Wilo Wilo-Star-Z NOVA User manual

GB Installation and operating instructions
FNotice de montage et de mise en service
EInstrucciones de instalación
yfuncionamiento
IIstruzioni di montaggio, uso e
manutenzione
GR    
TR Montaj ve kullanma klavuzu
HBeépítési és üzemeltetési utasítás
PL Instrukcja montau i obsugi
Wilo-Star-Z NOVA
4 160 098-Ed.01/2011-11-Wilo

GB Installation and operating instructions 2
FNotice de montage et de mise en service 14
EInstrucciones de instalación y funcionamiento 26
IIstruzioni di montaggio, uso e manutenzione 38
GR     50
TR Montaj ve kullanma klavuzu 62
HBeépítési és üzemeltetési utasítás 74
PL Instrukcja montau i obsugi 86

Overview
2WILO SE 11/2011
English
Installation and operating in-
1Overview
Turn the motor head or remove it
>Page 9
Connections >Page 5
Valves >Page 7
Connecting
>Page 9
Faults >Page 13
Type key >Page 5
Electrical connection >Page 10
Safety >Page 3
Principle of operation >Page 7
Installation >Page 8

Safety
Installation and operating instructions Wilo-Star-Z NOVA 3
English
2Safety
About these instructions • Read through these instructions completely
before installation. Non-observance of these
instructions can result in injury to persons and
damage to the pump/unit.
• Once installation work is complete, pass the
instructions on to the end user.
• Keep the instructions near the pump. They
can be used as a reference if problems occur
later.
• We accept no liability for damages resulting
from failure to follow these instructions.
Safety information Important safety information is indicated as fol-
lows:
Danger: Indicates a danger to life due to
electrical current.
Warning: Indicates a possible danger to
life or injury.
Caution: Indicates possible risks to the
pump or other items.
Note: Highlights tips and information.

Safety
4WILO SE 11/2011
English
Qualification The pump may only be installed by qualified per-
sonnel. This product may not be commissioned or
operated by persons with insufficient account-
ability (including children) or who do not possess
the relevant specialist knowledge. Exceptions are
only permitted on appropriate instruction from
safety-responsible persons. The electrical con-
nection may only be established by a qualified
electrician.
Regulations The current versions of the following regulations
must be observed when installing the equipment:
• Accident prevention regulations
• DVGW worksheet W551 (in Germany)
• VDE 0370/Part 1
• Other local regulations (e.g. IEC, VDE, etc.)
Conversion, spare parts The pump must not be technically modified or
converted. It is not permitted to open the pump
motor by removing the plastic lid. Only use origi-
nal spare parts.
Transport Unpack and check the pump and all accessories
upon receipt. Report any damage sustained in
transit immediately.
Dispatch the pump in the original packing only.
Electrical current There is a danger of an electric shock when work-
ing with electrical current. Therefore:
• Switch off the power before beginning work
on the pump and make sure that it cannot be
switched on again accidentally.
• Do not kink or nip the power cable or allow it
to come into contact with heat sources.
• The pump is protected against drips in
accordance with protection class IP 42. Pro-
tect the pump against water spray. Do not
immerse in water or other fluids.

Technical data
Installation and operating instructions Wilo-Star-Z NOVA 5
English
3 Technical data
3.1 Type key
3.2 Connections
Star-Z Series:
Standard secondary hot water circulation
pump, glandless pump
NOVA Type designation
A = with check valves
C = with check valves
C = and ready for connection with plug clock
C = timer
Star-Z NOVA
Screwed connection: 15 (Rp 1/2")
Star-Z NOVA A and Star-Z NOVA C
Screwed connection: 15 (Rp 1/2") and check
valves

Technical data
6WILO SE 11/2011
English
3.3 Data
See name plate or Wilo catalogue for further
information.
3.4 Scope of delivery
1Pump
2 Thermal insulation shell
3 Sealing rings
4Wilo-Connector
5 Installation and operating instructions
(not shown)
Star-Z NOVA, Star-Z NOVA A,
Star-Z NOVA C
Mains voltage 1 ~ 230 V / 50 Hz
Protection class 42
Nominal diameter
of connecting pipes R 1/2
Installation length 84 mm
(Type A: 138 mm)
Maximum permissible
operating pressure 10 bar
Permitted fluid
temperature range 2°Cto65°C,
in short-term operation up to 2 hours 70 °C
Max. ambient
temperature + 40 °C
Max. permitted total
hardness in secondary hot
water circulation systems 20 °dH

