Wilo TOP-S Series User manual

DEinbau- und Betriebsanleitung
GB Installation and operating instructions
FNotice de montage et de mise en service
NL Inbouw- en bedieningsvoorschriften
EInstrucciones de instalación y funcionamiento
IIstruzioni di montaggio, uso e manutenzione
Wilo-TOP-S/-SD/-Z/-D/-RL/-I
2 115 933-Ed.03/2011-05

Fig. 1:
Fig. 2: Fig. 3:

Fig. 4: 1~
Fig. 4: 3~
max.
med.
min.
1~230V

Fig. 4: 1~/3~ (3~400 V/3~230 V/1~230 V)
Fig. 5: Fig. 6:
Fig. 7:

Fig. 8: a Fig. 8: b Fig. 8: c
Fig. 8: d Fig. 8: e Fig. 8: f
Fig. 8: g Fig. 8: h
PE
TOP-D
1 ~ 230 V/N/50 Hz
L1 N
U1 V1 W1
W2 U2 V2
PE
TOP-D
3 ~ 400 V/N/50 Hz
L1 L2 L3
U1 V1 W1
W2 U2 V2
PE
TOP-D
3 ~ 230 V/N/50 Hz
L1 L2 L3
U1 V1 W1
W2 U2 V2
PE
PE
PE
TOP-D
SK 602
SK 622
3 ~ 400 V/N/50 Hz
L2
L2
VU
L3
L3
N
N
N1 2
WSK
WSK
W N 15 10 10 11
U1 V1 W1
15 10
W2 U2 V2
L1
L1
PE
PE
PE
TOP-D
SK 602
SK 622
3 ~ 230 V/N/50 Hz
L2
L2
VU
L3
L3
N
N
N12
WSK
WSK
W N 15 10 10 11
U1 V1 W1
15 10
W2 U2 V2
L1
L1
PE
PE
PE
TOP-D
SK 602
SK 622
1 ~ 230 V/N/50 Hz
L2
L1
VU
L3 N
N
N12
WSK
WSK
W N 15 10 10 11
U1 V1 W1
15 10
W2 U2 V2
L1
1 ~ 230 V/N/50 Hz
PE
PE
PE
TOP-S
SK 602
SK 622
L2L1
L1
VU
L3 N
N
N1 2
WSK
WSK
W N 15 10 10 11
LN
15 10
TOP-Z
TOP-SD
med.
min.
max.
n
X4 X3 X2 X1
TOP-S
TOP-SD
TOP-Z
TOP-RL
TOP-I
L1PE
1~230 V/N/50 Hz
N

English
28 WILO SE 05/2011
Installation and operating instructions
1 General
About this document
The language of the original operating instructions is German. All other lan-
guages of these instructions are translations of the original operating instruc-
tions.
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.
These installation and operating instructions correspond to the relevant version
of the product and the underlying safety 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 without our
agreement, 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 oper-
ating 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 from electrical voltage
USEFUL NOTE:
Signal words:
DANGER!
Acutely dangerous situation
Non-observance results in death or the most serious of injuries.

Installation and operating instructions Wilo-TOP-S/-SD/-Z/-D/-RL/-I 29
English
WARNING!
The user can suffer (serious) injuries. 'Warning' implies that (serious) injury
to persons is probable if this information is disregarded.
CAUTION!
There is a risk of damaging the product/unit. 'Caution' implies that damage
to the product is likely if this information is disregarded.
NOTE: Useful information on handling the product. It draws attention to possi-
ble problems.
Information that appears directly on the product, such as
• Direction of rotation arrow
• Identification for fluid connections
• Name plate
• Warning sticker
must be strictly complied with and kept in legible condition.
2.2 Personnel qualifications
The installation, operating and maintenance personnel must have the appropri-
ate 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. This can be accomplished if necessary 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 particular, lack of care may lead to problems such as:
• Danger to persons due to electrical, mechanical and bacteriological influences,
• damage to the environment due to leakage of hazardous materials,
• damage to property,
• 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.

