................................................................................................71
5 Detallesdel producto .........................................................................................................72
6 Descripción y funcionamiento ..........................................................................................74
7 Instalación y conexión eléctrica.......................................................................................80
8 Puestaen servicio ...............................................................................................................85
9 Mantenimiento/servicio técnico ......................................................................................96
10 Fallas, causas y soluciones................................................................................................97
11 Refacciones.......................................................................................................................102
12 Desecho .............................................................................................................................102

2

Installation and operating instructionsWilo-Stratos/-D/-Z 3
English
1 General
About this document
These Installation and Operating Instructionsform an integral part ofthe
product. They must be kept close to the product and in readiness whenever
required. Precise observance ofthese instructionsisapre-condition for use of
the product for the intended purpose and for itscorrect operation.
These Installation and Operating Instructionsconform to the relevant version of
the equipment and the underlying safety standardsvalid at the time ofgoing to
press.
2Safety
These instructionscontain important information which must be followed when
installing and operating the pump. It istherefore imperative that they be read
by both the installer and the operator before the circulator isinstalled or started
up.
Both the general safety instructionsin the ‘Safety precautions’ section and
those in subsequent sectionsindicated by danger symbolsshould be carefully
observed.
2.1 Symbols and signal words used in these operating instructions
Symbols:
NOTE:
General Safety symbol
Hazards from electrical causes

English
4Subject to technical alterations!WILOSE 02/2011
Signal words:
NOTE: Anotice with useful information for the user in relation to the product. It
attendsthe user to possible problems.
2.2 Qualified Personnel
The personnel installing the pump must have the appropriate qualificationsfor
thiswork.
2.3 Risks incurred by failure to comply with the safety precautions
Failure to comply with the safety precautionscould result in personal injury or
damage to the pump or installation. Failure to comply with the safety
precautionscould invalidate warranty and/or damage claims.
In particular, failure to comply with these safety precautionscould increase the
possibility ofthe following risks:
• the failure ofimportant partsofthe pump or installation,
•personal injury due to electrical and mechanical causes,
•material damage.
2.4 Safety precautions for the operator
Existing regulationsfor the prevention ofaccidentsmust be observed.
National Electrical Codes, local codesand regulationsmust be followed.
Thisdevice isnot intended to be operated by persons(including children) with
impaired physical, sensory or mental capacitiesor lack ofexperience and/or lack
ofknowledge, except in caseswhere they are supervised by aperson
responsible for their safety or where they receive instructionsfrom such a
person as to how the device isto be operated. Children must be kept under
supervision in order to ensure that they do not play with the device.
2.5 Safety precautions for inspection and installation
The operator must ensure that all inspection and installation work iscarried out
by authorized and qualified specialistswho 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.
DANGER!
Imminently hazardous situation.
Will result in death or serious injury if not avoided.
WARNING!
The user can be exposed to (severe) injury. 'Warning' refers that harm to the
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 instructionsWilo-Stratos/-D/-Z 5
English
2.6 Unauthorized alterations and manufacture of spare parts
Alterationsto the pump or installation may only be carried out with the
manufacturer'sconsent. The use oforiginal spare partsand accessories
authorized by the manufacturer will ensure safety. The use ofany other parts
may invalidate claimsinvolving the liability ofthe manufacturer for any
consequences.
2.7 Improper use
The operational safety ofthe pump or installation supplied can only be
guaranteed ifit isused in accordance with paragraph 4 ofthe operating
instructions. The limitsgiven in the catalogue or datasheet must under no
circumstancesbe exceeded.
3 Transport and interim storage
When receiving the material, check that there has been no damage during the
transport. Ifshipping damage has occurred, take all necessary stepswith the
carrier within the allowed time.
Handle the pump carefully so as not to damage the unit prior to installation.
4 Intended use (Application)
The high-efficiency pumpsofthe Wilo-Stratos/-D/-Z seriesare used to
circulate fluids(no oil or oleiferous fluids, no foodstuffs) in
•Hotwater heating systems,
• Cooling and cold water circuits,
•Closed circulation systems.
Permissible liquids and requirements:
•Heating water according the requirementsofaccepted standardsofwater
quality in heating systems.
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 of the Wilo-Stratos/-D can cause damage to one's health,
since they are not approved for use in secondary hot water circulation
systems.
Do not use Wilo-Stratos/-D pumps in secondary hot water systems.