Principle of operation
Installation and operating instructions Wilo-Star-Z NOVA 7
English
4 Principle of operation
4.1 Application
The pump is intended for pumping potable or
process water in a circulation system.
4.2 Functions
Valves The Star-Z NOVA A and Star-Z NOVA C versions
are equipped with a non-return valve (1) on the
pressure side and with a stop valve (2) on the suc-
tion side.
When exchanging the motor head (3), it is suffi-
cient to cut the power by unplugging the con-
nector (5) and to close the stop valve at the
rotating slot (4). The motor head can then be sim-
ply unscrewed >Page 9.

Installation
8WILO SE 11/2011
English
5Installation
5.1 Mechanical installation
Installation site Provide a weatherproof, frost-free, dust-free and
well-ventilated room for the installation. Choose
an installation site that is easily accessible.
1. Prepare the installation site so that the pump
can be installed without being exposed to
mechanical stresses.
2. Choose the right installation position - only as
shown in (Fig. A).
The arrow on the back of the housing indi-
cates the direction of flow.
Danger: Before starting work, make sure
that the pump has been disconnected from the
power supply.
Caution: Dirt can cause the pump to fail.
Flush the pipe system before installation.
Note: In the case of the Star-Z NOVA A
and Star-Z NOVA C versions, the stop valve and
non-return valve are pre-installed. In the case of
the Star-Z NOVA version, these valves have to
be installed additionally.

Installation
Installation and operating instructions Wilo-Star-Z NOVA 9
English
Turn the motor head or
remove it
3. Release the union nut - unscrew it completely
if necessary.
4. Turn the motor head so that the Wilo-Con-
nector points downwards.
5. Tighten the union nut again.
Open the stop valve 6. Turn slot (1) with a screwdriver so that it is
parallel to the direction of flow (only in the
case of the Star-Z NOVA A, and Star-Z
NOVA C versions).
7. Fit the thermal insulation shell.
Connecting 8. Connect the pipework.
Caution: Do not damage the housing seal.
Replace damaged seals.
Caution: If the position is wrong, water
can penetrate and destroy the pump.
1
Note: To close, turn the slot so that it is
across the direction of flow.
Caution: The plastic parts of the motor
may not be heat-insulated in order to protect
the pump from overheating.
Caution: For the versions with stop and
non-return valves, these are already pre-
installed and sealed with a tightening torque of
15 Nm (hand-tight). Screwing with excessive
tightening torque destroys the valve screw con-
nection and the O ring.
When installing the valve, use a fixed spanner to
prevent twisting.

Installation
10 WILO SE 11/2011
English
5.2 Electrical connection
Establish the electrical
connection as follows:
Danger: Only a qualified electrician is
allowed to work on the electrical connection.
Before establishing the connection, make sure
that the connecting cable is dead.
Fig. 1 Fig. 2
Fig. 3 Fig. 4
PE NL

Installation
Installation and operating instructions Wilo-Star-Z NOVA 11
English
5.3 Filling and bleeding
1. Fill the system.
2. The pump rotor space bleeds automatically
after a short time in operation. This may cause
noises. If necessary, switch off and on repeat-
edly to accelerate the bleeding. Dry running
for short periods will not harm the pump.
Fig. 5
Open the WILO- Connector as
follows:

Maintenance/faults
12 WILO SE 11/2011
English
Cleaning Clean the outside of the pump with a slightly
damp cloth only. Do not use detergents.
Replacing the motor head
Replacing the motor head >Page 9.
6 Maintenance/faults
Order the service motor from a specialist retailer.
Warning: When removing the motor head
or pump, hot fluid may spurt out under high
pressure. Allow the pump to cool down before-
hand.
Close the stop valves before removing the pump
>Page 9.
Note: When the motor is removed and
running, noises and a change in rotation may
occur. This is normal for this situation.
Faultless operation can only be guaranteed
when the pump is operated in fluid.