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30 WILO SE 05/2011
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 experience 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 appli-
ance.
• If hot or cold components on the product/the unit lead to hazards, local meas-
ures 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 the shaft seals) of hazardous fluids (which are explosive,
toxic or hot) must be led away so that no danger to persons or to the environ-
ment arises. National statutory provisions are to be complied with.
• Danger from electrical current must be eliminated. Local directives or general
directives [e.g. IEC, VDE etc.] and local power supply companies 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 on the product/unit must only be carried out when at a standstill. It is
mandatory that the procedure described in the installation and operating
instructions for shutting down the product/unit be complied with.
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 manufacturer's declarations
regarding safety.
Modifications to the product are only permissible after consultation with the
manufacturer. Original spare parts and accessories authorised by the manufac-
turer ensure safety. The use of other parts will absolve us of liability for conse-
quential events.
2.8 Improper use
The operating safety of the supplied product is only guaranteed for conven-
tional use in accordance with Section 4 of theoperating instructions. The values
in operation must on no account undershoot or overshoot the limit values spec-
ified in the catalogue/data sheet.

Installation and operating instructions Wilo-TOP-S/-SD/-Z/-D/-RL/-I 31
English
3 Transport and interim storage
On arrival, immediately check the product and its packaging for damage in tran-
sit. If damage is found, the necessary actions involving the forwarding agent
must be taken within the specified period.
CAUTION! Risk of injuries to personnel and damage to the product!
Incorrect transport and interim storage can cause damage to the product and
injury to personnel.
• The pump and its packaging must be protected against moisture, frost and
mechanical damage during transport and interim storage.
• Packaging that has become weakened loses its strength and call allow the
product to fall out, causing injury to personnel.
• When the pump must be transported, it may be carried only by the motor/
pump housing. Never carry it by the module/terminal box, cable or external
capacitor.
4Intendeduse
Circulation pumps are used for delivering liquids in
• hot water heating systems
• underfloor heating (recommendation TOP-Z and TOP-I)
• cooling and cold water circuits
• closed-circuit industrial circulation systems
WARNING! Health hazard!
Because of the materials used in their construction, pumps of the
TOP-S/-SD/-D/-RL range are unsuitable for use in applications involving
drinking water or foodstuffs.
Pumps of the TOP-Z and TOP-I range are additionally suitable for use in
• drinking water circulation systems

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32 WILO SE 05/2011
5 Product information
5.1 Type key
Example: TOP-S 25/5 EM
TOP Circulation pump, glandless
S -S/-RL=Standard type
-SD = Standard type, twin-head pump
-Z = Single-head pump for drinking water circulation sys-
tems
-D = Constant speed (max. 1400 rpm)
-I = Industrial type
25 Threaded connection [mm]:20 (Rp ¾), 25 (Rp 1), 30 (Rp 1¼)
Flange connection: DN 32, 40, 50, 65, 80, 100, 125
Combination flange
(PN 6/10): DN 32, 40, 50, 65
/5 Maximum delivery head in [m] Q = 0 m3/h
EM EM = single-phase motor
DM = three-phase motor
5.2 Technical data
Max. flow rate Depends on the pump type (see catalogue)
Max. delivery head Depends on the pump type (see catalogue)
Speed Depends on the pump type (see catalogue)
Mains voltage 1~230 V to DIN IEC 60038
3~400 V to DIN IEC 60038
3~230 V* to DIN IEC 60038
(optionally with change-over switch)
*Exception: TOP-S/-SD 80/15 and 80/20
For other voltages see name plate
Nominal current See name plate
Frequency See name plate (50 or 60 Hz)
Insulation class See name plate
Protection class See name plate
Power consumption P1See name plate
Nominal diameters See type key
Connection flange See type key
Pump weight Depends on the pump type (see catalogue)
Permitted ambient
temperature
-20 °C to +40 °C
Max. rel. humidity d95%

Installation and operating instructions Wilo-TOP-S/-SD/-Z/-D/-RL/-I 33
English
CAUTION! Risk of injuries to personnel and damage to the product!
Impermissible fluids can damage the pump and also cause injury to persons.
Comply strictly with the relevant safety data sheets and manufacturer's
data!
Approved fluids
TOP-S/-SD/-Z/-D/-RL/-I
Heating water (to VDI 2035)
water/glycol mixtures, max. mixing ratio 1:1 (for mixtures
with glycol the conveying data of the pump should be cor-
rected to those for the higher viscosity, depending on the
percentage mixing ratio)
Only use brand-name goods with corrosion protection
inhibitors; comply with the manufacturer's specifications
and safety data sheets. The pump manufacturer's approval
must be obtained for use of other fluids.
Special versions with fluids-resistant materials (e.g. ver-
sions for use with oil) available on request.
TOP-Z/-I Drinking water and water for foodstuff applications to
EC drinking water directive. In systems to the German
drinking water regulations 2001 and DIN 50930-6, pumps
with housings of bronze (CC 499K) or stainless steel must
be used.
Permissible
fluid temperature
Heating water:
TOP-S/-SD/-D/-RL:
-20 °C to +130 °C (for a short time (2h): +140 °C)
Exception: TOP-S 25/13; TOP-S/-SD 80/15 and 80/20:
-20°Cto+110°C
TOP-Z/-I:
-20°Cto+110°C
TOP-S/-SD/-RL:
If used with Wilo-Protect module C: -20 °C to +110 °C
Drinking water:
TOP-Z/-I:
to 24 °e: max. +80 °C (for a short time (2h): +110 °C)
Exception: TOP-Z/TOP-I 20/4 and 25/6:
to 22 °e: max. +65 °C (for a short time (2h): +80 °C)
Max.permissibleoperating
pressure
See name plate
Emission sound-pressures
level
< 50 dB(A)
(depending on the pump type)
Emission of interference EN 61000-6-3
Resistance to interference EN 61000-6-2
5.2 Technical data