English
6Subject to technical alterations!WILOSE 02/2011
•Water and water/glycol mixturesin amaximum ratio up to 1:1. High glycol
concentration and low temperature systemsmay require areassessment ofthe
hydraulic datato compensate for the increased viscosity (please contact your
WILOrepresentativesfor more information). Use ofadditives(corrosion
inhibitors, oxygen scavengersetc.) must be in compliance with the
manufacturer instructions.
•Ifother fluidsor additivesare used, please contact WILOfor proper
authorization.
The high-efficiency pumpsofthe Wilo-Stratos-Z seriesare also suitable for use
in
• Secondary hot water circulation systems
5 Product details
5.1 Type key
CAUTION! Possible damage of the pump!
Unacceptable fluids may destroy the pump.
Observe the specifications of the manufacturer regarding the mixing ratios.
Add additives to the fluid on the pressure side of the pump.
Example: Stratos-D 2x3-40
StratosHigh-efficiency pump
Wet-rotor circulating pump
D = single-head pump (no letter)
-D = twin-head pump
-Z = single-head pump for secondary hot water circulation systems
2 Pipe connection [inch]
3-40 Infinitely variable nominal pump head 3to 40 [ft]
Hmin: 3.3ft, Hmax: 39.4 ft
5.2 Technical Data
Power supply 1~230V± 10%
Frequency 60 Hz
Degree ofprotection Enclosure 2
Insulation class H
Motor protection Standard built-in full motor protection
Maximum sound pressure level 54 dB(A)
Liquid temperature Heating, ventilation, air-conditioning applications:
14°F (-10°C) to 230°F (+110°C)
Secondary hot water circulation applications:
32°F(0°C) to 176°F(+80°C )
Max. ambient temperature 104°F (40°C)
Max. rel. humidity  95%
Max. working pressure at the pump 145 psi
Residual current I  3.5 mA(see also Chap. 7.2)

Installation and operating instructionsWilo-Stratos/-D/-Z 7
English
Min. pump inlet pressure [psi] at the suction side during operation by Wilo-
Stratos model:
The valuesapply up to 984 ft above sealevel, add-on for higher altitudes:
0.15 psi/328 ft increase in height
5.3 Scope of Supply
• Complete pump
•Installation and operating instructions
•2flange gaskets(only for 1.25, 1.5 and 2 inch flange pumps)
5.4 Accessories
•Accessoriessuch as companion flangesmust be ordered separately.
•Companion flanges(included bolts, nutsand gaskets) for flange-pipe connection.
• IR (infra-red) module for special setup and diagnostics.
• IF (interface) Module StratosExt. Off/SBM, Ext.Min, LON, BACnet.
6 Description and function
6.1 Pump description
Wilo-Stratoshigh-efficiency pumpsare glandless pumpswith integrated
differential pressure control and “Electronic Commutated Motor” (ECM)
technology. They can be installed as single-head (Fig. 1a) or twin-head pumps
(Fig. 1b).
1 Control module
1.1 Infrared interface
1.2 LC display
1.3Red button
2 Pump housing
6.2 Operation of the pump
Ifthe pump has an axial design, there isacontrol module (Fig. 1a, Pos.1) on the
motor housing, which regulatesthe differential pressure ofthe pump to an
adjustable setpoint within the control range. The differential pressure isbased
on different criteria, depending on the control mode. In all control modes,
however, the pump constantly adaptsto the changing output requirementsof
the system, which arise in particular when using thermostatic valves, zone
valvesor mixers.
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)
3inch 10.2 (psi) 21.8 (psi) 33.4 (psi)

