Wilo TOP-S User manual

2088193-Ed.01/2008-03-DDD
Wilo-TOP-S, TOP-Z
Installation and operating instructions
Notice de montage et de mise en service
Instrucciones de instalación y funcionamiento

Fig. 1a
Fig. 2
Fig. 1b
Fig. 3
Fig. 4

Fig. 5
Fig. 6
Fig. 7

PROTECTION TO BE PROVIDED BY THE INSTALLER
ACCORDING TO N.E.C
PROTECTION À FOURNIR PAR L’INSTALLATEUR CON-
FORMÉMENT AU CODE NATIONAL DE L’ÉLECTRICITÉ.
PROTECCIÓN QUE EL INSTALADOR DEBE PROPORCIO-
NAR DE ACUERDO CON LOS CÓDIGOS ELÉCTRICOS
NACIONALES.
Fig. 8
PROTECTION TO BE PROVIDED BY THE INSTALLER
ACCORDING TO N.E.C
PROTECTION À FOURNIR PAR L’INSTALLATEUR CON-
FORMÉMENT AU CODE NATIONAL DE L’ÉLECTRICITÉ.
PROTECCIÓN QUE EL INSTALADOR DEBE PROPORCIO-
NAR DE ACUERDO CON LOS CÓDIGOS ELÉCTRICOS
NACIONALES.
Fig. 9

Table of contents page
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Transport and interim storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Intended use (Application) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6 Description and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
7 Installation and electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
8 Start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
9 Maintenance / Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
10 Faults, causes and remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
11 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Table des matières page
1 Généralités . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2 Sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3 Transport et stockage avant utilisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
4 Utilisation prévue (application) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
5 Données techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
6 Description et fonctionnement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
7 Installation et raccordement électrique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
8 Démarrage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
9 Entretien / Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
10 Défauts, causes et remèdes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
11 Pièces de rechange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Contenido página
1 Generalidades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
2 Seguridad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
3 Transporte y almacenaje . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
4 Uso previsto (aplicación) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5 Datos técnicos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
6 Descripción y funcionamiento . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
7 Instalación y conexión eléctrica . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
8 Puesta en marcha . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
9 Mantenimiento / Reparación . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
10 Averías, causas y soluciones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
11 Repuestos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
01-12.qxd:2058935_NAMEX_USA_1b12.qxd 06.03.2008 9:20 Uhr Seite 1

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 in-
structions is a pre-condition for use of the product for the intended purpose and for its correct
operation.
These Installation and Operating Instructions conform to the relevant version of the equipment
and the underlying safety standards valid at the time of going to press.
2 Safety
These instructions contain important information which must be followed when installing and
operating the pump. It is therefore imperative that they are read by both the installer and the
operator before the circulator is installed or started 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:General Safety symbol
Hazards from electrical causes
Signal words:
A notice with useful information for the user in relation to the product. It attends the
user to possible problems.
2.2 Qualified Personnel
The personnel installing the pump must have the appropriate qualifications for this work.
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.
In particular, failure to comply with these safety precautions could increase the possibility of the
following risks:
xthe failure of important parts of the pump or installation,
xpersonal injury due to electrical and mechanical causes,
xmaterial damage.
NOTE!
ENGLISH
3
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 to the risk of
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.
01-12.qxd:2058935_NAMEX_USA_1b12.qxd 06.03.2008 9:20 Uhr Seite 3