Maintenance/faults
Installation and operating instructions Wilo-Star-Z NOVA 13
English
7 Maintenance/faults
8
Faults Causes Remedies
Pump does not
start. Interruption in the power
supply, short- circuit or
defective fuses.
Have the power supply
checked by a qualified
electrician.
Time switching function
has switched off auto-
matically(Star-ZNOVAC
version only).
Check the plug clock
timer setting.
Motor is blocked, e.g. by
deposits from the water
mains.
Have the pump removed
by a qualified technician
>Page 9.
Check that the impeller
can move by turning it
and rinseout thedirt that
has accumulated.
Pump is making
noises. Motor scraping, e.g.
through deposits from
the water mains
Running dry, too little
water. Check the check valves, they must be fully open.
Air in the pump. Switch the pump on/off
5 times for 30 s in each
case.
Note: If you cannot remedy the fault,
contact a specialist retailer.

D EG - Konformitätserklärung
GB EC – Declaration of conformity
F Déclaration de conformité CE
Hiermiterklären wir, dass dieBauarten der Baureihe: Star Z Nova
Herewith, we declare that this product:
Par le présent, nous déclarons que cet agrégat :
in der gelieferten Ausführungfolgenden einschlägigen Bestimmungen entspricht:
in its delivered state complies with the following relevant provisions:
est conforme aux dispositions suivants dont il relève:
Elektromagnetische Verträglichkeit - Richtlinie 2004 / 108 / EG
Electromagnetic compatibility - directive
Compatibilité électromagnétique- directive
Niederspannungsrichtlinie 2006 / 95 / EG
Low voltage directive
Directive basse-tension
und entsprechender nationaler Gesetzgebung.
and with the relevant national legislation.
et aux législations nationales les transposant.
Angewendete harmonisierte Normen, insbesondere: EN 60335-2-51
Applied harmonized standards, in particular: EN 61000-3-2
Normes harmonisées, notamment: EN 61000-3-3
EN 55014-1&2
Bei einer mitunsnichtabgestimmten technischen Änderungder oben genannten Bauarten, verliertdiese ErklärungihreGültigkeit.
Iftheabove mentioned series aretechnicallymodified without our approval, thisdeclaration shall nolonger be applicable.
Si les gammes mentionnées ci-dessus sontmodifiées sansnotreapprobation, cette déclaration perdrasa validité.
Dortmund, 15.04.2009
Oliver Breuing
Quality Manager
WILO SE
Nortkirchenstraße100
44263 Dortmund
Germany
Document: 2104092.1