English
34 WILO SE 05/2011
Minimum inlet pressure (above atmospheric pressure) at the pump suction port
in order to avoid cavitation noises (at fluids temperature TMed):
The values apply up to 300 m above sea level; addition for higher locations:
0.01 bar/100 m increase in height.
5.3 Scope of delivery
• Pump, complete
• Two seals for threaded connection
• Two-part thermal insulation shell (only single-head pump); not for TOP-RL
and TOP-I
• Eight M12 washers
(for M12 flange bolts for DN 32-DN 65 combination flanged version)
• Eight M16 washers
(for M16 flange bolts for DN 32-DN 65 combination flanged version)
• Installation and operating instructions
TOP-S/-SD/-RL
TMed Rp ¾ Rp 1 Rp 1¼ DN 32/40 DN 50 DN 65 DN 80 DN 100
+50 °C 0.05 bar 0.3 bar
+95 °C 0.5 bar 1.0 bar
+110 °C 1.1 bar 1.6 bar
+130 °C 2.4 bar(*) 2.9 bar(*)
(*) not applicable to TOP-S 25/13, TOP-S/-SD 80/15, TOP-S/-SD 80/20
TOP-Z, TOP-I
TMed Rp ¾ Rp 1 Rp 1¼ DN 40 DN 50 DN 65 DN 80
+50 °C 0.5 bar 0.8 bar
+80 °C 0.8 bar 1.0 bar
+110 °C 2.0 bar 3.0 bar
TOP-D
TMed Rp 1 Rp 1¼ DN 32/40 DN 50 DN 65 DN 80 DN 100 DN 125
+50 °C 0.05 bar
+95 °C 0.2 bar 0.3 bar
+110 °C 0.8 bar 0.9 bar
+130 °C 2.1 bar 2.2 bar

Installation and operating instructions Wilo-TOP-S/-SD/-Z/-D/-RL/-I 35
English
5.4 Accessories
Accessories must be ordered separately:
• Wilo-Protect module C
• Change-over switch for 3~230 V
• ClimaForm cold water insulation for pump
• For TOP-D for single-phase connection:
• External capacitor with installation accessories
See catalogue for detailed list.
6Descriptionandfunction
6.1 Description of the pump
The pump is fitted with a glandless motor (single-phase (1~) or three-phase
(3~), for main connection voltage and mains frequency see the name plate, in
which all the rotating parts are in contact with the fluid. The design relies on the
fluid to provide lubrication for the plain bearings of the rotor shaft.
The motor speed can be switched over (not for TOP-D). The speed switching is
executed in different ways depending on the terminal box. The ways are either
by a speed selection switch, by plugging in the change-over plug differently or
by an internal or external jumpering of the contacts. (see commissioning/speed
change-over).
A suitable change-over switch is available as an accessory for the voltage 3 ~230 V.
The assignment of terminal boxes to the individual pump types is described
in the section “Terminal boxes” (chapter 6.2).
TOP-SD:
For a twin-head pump the two motor impeller units are fitted identically and
accommodated in a common pump housing.
TOP-Z:
The selected materials and designs of the pumps of this series comply with the
relevant guidelines (TrinkwV2001, ACS,WRAS) and are specially intended for
use under the operating conditions found in drinking water circulation systems.
In systems to the German drinking water regulations 2001, pumps with hous-
ings of bronze (CC 499K) or stainless steel must be used. If pumps of the series
Wilo-TOP-Z in GG (pump housing of grey cast iron) are used in drinking water
circulation systems, the national regulations and guidelines should be complied
with as necessary.
TOP-D:
The maximum speed is 1400 rpm, constant speed.