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
The operator must ensure that all inspection and installation work is carried out 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 from the power
supply and at complete standstill.
2.6 Unauthorized alterations and manufacture of spare parts
Alterations to the 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 sa-
fety. The use of any other parts may invalidate claims relieving 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 in the 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 ship-
ping damage has occurred, take all necessary steps with 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 circulating pumps are used to circulate liquids in
xWarm and hot water heating systems,
xCooling and cold water circuits,
xClosed circulation systems,
xOpen circulation systems (pumps should be bronze body),
xCirculation systems for domestic hot (drinking) water (only TOP-Z).
Permissible liquids and requirements:
xHeating water according the requirements of accepted standards of water quality in heating systems.
xWater and water/glycol mixtures in a maximum ratio up to 1:1. High glycol concentration and low
temperature systems may require a reassessment of the hydraulic data to compensate for the incre-
asedviscosity (pleasecontact yourWILO representativesfor moreinformation).Use ofadditives (cor-
rosion inhibitors, oxygen scavengers etc.) must be in compliance with the manufacturer instructions.
xDomestic hot (drinking) water (only TOP-Z).
xIf other fluids or additives are used, please contact WILO for proper authorization.
ENGLISH
4
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.).
WARNING! Health hazard
The materials of the TOP-S circulators are not designed for drinking water supply.
The pumps in the TOP-S range must not be used for drinking water.
CAUTION!
This pump has been approved for use with water only.
01-12.qxd:2058935_NAMEX_USA_1b12.qxd 06.03.2008 9:20 Uhr Seite 4

5 Technical data
5.1 Type key
5.2 Data table
5.3 Scope of supply
xComplete pump
xInstallation and operating instructions
x2 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.
xCompanion flanges (included bolts, nuts and seals).
ENGLISH
5
Voltages 1~115 V , 1~230 V , 3~208-230 V , 3~460 V ,
3~575 V (see rating plate)
Frequency 60 Hz
Power consumption See rating plate
Speed setting 2-speed
Liquid temperatures for TOP-S closed system: 14°F (-10 °C) up to 248°F (120°C)
open system: < 140°F (60°C) Max. ambient temperature 104°F (40°C)
Liquid temperatures for TOP-Z closed system: 14°F (-10 °C) up to 176°F (80°C)
open system: < 140°F (60°C)
Domestic hot water system: 32°F (0 °C) up to 176°F (80°C)
Max. permitted degree of hardness in domestic
hot water circulation systems: 18,8 gr/gal (US)
Max. ambient temperature 104°F (40°C)
Max. working pressure 145 psi
Protection class Enclosure 2
Min. pump inlet pressure [psi] at suction side during operation by Wilo-TOP-S model
At these liquid temps nominal flange diameter [inch]
1.25 1.5 2 3
140°F (60°C) 1.8 (psi) 6.3 (psi)
194°F (90°C) 7.3 (psi) 15.4 (psi)
248°F (120°C) 29.9 (psi) 38.9 (psi)
Min. pump inlet pressure [psi] at suction side during operation by Wilo-TOP-Z model
At these liquid temps nominal flange diameter [inch]
1.5 2 3
104°F (40°C) 7.1 (psi) 11.4 (psi)
176°F (80°C) 11.4 (psi) 14.2 (psi)
Example: TOP- S 2x25 ()
Circulator pump
S=Standard Type
Z= Drinking water circulating pump
Pipe connection [inch]
Maximum head [ft]
Pump housing
= Cast iron (no letter = cast iron, only for TOP-S)
B= Bronze (only for TOP-S)
TOP-Z = Bronze as standard
01-12.qxd:2058935_NAMEX_USA_1b12.qxd 06.03.2008 9:20 Uhr Seite 5