English
8Subject to technical alterations!WILOSE 02/2011
The main benefits of electronic control are:
•itsavesenergy while reducing operating costs,
• it reducesnoise caused by the excess flow,
• it doesnot require pressure bypass valves.
Thiswet rotor pump isdesigned to have all rotating partssurrounded by the
liquid being pumped. The pump ismaintenance free and requiresno further
maintenance after the air bleeding procedure during the initial start-up (no
after start-up maintenance).
High-efficiency pumpsofthe Wilo-Stratos-Z seriesare adapted specifically to
the operating conditionsin secondary hot water circulation systemsdue to the
materialsselected and their design. All materialswhich come into contact with
the fluid are approved in accordance with KTW/WRC (WRAS).
6.2.1 Operating modes
The Stratosseriescan be operated in the operating modes“Heating” or
“Cooling/ air-conditioning”. The two operating modesare distinguished from
one another in their tolerance for faultsin the handling offault signalsthat
occur.
“Heating” operating mode:
Faultsare handled in atolerant fashion (as isnormally the case), e.g. depending
on the type offault, the pump doesnot signal afault until the same fault has
occurred repeatedly within aparticular time period. Error matrix: “HV”
“Cooling/air-conditioning” operating mode:
For all applicationsfor which each fault (in the pump or the system) must be
recognised quickly (e.g. air-conditioning applications).
Each fault, with the exception ofthe fault E10 (blocking), will be signalled at
once (< 2 sec.). In the event ofablocking (E10), various restart attemptswill be
carried out, which meansthat in such casesno fault message will occur until
after amaximum of40 sec. Error matrix: “AC”
Both operating modesdistinguish between faultsand warnings. In the event of
amalfunction, the motor isswitched off, the error code on the monitor is
displayed and the malfunction issignalled with the red LED.
Malfunctionsalwayslead to activation ofthe SSM.
In the case oftwin-head pump management (twin-head pump or 2x singlehead
pumps), the standby pump startswithin the time period specified below
following the appearance ofthe fault.
Stratos, Stratos-D, Stratos-Z Starting time
1.25x3-20, 1.25x3-25 approx. 9 sec
1.25x3-30, 1.25x3-35, 1.5x3-25 approx. 4 sec
1.5x3-40, 2x3-30, 2x3-35, 2x3-40 approx. 4 sec
3x3-30approx. 3sec
3x3-40 approx. 7 sec

Installation and operating instructionsWilo-Stratos/-D/-Z 9
English
6.2.2 Differential-pressure control systems
The control systems which can be selected are:
•'p-v: (Factory default setting) The electronicsincrease the pump'sdifferential
pressure set point in astraight line between ½ Hsand Hs. The differential
pressure set point Hsincreasesor decreasesin accordance with the required
flow rate (fig. 6).
•'p-c: The electronicskeep the differential pressure generated by the pump at
aconstant differential pressure set point Hsover the entire operation range of
the pump (fig. 7).
•'p-T: The electronicsalter the nominal differential pressure set point
dependant on the fluid temperature measured. Thiscontrol system can only be
adjusted with the IR module. There are two possible settings(fig. 8):
•Positive control: As the system temperature rises, the nominal differential
pressure set point isincreased linearly between Hsmin and Hsmax. (setting on
IR module: Hsmax> Hsmin).
Used e.g. with standard boilerswith sliding flow temperature.
•Negative control: As the system temperature rises, the nominal differential
pressure set point isdecreasedlinearly between Hsmin and Hsmax (setting on
IR module: Hsmax< Hsmin).
Used e.g. with condensing boilerswhere aspecific 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'sreturn flow section.
6.2.3 Other energy-saving operating modes
• Speed regulation mode operation: The speed ofthe pump iskept at an
externally set constant speed between minimum and maximum speeds(fig. 9).
The speed regulation mode deactivatesthe differential pressure control.
• In the "auto" operating mode (factory default setting) the pump isable to
recognize aminimum system heat output requirement due to asustained drop
in the system temperature and then automitically switch to night setback
mode. Ifthe heat output requirement rises, the pump automatically switchesto
standard mode. Thissetting ensuresthat the pump'senergy consumption is
reduced to aminimum and in most casesisthe optimum setting.
6.2.4 General pump functions
• The pumpsare fitted with an electronic overload protection system which
switchesthe pump off should it become overloaded.
• The control module isequipped with anon-volatile memory for data storage.
What thismeansisthat dataissaved, even during long periodsofdown time.
Once the voltage returnsthe pump startsoperating again with the valuesset
before the power outage.
CAUTION! Possible damage of the pump!
Setback mode may only be enabled when the system is hydraulically
balanced. Inadequately supplied system parts may otherwise freeze in the
event of frost.

