Wilo Wilo-Stratos PICO Series User manual

4 207 704-Ed.01 / 2015-11
Wilo-Stratos PICO
Pioneering for You
en Installation and operating instructions
fr Notice de montage et de mise en service
it Istruzioni di montaggio, uso e manutenzione
sv Monterings- och skötselanvisning
da Monterings- og driftsvejledning
 Asennus- ja käyttöohje
pl  Instrukcjamontażuiobsługi
ru  Инструкцияпомонтажуиэксплуатации

Fig. 1:
Fig. 2a: Fig. 2b:
H
Q
H max
½ H
H min
H
Q
H max
H
H min

Fig. 3:
Fig. 4a: Fig. 4b:
PE NL

Fig. 4c: Fig. 4d:
Fig. 4e: Fig. 5:

Installation and operating instructions Wilo-Stratos PICO 3
English
Installation and operating instructions
1 General
About this document
The language of the original operating instructions is German.
All other languages of these instructions are translations of the
original operating instructions.
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.
The installation and operating instructions correspond to the
relevant version of the product and the underlying safety regu-
lations and 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 or the declarations made in the instal-
lation and operating instructions on product/personnel safety
are not observed, this declaration loses its validity.
2 Safety
These operating instructions contain basic information which
must be adhered to during installation, operation and mainte-
nance. For this reason, these operating instructions must with-
out 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 fol-
lowing main points.

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4WILO SE 11/2015
2.1 Indication of instructions in the operating instructions
Symbols:
General danger symbol
Danger due to electrical voltage
Note:
Signal words:
DANGER!
Acutely dangerous situation.
Non-observance results in death or the most serious of injuries.
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 informa-
tion is disregarded.
Note: Useful information on handling the product. It draws
attention to possible problems.
Information applied directly to the product, such as:
• direction of rotation arrow,
• identifiers for connections,
• name plate,
• and warning sticker,
must be strictly complied with and kept in legible condition.

Installation and operating instructions Wilo-Stratos PICO 5
English
2.2 Personnel qualifications
The installation, operating and maintenance personnel must
have the appropriate qualifications for this work. Area of
responsibility, terms of reference and monitoring of the per-
sonnel 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 oper-
ator.
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 prod-
uct/unit. Non-observance of the safety instructions results in
the loss of any claims to damages.
In detail, non-observance can, for example, result in the follow-
ing risks:
• danger to persons from electrical, mechanical and bacteriolog-
ical influences,
• damage to the environment due to leakage of hazardous mate-
rials,
• property damage,
• 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 oper-
ating 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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6WILO SE 11/2015
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 appliance.
• If hot or cold components on the product/the unit lead to haz-
ards, local measures 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 a shaft seal) of hazardous fluids (e.g. explo-
sive, toxic or hot) must be led away so that no danger to persons
or to the environment arises. National statutory provisions are
to be complied with.
• Danger from electrical current must be eliminated. Local direc-
tives or general directives [e.g. IEC, VDE etc.] and local energy
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 to 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 protec-
tive devices must be put back in position and/or recommis-
sioned.

Installation and operating instructions Wilo-Stratos PICO 7
English
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 consul-
tation with the manufacturer. Original spare parts and accesso-
ries authorised by the manufacturer ensure safety. The use of
other parts will absolve us of liability for consequential events.
2.8 Improper use
The operating safety of the supplied product is only guaranteed
for conventional use in accordance with Section 4 of the oper-
ating instructions. The limit values must on no account fall
under or exceed those specified in the catalogue/data sheet.
3 Transport and interim storage
Immediately after receiving the product:
• check the product for damage in transit,
• in the event of damage in transit, take the necessary steps with
the forwarding agent within the respective time limits.
CAUTION! Risk of damage to property!
Incorrect transport and interim storage can cause damage to
the product.
• The pump should be protected from moisture, frost and
mechanical damage due to impact during transport and
interim storage.
• The device must not be exposed to temperatures outside the
range of -10 °C to +50 °C.

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8WILO SE 11/2015
4 Intended use
The circulation pumps in the Wilo-Stratos PICO series are
designed for warm water heating systems and similar systems
with constantly changing volume flows. Approved fluids are
heating water in accordance with VDI 2035, water/glycol mix-
ture at a mixing ratio of max. 1:1. If glycol is added, the delivery
data of the pump must be corrected according to the higher
viscosity, depending on the mixing ratio percentage.
Intended use of the pump/installation also includes following
these instructions.
Any other use is regarded as incorrect use.
5 Product information
5.1 Type key
Example: Wilo-Stratos PICO 25/1-6
Stratos PICO High-efficiency pump
25 Threaded connection DN 25 (Rp 1)
1-6 1 = Minimum delivery head in m
(adjustable down to 0.5 m)
6 = Maximum delivery head in m
at Q = 0 m³/h
5.2 Technical data
Connection voltage 1 ~ 230 V ± 10%, 50/60 Hz
Protection class IP See name plate
Energy efficiency index (EEI) See name plate
Water temperatures at max. ambient
temperature of +25 °C
+2 °C to +110 °C
Water temperatures at max. ambient
temperature of +40 °C
+2 °C to +95 °C
Water temperatures at max. ambient
temperature of +60 °C
+2 °C to +70 °C *