6 Description and function
6.1 Product description (see Fig. 1a)
1 Terminal box 6 Motor housing
2 Suction side 7 Cable entry
3 Pump housing 8 Capacitor (only for single phase pumps)
4 Discharge side 9 Venting plug (only on some types)
5 Condensate outlet 10 Rating plate
6.2 Design of pump and motor
This wet rotor pump is designed to have all rotating parts surrounded by the liquid being pumped and
is suitable for single or three phase operation (see pump rating plate). A shaft seal, which would be sub-
ject to wear and maintenance is not required. Depending on the design of the pump, the system fluid
lubricates the sleeve bearings and cools both bearings and motor. 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).
The Wilo model TOP-Z is specially designed for use in conjunction with drinking water circulation sy-
stems. Thanks to its design and materials used in its construction the pump is resistant to corrosion
from elements in domestic hot water ( drinking water). All materials coming in contact with the deli-
very medium are NSF/ANSI 61 certified.
6.3 Functions
Speed setting of TOP-S.../TOP-Z... pumps (Fig. 5 and Fig.6)
The required speed of the pump can be adjusted manually in 2 positions (Max. and Min.) by mo-
ving the switch connector to the relevant socket. Procedure see Chapter “8.2 speed setting”.
Ensure power is turned off prior to changing speeds!
7 Installation and electrical connection
Installation and electrical work in compliance with any local codes and by quali-
fied personnel only!
7.1 Installation
xThe pump must be installed in a dry, well ventilated and frost-free place.
xThe pump must be installed in an easily accessible position to facilitate inspection or replacement.
xThe pump should never be located at the lowest point of the piping system, where dirt and se-
diment collect. Nor should it be located at the highest point of the piping system, where air ac-
cumulates. Please ensure at least a minimum of three pipe diameters of straight on the suc-
tion side of the pump.
ENGLISH
6
WARNING! Bodily injury
Existing regulations for the prevention of accidents must be observed.
WARNING! Electrical shock hazard
Dangers caused by electrical energy must be excluded.
National Electrical Codes, local codes and regulations must be followed.
CAUTION! Possible damage of the pump
Foreign materials such as dirt and solder can effect the pump operation.
xIt is recommended that any welding and soldering work be done before installing
the pump.
xThoroughly flush the system prior to installing and operating the pump.
xForeign material in the system resulting from construction may damage the pump
and is not warrantable.
01-12.qxd:2058935_NAMEX_USA_1b12.qxd 06.03.2008 9:20 Uhr Seite 6

xIt is recommended that isolation valves be installed on the suction and discharge side of the
pump.
This will save having to drain and refill the system if the pump needs replacing. The valves are
to be installed so that any water that escapes cannot drip onto the pump motor or terminal box.
xAn arrow on the pump housing indicates the direction of water flow (Fig. 3, Pos. 1).
xPump must be installed with the shaft in the horizontal position in such a way that it is not
stressed by the pipework (Installation positions in Fig. 2).
xIt is recommended that pressure gages be installed in the suction and discharge volute flanges
(Fig.1b, Pos.2) to check pump and system performance.
xIn order to obtain the correct terminal box position the motor housing can be turned after re-
moving the four allen screws (Fig. 4).
xPermitted terminal box positions see Fig. 2
xCarefully lift the pump head and rotate it so that the terminal box is in the desired position.
Replace the pump head onto the pump housing and thighten the allen screws evenly in a di-
agonal method.
Torque to: M6 ……. 17 ft lb
M10 ……. 22 ft lb
M12 ……. 45 ft lb
xAfter replacing, check that the rotor shaft still rotates freely.
TOP-S and TOP-Z pumps which are equipped with vent screws can be checked as follow (Fig.
1a, Pos.9): Remove the plug (located in the middle of the rating plate), insert a flat head
screwdriver into the slot end of the shaft and turn to ensure free rotation.
TOP-S and TOP-Z pumps without vent screws and not installed can be checked as follows:
Insert a long screwdriver in the discharge port of the pump body (Fig.1, Pos.4) until you can
feel the impeller and rotate it with the tool. If the impeller does not turn easily, repeat the dis-
assembly / reassembly process.
xBetween the stator housing and pump volute, there are three drain holes to allow condensed
water to escape (Fig. 3, Pos. 2).
7.2 Electrical connection
xSuitable fused overload protection is required to protect the motor per local electrical codes.
ENGLISH
7
WARNING!
If the pump is already installed in the system, the system must be drained or the iso-
lating 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.
CAUTION! Possible damage of the pump!
The motor and condensate holes must remain free.
For units which are to be insulated, only the pump volute may be insulated.
WARNING! Electrical shock hazard
Dangers caused by electrical energy must be excluded.
xElectrical work by a qualified electrician only!
xNational Electrical Codes, local codes and regulations must be strictly followed.
x All electrical connections must be performed after the electrical supply has been
switched off and secured against unauthorized switching.
xFor safe installation and operation a proper grounding of the pump to the power
supply’s grounding terminals is required.
01-12.qxd:2058935_NAMEX_USA_1b12.qxd 06.03.2008 9:20 Uhr Seite 7