English
10 Subject to technical alterations!WILOSE 02/2011
•Pump kick: Any pumpsswitched off viathe menu(ON/OFF), abus
communication, the infrared interface, the Ext.Off control input or 0-10Vstart
running for ashort timeevery24 hoursto prevent blockagesin the event oflong
periodsofstandstill. The mainsvoltage must not be interrupted for this
function.
Ifthe mainsisintended to be switched off for along period oftime, the pump
kick must be assumed by the heating/boiler control system by briefly switching
on the mainsvoltage. For thispurpose, the pump must be switched on by the
control system prior to the interruption to the mainssupply (display omotor/
module symbol lit up).
Connections to the building management system (BMS)
•FC: Acollective fault contact FC (potential-free closed contact) can be
connected to acontrol point (building management system) as standard. The
internal contact isclosed ifthe pump isturned off, or there are no problemsor
failureson the part ofthe control module. The faultsare described in detail in
chapter 10.
•IF(Interface) modules (accessory):
Analog interfacesare available in the form ofadd-on IF modulesfor connecting
to external control system (e.g. DDC/BMS).
6.2.5 Twin-head pump operation
Twin-head pumpsor two corresponding single pumpsin aparallel pump
installation can be fitted with built-in double-pump management.
•Stratos IF module: Two IF modulesconnected viathe DP (double pump)
interface are required for communication between pumps. In addition to double
pump management, the IF modulesprovide other interfacesfor the double
pump.
Thisdouble pump management has the following functions:
•Master/Slave: Both pumpsare controlled by the master. All settingsare made
by the master.
•Optimum-efficiency peak-load operation: The twin-head pumpsor two
corresponding single pumpscan be run in alow/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 isprovided by one pump
only. The second pump isswitched on at optimum efficiency, when the sum of
power consumptionsP1ofboth pumpsisless than the power consumptionsP1
ofone pump. Both pumpsare then adjusted upwardssimultaneously to max.
speed ifnecessary. In relation to the conventional peak load operation (load
controlled switch on and off) afurther energy saving isreached by thismode of
operation.
•Duty/Standby mode: Each ofthe two pumpsproducesthe design delivery rate.
The other pump can be used in the event ofthe first pump malfunctioning or
following apump swap. Only one pump operatesat atime.
• In the event that one pump experiencesafailure/problem, the other will run as
asingle pump in standard mode as instructed by the master.

Installation and operating instructionsWilo-Stratos/-D/-Z 11
English
• In the event ofabreak in communication: The slave pump runsat the last set
value ofthe master prior to the interruption.
•Pump swap: Ifonly one pump isoperational (duty/standby, peak- or low-load
operation), the pumpsare swapped after every 24 hrs’ ofactual operating time.
Both pumpsare running at the time ofthe pump alteration in order to ensure
that operation isnot interrupted.
NOTE: Both pumpswill alwaysbe running ifboth the manual control mode and
the synchronous mode are active at the same time.
No pump alteration takesplace. No pump alteration takesplace during the
active night reduction after 24 h ofeffective running time.
•FC: The collective fault contact (FC) ofthe master can be connected to acentral
control point. In thiscase, contact isonly established with the master. The
reading isvalid for both pumps.
As an option, the error message contactsofmaster 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.
6.2.6 Definition of the symbols on the LC display
Symbol Definition
auto
Control mode; automatic switch-over to night setback mode isenabled.
Night-time mode isactivated at minimum heat output requirement
(default).
auto
Pump runsin night-time mode (night setback operation) at min. speed.
(no symbol) Automatic switch-over to night setback mode blocked, i.e. pump runsin
standard mode only.
Night setback mode activated viaPLR/LON/CAN interface Ext.Min,
regardless ofthe system temperature.
Pump runsin warm-up mode at maximum speed. The setting can be
activated only viaPLR/LON/CAN.
Pump switched on (default).
Pump switched off.
Differential pressure set value set to H = 18.0 ft. (example)
Control mode 'p-v, regulated to variable differential pressure set value
(fig. 6) (default).
Control mode 'p-c, regulated to constant differential pressure set value
(fig. 7).