NL EG-verklaring van overeenstemming
Hiermedeverklaren wij dat ditaggregaat in de
geleverdeuitvoeringvoldoet aan devolgende
bepalingen:
Elektromagnetischecompatibiliteit2004/108/EG
EG-laagspanningsrichtlijn 2006/95/EG
Gebruikte geharmoniseerdenormen, in het
bijzonder:
1)
I Dichiarazione di conformità CE
Con lapresente si dichiarachei presenti prodotti
sonoconformi alleseguenti disposizioni e
direttive rilevanti:
Compatibilità elettromagnetica 2004/108/EG
Direttiva bassa tensione2006/95/EG
Normearmonizzate applicate, in particolare: 1)
E Declaración de conformidad CE
Por lapresente declaramos laconformidad del
producto en su estadodesuministrocon las
disposiciones pertinentes siguientes:
Directiva sobrecompatibilidad electromagnética
2004/108/EG
Directiva sobreequipos debajatensión
2006/95/EG
Normas armonizadas adoptadas, especialmente: 1)
P Declaração de Conformidade CE
Pelapresente, declaramos que esta unidadeno
seu estadooriginal, está conformeos seguintes
requisitos:
Compatibilidadeelectromagnética 2004/108/EG
Directiva debaixavoltagem2006/95/EG
Normas harmonizadas aplicadas, especialmente:
1)
S CE- försäkran
Härmed förklarar vi att dennamaskin i levererat
utförandemotsvarar följandetillämpliga
bestämmelser:
EG–Elektromagnetisk kompatibilitet – riktlinje
2004/108/EG
EG–Lågspänningsdirektiv2006/95/EG
Tillämpadeharmoniseradenormer, i synnerhet:
1)
N EU-Overensstemmelseserklæring
Vi erklærer hermed at denneenheten i utførelse
som leverter i overensstemmelse med følgende
relevante bestemmelser:
EG–EMV–Elektromagnetisk kompatibilitet
2004/108/EG
EG–Lavspenningsdirektiv2006/95/EG
Anvendte harmoniserte standarder, særlig:
1)
FIN CE-standardinmukaisuusseloste
Ilmoitammetäten, että tämä laite vastaa seuraavia
asiaankuuluviamääräyksiä:
Sähkömagneettinen soveltuvuus 2004/108/EG
Matalajännite direktiivit: 2006/95/EG
Käytetyt yhteensovitetut standardit, erityisesti: 1)
DK EF-overensstemmelseserklæring
Vi erklærer hermed, at denneenhed ved levering
overholder følgenderelevante bestemmelser:
Elektromagnetisk kompatibilitet: 2004/108/EG
Lavvolts-direktiv2006/95/EG
Anvendte harmoniseredestandarder, særligt: 1)
H EK. Azonossági nyilatkozat
Ezennel kijelentjük,hogy az berendezés az
alábbiaknak megfelel:
Elektromágneses zavarás/türés: 2004/108/EG
Kisfeszültségü berendezések irány-Elve:
2006/95/EG
Felhasználtharmonizáltszabványok, különösen: 1)
CZ Prohlášení o shod EU
Prohlašujemetímto, žetento agregát vdodaném
provedeníodpovídánásledujícím píslušným
ustanovením:
Smrnicím EU–EMV 2004/108/EG
Smrnicím EU–nízkénaptí 2006/95/EG
Použité harmonizanínormy, zejména: 1)
PL Deklaracja Zgodnoci CE
Niniejszym deklarujemyz pen
odpowiedzialnosci edostarczonywyrób jest
zgdonyz nastpujcymi dokumentami:
Odpowiednio elektromagnetyczna
2004/108/EG
Normieniskich napi 2006/95/EG
Wyroby s zgodnezeszczegóowymi normami
zharmonizowanymi:
1)
RUS   
 
  ,  
     
  :
  2004/108/EG
   
2006/95/EG
   
,   :
1)
GR  !"# $# %.%.
    ’  
   
 :
  EG-
2004/108/EG
 EG–2006/95/EG
,
:
1)
TR EC Uygunluk Teyid Belgesi
Bu cihazn teslim edildii ekliyleaadaki
standartlarauygun olduunuteyid ederiz:
Elektromanyetik Uyumluluk 2004/108/EG
Alçak gerilim direktifi 2006/95/EG
Ksmen kullanlan standartlar:
1)
1) EN 60335-2-51,
EN 61000-3-2,
EN 61000-3-3,
EN 55014-1&2.
Oliver Breuing
Quality Manager
WILO SE
Nortkirchenstraße 100
44263 Dortmund
Germany

WILO SE
Nortkirchenstraße 100
44263 Dortmund
Germany
T [phone]
F [phone]
[email protected]
www.wilo.com
Wilo– International (Subsidiaries)
Wilo– International (Representation offices)
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de Buenos Aires
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Bombas Wilo-Salmson
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(Madrid)
T [phone]
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WILO Sverige AB
35246 Växjö
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Switzerland
EMB Pumpen AG
4310 Rheinfelden
T [phone]
[email protected]
Taiwan
WILO-EMU Taiwan Co. Ltd.
110 Taipeh
T [phone]
nelson.wu@
wiloemutaiwan.com.tw
Turkey
WILO Pompa Sistemleri
San. ve Tic. A.S¸.
34888 Istanbul
T [phone]
[email protected]
Ukraina
WILO Ukraina t.o.w.
01033 Kiew
T [phone]
[email protected]
United ArabEmirates
WILO Middle East FZE
Jebel Ali Free Zone - South
- Dubai
T [phone]
[email protected]
USA
WILO USA LLC
1290 N 25th Ave
Melrose Park, Illinois 60160
T [phone]
[email protected]
Vietnam
WILO Vietnam Co Ltd.
Ho Chi Minh City, Vietnam
T [phone]
[email protected]
Algeria
Bad Ezzouar, Dar El Beida
T [phone]
Armenia
0001 Yerevan
T [phone]
Bosnia andHerzegovina
71000 Sarajevo
T [phone]
Georgia
0179 Tbilisi
T [phone]
Macedonia
1000 Skopje
T [phone]
Mexico
07300 Mexico
T [phone]
Moldova
2012 Chisinau
T [phone]
Rep. Mongolia
Ulaanbaatar
T [phone]
Tajikistan
734025 Dushanbe
T [phone]
Turkmenistan
744000 Ashgabad
T [phone]
Uzbekistan
100015 Tashkent
T [phone]
March 2011