English
36 WILO SE 05/2011
6.2 Terminal boxes
There are nine terminal boxes (Fig. 4) covering all the pump types. Table 1 lists
the assignment of terminal boxes to pump types:
Table 1: Assignment of terminal box types to pump types (see also Fig.4)
The fittings for the terminal boxes can be found in Table 2:
Table 2: Fitting of terminal boxes
1) The light indicator signals are carried by a common fibre optic cable to the cover, so that the signals are visible
from outside.
2) When mains voltage is present, the lamp lights up green
• The direction of rotation indicator light lights up green when mains voltage is
present and the direction of rotation is correct; if the direction of rotation is
incorrect, the indicator light goes out (see chapter “Commissioning”).
•
The fault indicator light lights up red if the integral motor protection has tripped .
Mains
connection
Max. power consumption P1Terminal box type
(see name plate data) TOP-RL
TOP-I
TOP-S
TOP-SD
TOP-Z TOP-D
1~ P1max  85 W - - - 8
95 W  P1max  265 W 1 1/2 1 9
320 W  P1max  400 W - 3/4/5 3 9
650 W  P1max  960 W- 5 - -
3~ P1max  90 W - - - 8
100 W  P1max  270 W 6 6 6 9
305 W  P1max  3125 W - 7 7 9
Terminal box
type
Direction of
rotation
indicator light
Fault signal
light
Variable speed control
(Fig. 4, item 1) (Fig. 4, item 2) (Fig. 4, item 3)
1 - - Speed selection switch, 3-step
2 - - Internal or external,
jumpering the contacts “x1-x2” or
“x1-x3” or “x1-x4”
3 - - Speed selection switch, 3-step
4 - - Internal or external,
jumpering the contacts “x1-x2” or
“x1-x3” or “x1-x4”
5-
2) X 1) Change-over switch, 2-step
6 X (internal) - Change-over switch, 3-step
7X
1) X 1) Change-over switch, 3-step
8X(internal)--
9X(internal)--

Installation and operating instructions Wilo-TOP-S/-SD/-Z/-D/-RL/-I 37
English
7 Installation and electrical connection
DANGER! Danger of death!
Incorrect installation and inexpert electrical connection can pose a risk of
fatal injury. Danger from electrical current must be eliminated.
• The installation and electrical connection may only be carried out by quali-
fied personnel in accordance with the applicable regulations!
• Accident prevention regulations must be observed!
• Comply with the regulations of the local power supply company!
Pumps with pre-assembled cable:
• Never pull on the pump cable
• Do not kink the cable.
• Do not place any objects on the cable
7.1 Installation
WARNING! Danger of personal injury!
Incorrect installation can result in personal injury.
• There is a crush hazard
• There is an injury hazard due to sharp edges/burrs. Wear appropriate protec-
tive clothing (e.g. safety gloves)!
• There is an injury hazard due to the pump/the motor falling. Use suitable lift-
ing gear to secure the pump/motor against falling.
CAUTION! Risk of damage!
Incorrect installation can result in damage to the product.
• Only use qualified personnel for the installation work!
• Observe national and regional regulations!
• Installation within a building
• Install the pump in a dry, well-ventilated, frost-free room.
• Installation outside a building (outdoor installation):
• Install the pump in a sump (e.g. light sump, annular sump) with cover or in
a cupboard/housing as weather protection.
• Avoid exposure of the pump to direct sunlight.
• Protect the pump against rain. Dripping water from above is permitted pro-
vided that the electrical connection has been established in accordance with
the installation and operating instructions and the terminal box has been
properly sealed
CAUTION! Risk of damage!
Ensure sufficient ventilation/heating if the ambient temperature exceeds/
falls below the permitted limit values.
• Carry out all welding and soldering work prior to the installation of the pump.