English
12 Subject to technical alterations!WILOSE 02/2011
Manual control mode deactivatesthe module pressure variations. The
speed ofthe pump iskept at aconstant level. The speed isset internally
using the contol button (fig. 9).
Pump set to aconstant speed (2.600 rpm example shown) - manual
control mode.
In the manual control mode, the speed or nominal lift ofoperating mode
'p-c or 'p-v ofthe pump isset viainput 0...10 Vofthe StratosIF
module Ext.Min. The button then has no set value input function. (fig.
10)
Control mode 'p-T, regulated to temperature dependent differential
pressure set value (fig. 8). The maximum set value Hsmaxisdisplayed.
Thiscontrol mode can only be activated viathe IR module or viaPLR/
LON/CAN.
All settingson module except "acknowledge error" blocked. Settings
locked out by IR module. Settingscan only be altered using IR .
The pump isoperated viaaserial datainterface. The “On/Off” function
isnot activated at the module. Only , , the display
position and fault acknowledgement still have to be set on the module.
Operation at the interface can be interrupted temporarily with the IR-
Monitor/IR-module (for inspection or for reading out data).
Pump runsas slave pump. No changescan be made to the position
setting ofthe display.
Two single pumpsas double pump running in peak load mode (master +
slave)
Two single pumpsas double pump running in duty / standby mode
(master or slave)
Displayed for pump with IF module LON in order to send aservice mes-
sage to the building control centre.
The pump isset in the “SI units” mode.
Fault-tolerant error matrix activated.
Heating operating mode (in case ofmalfunction, see Chap. 10)
Fault-tolerant error matrix deactivated.
Air-conditioning operating mode (in case ofmalfunction, see Chap. 10)
Symbol Definition

Installation and operating instructionsWilo-Stratos/-D/-Z 13
English
Menu structure: There are three menulevels. The levelsbeneath the display of
the basic settingsare alwaysaccessed from 1 level by pressing the control
button
for different lengthsoftime.
Level 1 – Status display (display ofthe operating state)
Level 2 – Operation menu (setting the basic functions):
•Pressing the control button longer than 1 s
Level 3 – Options menu (additional settings):
•Pressing the control button longer than 6 s
NOTE: After 30 swithout any new entry being made, the display jumpsback to
Level 1 (display ofthe operating state). Temporary, non-acknowledged
modificationsare discarded.
7 Installation and electrical connection
Installation and electrical work in compliance with any local codes and by
qualified personnel only!
7.1 Pump installation
•Installation within abuilding: install the pump in adry, well ventilated and
frostresistant room.
•Installation outside abuilding (outdoor installation):
•Install the pump in ashaft (e.g. light well, annular shaft) with cover or in a
cupboard/housing as weather protection.
•Avoid exposure ofthe pump to direct sunlight.
• Protect the pump against rain. Dripping water from above ispermitted,
provided the electrical connection isestablished in accordance with the
installation and operating instructionsand the terminal box isclosed properly.
DANGER! Electrical shock hazard!
Dangers caused by electrical energy must be excluded.
National Electrical Codes, local codes and regulations must be followed.
WARNING! Bodily injury!
Existing regulations for the prevention of accidents must be observed.
CAUTION! Possible damage of the pump!
Dirt and solder drops in the pump body can effect the pump operation.
• It is recommended that any welding and soldering work be done before
installing the pump.
• Thoroughly flush the system prior to installing and operating the pump.
• Foreign material in the system resulting from construction may damage the
pump and is not warrantable.

English
14 Subject to technical alterations!WILOSE 02/2011
• The pump must be installed in an easily accessible position to facilitate
inspection or replacement.
•Thepump should never be located at the lowest point ofthe piping system,
where dirt and sediment collect. Nor should it be located at the highest point of
the piping system, where air accumulates. Please ensure at least aminimum of
three pipe diametersofstraight on the suction side ofthe pump.
•Itisrecommended that isolation valvesbe installed on the suction and
discharge side ofthe pump.
Thiswill save having to drain and refill the system ifthe pump / pump head
needsexchange-service. The valvesare to be installed so that any water that
escape cannot drip onto the pump motor or terminal box.
•An arrow on the pump housing indicatesthe direction ofwater flow (fig.1, pos.2).
•Install the pump in an easily accessible place, so that subsequent servicing work
can easily be carried out.
Installation isto be carried out such that dripping water cannot drip onto the
pump motor or control module.
•Pump must be installed with the shaft in the horizontal position in such away
that it isnot stressed by the pipework. (Installation positionsin fig. 2). When
installing in confined spaces, for example in compact distributors, the control
module can be placed in avertical position by rotating the motor, see
chapter 7.1.1.
• In order to obtain the correct terminal box position the motor housing can be
turned after removing the four allen screws(fig. 3).
• Permitted terminal box positionssee fig. 2
•Carefully lift the pump head and rotate it so the terminal box isin the desired
position. Replace the pump head onto the pump housing and thighten the allen
screwsevenly in adiagonal method.
Torque to:
• M6 ............ 7 ft lb
• M10 ........ 22 ft lb
WARNING! Risk of scalding!
If the pump is already installed in the system, the system must be drained or
the isolating valves on both sides of the pump must be closed before the
allen screws are removed as the pumped liquid may be scalding hot and/or
under pressure.
Do not start the pump until the system has been filled with liquid and
vented.
CAUTION! Possible damage of the pump!
When rotating the motor housing, ensure the O-ring between the cartridge
and pump housing (volute) does not become damaged.