WILO SE
Nortkirchenstraße 100
44263 Dortmund
Germany
T 0231 4102-0
F 0231 4102-7363
[email protected]
www.wilo.de
Nord
WILO SE
Vertriebsbüro Hamburg
Beim Strohhause 27
20097 Hamburg
T 040 5559490
F 040 55594949
[email protected]
Nord-Ost
WILO SE
Vertriebsbüro Berlin
Juliusstraße 52–53
12051 Berlin-Neukölln
T 030 6289370
F 030 62893770
[email protected]
Ost
WILO SE
Vertriebsbüro Dresden
Frankenring 8
01723 Kesselsdorf
T 035204 7050
F 035204 70570
[email protected]
Süd-Ost
WILO SE
Vertriebsbüro München
Adams-Lehmann-Straße 44
80797 München
T 089 4200090
F 089 42000944
[email protected]
Süd-West
WILO SE
Vertriebsbüro Stuttgart
Hertichstraße 10
71229 Leonberg
T 07152 94710
F 07152 947141
stuttgar[email protected]
Mitte
WILO SE
Vertriebsbüro Frankfurt
An den drei Hasen 31
61440 Oberursel/Ts.
T 06171 70460
F 06171 704665
frankfur[email protected]
West
WILO SE
Vertriebsbüro Düsseldorf
Westring 19
40721 Hilden
T 02103 90920
F 02103 909215
duesseldorf[email protected]
Kompetenz-Team
Gebäudetechnik
WILO SE
Nortkirchenstraße 100
44263 Dortmund
T 0231 4102-7516
T 01805 R•U•F•W•I•L•O*
7•8•3•9•4•5•6
F 0231 4102-7666
Kompetenz-Team
Kommune
Bau + Bergbau
WILO SE, Werk Hof
Heimgartenstraße 1-3
95030 Hof
T 09281 974-550
F 09281 974-551
Werkskundendienst
Gebäudetechnik
Kommune
Bau + Bergbau
Industrie
WILO SE
Nortkirchenstraße 100
44263 Dortmund
T 0231 4102-7900
T 01805 W•I•L•O•K•D*
9•4•5•6•5•3
F 0231 4102-7126
[email protected]
Täglich 7-18 Uhr
erreichbar
24 Stunden Technische
Notfallunterstützung
– Kundendienst-
Anforderung
– Werksreparaturen
– Ersatzteilfragen
– Inbetriebnahme
– Inspektion
– Technische
Service-Beratung
–Qualitätsanalyse
Wilo-International
Österreich
Zentrale Wiener
Neudorf:
WILO Pumpen Österreich
GmbH
Wilo Straße 1
A-2351 Wiener Neudorf
T [phone]
F [phone]
[email protected]
www.wilo.at
Vertriebsbüro Salzburg:
Gnigler Straße 56
A-5020 Salzburg
T [phone]
F [phone]
[email protected]
www.wilo.at
Vertriebsbüro
Oberösterreich:
Trattnachtalstraße 7
A-4710 Grieskirchen
T [phone]
F [phone]
office.oberoester-
[email protected]
www.wilo.at
Schweiz
EMB Pumpen AG
Gerstenweg 7
CH-4310 Rheinfelden
T [phone]
F [phone]
[email protected]
www.emb-pumpen.ch
Wilo-Vertriebsbüros in Deutschland
Erreichbar Mo–Do 7-18 Uhr, Fr 7-17 Uhr.
– Antworten auf
– Produkt- und Anwendungsfragen
– Liefertermine und Lieferzeiten
– Informationen über Ansprechpartner vor Ort
– Versand von Informationsunterlagen
* 0,14 €/Min. aus dem Festnetz,
Mobilfunk max. 0,42 €/Min.
Standorteweiterer
Tochtergesellschaften
Die Kontaktdaten finden
Sie unter www.wilo.com.
Stand September 2011