English
38 WILO SE 05/2011
CAUTION! Risk of damage!
Contamination from the pipe system can damage the pump during operation.
Before installing the pump, flush the pipe system.
• Provide shut-off valves upstream and downstream of the pump.
• Attach pipework to the floor, ceiling or wall using appropriate fittings so that
the pump does not bear the weight of the pipework.
• If installed at the inlet to an open system, the safety inlet must branch off at the
pump's discharge side.
• If necessary remove the two half shells of the thermal insulation before install-
ing the single-head pump.
• Install the pump at an easily accessible location to allow it to be easily checked
or replaced at a later time.
• Precautions during installation:
• Perform assembly such that the pump shafts are horizontal and not under
strain (see the installation positions shown in Fig. 2). The motor terminal box
must not face downward. If necessary, slacken the socket-head screws and
rotate the motor housing (see chapter 9).
• The direction of flow of the fluid must correspond to the direction arrow on
the pump housing or the pump flange.
7.1.1 Installation of a threaded pipe union pump
• Install appropriate pipe unions before installing the pump.
• Use the supplied flat gaskets between the suction/pressure ports and pipe
unions when installing the pump.
• Screw union nuts onto the threads of the suction/pressure ports and tighten
them using a monkey wrench or pipe wrench.
CAUTION! Risk of damage!
When tightening the pipe unions, keep the pump in position by gripping the
motor. Not the module/terminal box!
• Check the pipe unions for leaks.
• Single-head pump:
Fit the two half-shells of the thermal insulation before commissioning and push
them together so that the guide pins engage in the opposing holes.

Installation and operating instructions Wilo-TOP-S/-SD/-Z/-D/-RL/-I 39
English
7.1.2 Installation of a flanged pump
Installation of pumps with PN6/10
combination flange (flange-end pumps D32 up to DN 65 inclusive)
WARNING! Risk of injury and material damage!
The flange connection can be damaged and develop leaks. There is an injury
hazard/risk of damage by the escape of a hot fluid.
• Never connect two combination flanges to each other!
• Pumps with combination flanges are not suitable for operating pressures
PN16.
• The use of securing elements (e.g. spring rings) can leads to leaks at the
flange connection. They are therefore not permissible. The washers supplied
(Fig. 3, item 1) must be inserted between screw heads/nuts and the combi-
nation flange.
• The permissible tightening torques listed in the table below must not be
exceeded, even if screws of higher strength (4.6) are used, since otherwise
splintering can occur at the edges of the long holes. This causes the screws
to lose their preload and the flange connection can become leaky.
• Use screws of sufficient length. The screw thread must protrude at least one
thread turn beyond the nut (Fig. 3, item 2).
DN 32, 40, 50, 65 Rated pressure PN 6 Rated pressure
PN 10/16
Screw diameter M12 M16
Tensile strength class 4.6 4.6
Permitted tightening torque 40 Nm 95 Nm
Min. screw length for
• DN 32/DN 40 55 mm 60 mm
• DN 50/DN 65 60 mm 65 mm
DN 80, 100, 125 Rated pressure PN 6 Rated pressure
PN 10/16
Screw diameter M16 M16
Tensile strength class 4.6 4.6
Permitted tightening torque 95 Nm 95 Nm
Min. screw length for
• 80 65mm 65mm
• 100 70 mm 70 mm
• 125 70 mm 75 mm

English
40 WILO SE 05/2011
• Install appropriate flat gaskets between pump and counter flanges.
• Tighten the flange bolts across diagonals in two steps to the prescribed tight-
ening torque (see Table 7.1.2).
• Step 1: 0.5 x permissible tightening torque
• Step 2: 1.0 x permissible tightening torque
• Check the flange connections for leaks.
• Single-head pump:
Fit the two half-shells of the thermal insulation before commissioning and push
them together so that the guide pins engage in the opposing holes.
7.1.3 Insulation of the pump in refrigeration/air-conditioning systems
• The series TOP-S/-SD/-RL are suitable for use in refrigeration and air-condi-
tioning systems with temperatures of the fluid down to -20 °C.
• The thermal insulation shells included in the scope of delivery of the individual
pumps may however only be used in heating systems at fluid temperatures of
+20 °C or higher, since these thermal insulation shells do not enclose the pump
housing in a diffusion-proof manner.
• For applications in refrigeration and air-conditioning systems, Wilo-ClimaForm
diffusion-proof thermal insulation shells or other commercially-available diffu-
sion-proof thermal insulation materials must be used.
CAUTION! Risk of damage!
If the diffusion-proof insulation is applied by the customer, the pump hous-
ing may be insulated only up to the motor separation joint, so that the con-
densate drain openings remain open and allow the condensate accumulating
in the motor to flow out without obstruction (Fig. 7).Otherwise condensate
can accumulate in the motor, eventually causing an electrical defect.
7.2 Electrical connection
DANGER! Danger of death!
Improper electrical connections pose a risk of fatal injury due to electric
shock.
• Only allow the electrical connection to be made by an electrician approved
by the local electricity supplier and in accordance with the local regulations
in force.
• Before working on the pump, all poles of the power supply must be discon-
nected. Because voltages hazardous to persons persist for some time
(in capacitors), no work may be commenced on the module until 5 minutes
have elapsed (applies only to 1~ systems). Check to ensure all connections
(including potential-free contacts) are voltage-free.