Installation and operating instructionsWilo-Stratos/-D/-Z 15
English
7.1.1 Removing/installing the motor head unit
Ifthe control module isto be moved into adifferent position, the motor does
not need to be completely removed from the pump housing. The motor can be
turned to the desired position in the pump housing.
To remove the motor, (4x) M6 or (4x) M10 hexagon socket screwsmust be
loosened. These screwscan be reached with the following tools(fig. 3):
• 90° offset socket-head screwdriver
•spherical head socket-head screwdriver
• ¼” reversing ratchet with suitable bit
7.1.2 Insulating the pump in refrigerating/air-conditioning systems
The Wilo-Stratosseriesissuitable for use in refrigeration and air-conditioning
systemswith flow medium temperaturesdown to 14°F (-10°C).
Use the diffusion-proofWilo-ClimaForm low-temperature insulation shell in
cooling and air-conditioning systems.
DANGER! Electrical shock hazard!
If the pump is operated by means of a generator, a dangerous voltage is
created at the motor terminals after the control module is removed. The
motor terminals are designed as VDE-approved bushings, so that there is no
danger if simply touched with the finger. However, there would be a danger
if a pointed object (nail, screwdriver, wire) were poked into one of the
bushings.
CAUTION! Possible damage of the pump!
Be careful not to damage the O-ring situated between the motor head and
the pump housing. The O-ring must lie untwisted in the bevel of the end
shield pointing to the impeller.
CAUTION! Possible damage of the pump!
The impeller is permemtantly attached to the shaft, the end shield and the
rotor. As the rotor has extremely strong rare earth magnets, if the rotor is
removed from the rotor can, it has a considerable potential for danger e.g.
by suddenly attracting objects made from iron/steel, influencing electrical
equipment (risk to people with pacemakers), destroying magnetic cards,
etc.
CAUTION! Possible damage of the pump!
If the diffusion-proof insulation is created by the customer, the pump
housing may be insulated towards the motor only up to the motorflange, so
that the condensate drain openings remain open and allow the condensate
accumulating in the motor to flow out without obstruction (fig. 4).

English
16 Subject to technical alterations!WILOSE 02/2011
7.2 Electrical connection
•Suitable mainsfuse isrequired to protect the motor per local electrical codes.
• The operating voltage and frequency are marked on the rating plate.
• The pump must be connected with apower supply equipped with agrounded
plug-connection and amain power switch.
•Aminimum cable size of14 AWG should be used (refer to the local code for
wiring restrictions).
•Thefollowing minimum requirementsare to be met ifashutdown takesplace
by meansofan onsite network relay: nominal current 10 A, nominal voltage
250 VAC.
•Leakage current per pump Ieff  3,5 mA
• The electrical cable must be installed so that it never touchesthe pipework and/
or the pump and motor housing.
• The connecting cable can be fed through the cable entry below or beside the
terminal box, depending on it’sorientation. It isadvisable to install the screwed
cable glandswith the entrance ofthe conduit pointing downwards. The cable
entry which isnot used must be closed by ablind plug (fig. 5).
•Watertight screwed cable glandsand conduit connectionsmust be used to
prevent any entrance ofwater to the terminal box.
• Connect power as shown in fig. 5.
•Mainsfuse: see rating plate
•Pump/installation must be grounded in compliance with regulations.
DANGER! Electrical shock hazard!
Dangers caused by electrical energy must be excluded.
• Electrical work by a qualified electrician only!
• National Electrical Codes, local codes and regulations must be strictly
followed.
• All electrical connections must be performed after the electrical supply has
been switched off and secured against unauthorized switching.
• For safe installation and operation a proper grounding of the pump to the
power supply’s grounding terminals is required.
CAUTION! Possible damage of the pump!
All conductors must be for at least 167°F (75°C).
CAUTION! Possible damage of the pump!
In insulation tests with a high-voltage generator the pump is to be
disconnected on all poles from the mains in the control module. The free
cable ends are to be insulated in accordance with the voltage of the high-
voltage generator.