Installation and operating instructions Wilo-TOP-S/-SD/-Z/-D/-RL/-I 41
English
CAUTION! Risk of damage!
If the wrong voltage is applied, the motor can be damaged!
• The current type and voltage of the mains connection must correspond to the
specifications on the name plate.
• The electrical connection must be established via a fixed connection line
equipped with a connector device or an all-pole switch with a contact opening
width of at least 3 mm.
• Mains-side fuse protection: 10 A, slow.
• Twin-head pumps: provide a separate mains connection cable and a separate
fuse on the mains side for both motors of the twin-head pump.
• The pumps can also be used without restriction in existing installations with and
without FI-protection switches. When dimensioning the FI-protection switch,
consider the number of pumps connected and their motor currents.
• When pumps are used in systems with water temperatures above 90°C, a suit-
able heat-resistant supply cable must be used.
• The supply cable is to be placed in such a way that under no circumstances can
it come into contact with the pipe and/or the pump and motor housing.
• To ensure protection against dripping water and to provide the cable sheath
with strain relief, (PG 13.5), a connection cable with an outside diameter of 10 -
12 mm should be used, and fitted as shown in Fig. 6. In addition, the cable near
the threaded cable gland should be bent into the form of a drip loop, to from
which any accumulated drips will fall. Unused cable glands should be blanked
off with the sealing plates provided, and screwed up tight.
• Commission pumps only if they are fitted with the correct modular cover. Check
that the cover gasket is correctly seated.
• Earth the pump/system according to regulations.
• TOP-D pumps for all connection voltages are fitted with three-phase motors:
• For single-phase operation 1~230 V in a Steinmetz circuit (Fig. 8 a).
The capacitor available as an accessory is attached to one of the motor secur-
ing screws, using the attachment strap supplied (Fig. 5). In this area, the ther-
mal insulation is cut back to from a collar. The capacitor connection cable is
fed though the second cable gland (PG 9).
• For three-phase operation 3~400 V in star arrangement (Fig. 8 b),
• For three-phase operation 3~230 V in  arrangement (Fig. 8 b),
For voltage change-over from 400 V to 230 V the respective star- jumpers
must be swapped over (Fig. 8 a to 8 c).

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42 WILO SE 05/2011
7.2.1 Collective fault signal (SSM)
DANGER! Danger of death!
Improper electrical connections pose a risk of fatal injury due to electric
shock.
If the mains leads and SSM lead are brought together in a 5-core cable, the
SSM-lead must not be monitored using a protective low voltage.
For pumps with terminal boxes of types 5 and 7 (Fig. 4) a collective fault signal
“SSM” for connection to thebuilding automation system is available as a poten-
tial-free NC relay (max. contact loading 250 VAC/1A). The contacts open if the
integral motor protection trips to disconnect the motor. After a manual reset
(Fig. 4, item 4) at the pump, the contacts close again and the fault signal is
acknowledged.
If the collective fault signal “SSM” is connected to an external Wilo switch/con-
trol unit using the “WSK” (terminal 15, 10) facility, any fault that occurs should
first be acknowledged at the pump and then at the switch/control unit.
7.2.2 Motor protection
CAUTION! Risk of damage!
If the winding protection contact (WSK) of the pump is not connected to
a motor protection system, the motor can be damaged due to thermal
overload!
Pump with terminal
box type
Tripping SSM Fault acknowl-
edgement
TOP-S
TOP-SD
TOP-Z
TOP-RL
TOP-I
1~230 V
1
(P1max  265 W)
Internal switching off
of motor voltage -Automatically, after themotorhascooled
down
2
(P1max  265 W)
Internal switching off
of motor voltage -Automatically, after themotor hascooled
down
3
(320 W  P1max
 400 W)
WSK and external trip-
ping unit (SK602/
SK622 or other switch/
control unit)
-Manually at the trip-
ping unit, after the
motor has cooled
down
4
(320 W  P1max
 400 W)
WSK and external trip-
ping unit (SK602/
SK622 or other switch/
control unit)
-Manually at the trip-
ping unit, after the
motor has cooled
down
5
(650 W  P1max
 960 W)
All-pole switching off
by the integral tripping
electronics
Tripping the SSM is
performed in parallel
with switching off of
the integral tripping
electronics
Manually at the
pump, after the
motor has cooled
down