Installation and operating instructions Wilo-Stratos PICO 9
English
* The pump is equipped with a power limiting function which provides protection
against overload. This can have an effect on the output depending on operation.
5.3 Scope of delivery
• Complete circulation pump
• including thermal insulation shell
• Wilo-Connector included
• Installation and operating instructions
6 Description and function
6.1 Description of the product
The pump (Fig. 1/1) consists of a hydraulic system, a glandless
pump motor with a permanent magnet rotor, and an electronic
control module with an integrated frequency converter. The
control module includes a red operating knob and an LCD
(Fig. 1/2) for setting all parameters and for displaying the cur-
rent electricity consumption in W, or the effective flow in m³/h
and the cumulative electricity consumption in kWh since com-
missioning.
6.2 Functions
All functions can be set, activated or deactivated using the red
operating knob.
Display of the current power consumption in W.
or
Display of effective flow in m³/h.
Max. operating pressure 10 bar (1000 kPa)
Min. inlet pressure at
+70 °C/+95 °C/+110 °C
0.15 bar/0.3 bar/1.0 bar
(15 kPa/30 kPa/100 kPa)
5.2 Technical data

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10 WILO SE 11/2015
Note: By turning the red button the indication will switch from
W to m³/h. For duty points for which the flow cannot be mea-
sured accurately, the display shows “<” or “>” in front of the
respective value.
Display of the cumulative power consumption in kWh since
commissioning.
Setting the delivery head in m.
Control mode:
Variable differential pressure (Δp-v):
The differential-pressure setpoint H is increased linearly over
the permitted volume flow range between ½H and H (Fig. 2a).
The differential pressure generated by the pump is adjusted to
the corresponding differential-pressure setpoint. This control
mode is especially useful in heating systems with radiators,
since the flow noises at the thermostatic valves are reduced.
Constant differential pressure (Δp-c):
The differential-pressure setpoint H is kept constant over the
permitted volume flow range at the set differential-pressure
setpoint up to the maximum pump curve (Fig. 2b). Wilo recom-
mends this control mode for underfloor-heating circuits or
older heating systems with large-sized pipes as well as for all
applications with no changeable pipe system curve, e.g. boiler
charge pumps.

Installation and operating instructions Wilo-Stratos PICO 11
English
Setback operation
When setback operation is enabled, the pump follows the set-
back operation of the heating system with electronic evalua-
tion of a temperature sensor. It then switches to minimum
speed. When the heat generator heats up again, the pump
switches back to the pre-set setpoint stage.
When the setback operation is used, the pump must be
installed in the feed of the heating system.
Dynamic Adapt:
Dynamic Adapt is the dynamic adaptation of the setpoint in the
pump's partial load range at less than half of the intended flow
volume. Starting from the set value, the pump analyses the heat
requirement, and, based on this analysis, the established set-
point is continuously corrected operating in partial load mode.
In this way, the pump output in a control range (Fig. 2a) is con-
tinuously optimised up to the energetic minimum. For very
small volume flows, the pump goes into a hydraulic standby for
this. If the volume flow increases due to higher heat require-
ment, the performance will increase automatically. The short
reaction time prevents the heating system from being under-
supplied.
Venting routine:
The duration of the venting routine is 10 minutes after activa-
tion; it is shown with a countdown in the display.
Key lock (hold function):
The key lock locks the settings on the pump, thus protecting it
from unintended or unauthorized adjustments to the pump.

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12 WILO SE 11/2015
7 Installation and electrical connection
DANGER! Danger of death!
Incorrect installation and electrical connection can result in
fatal injury.
• Installation and electrical connection may only be carried out
by qualified personnel and in accordance with the applicable
regulations!
• Adhere to regulations for accident prevention
7.1 Installation
• Only install the pump after all welding and soldering work has
been completed and, if necessary, the pipe system has been
flushed through.
• Install the pump in a readily accessible place for easy inspection
and dismantling.
• When installing in the feed of open systems, the safety supply
must branch off upstream of the pump (DIN EN 12828).
• Install check valves upstream and downstream of the pump to
facilitate a possible pump replacement.
• Perform installation so that any leaking water cannot drip
onto the control module.
• To do this, align the upper gate valve laterally.
• In thermal insulation work, make sure that the pump motor and
the module are not insulated. The condensate-drain openings
must remain uncovered.
• Install with the power switched off and the pump motor in a hor-
izontal position. See fig. 3 for installation positions of the pump.
• Other installation positions on request.
• Direction arrows on the pump housing and the insulation shell
indicate the direction of flow.
• If the installation position of the module is changed, the motor
housing has to be turned as follows:
• Lever up the thermal insulation shell with a screwdriver and
remove it,

Installation and operating instructions Wilo-Stratos PICO 13
English
• Loosen the internal hexagon screws
• Turn the motor housing, including control module.
Note: Generally turn the motor head before the installation is
filled. When turning the motor head in an installation which is
already filled, do not pull the motor head out of the pump hous-
ing. Turn the motor head with a small amount of pressure on the
motor unit so that no water can come out of the pump.
CAUTION! Risk of damage to property!
The gasket may be damaged when the motor housing is
turned. Replace defective gaskets immediately.
• Screw the internal hexagon screws back in and tighten them.
• Fit the thermal insulation shell.
7.2 Electrical connection
DANGER! Danger of death!
A fatal shock may occur if the electrical connection is not
made correctly.
• Only allow the electrical connection to be made by an electri-
cian approved by the local electricity supplier and in accord-
ance with the local regulations in force.
• Disconnect the power supply before any work.
• If setting and operating elements are improperly removed,
there is a danger of electric shock if interior electrical com-
ponents are touched.
High-efficiency pumps may not be operated with phase angle
control!
CAUTION! Risk of damage to property!
When the pump is switched on/off by external control
devices, the mains voltage pulsing (e.g. phase angle control)
must be deactivated to prevent damage to the electronics.

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14 WILO SE 11/2015
For applications where it is not clear whether the pump will be
operated with pulsed pump voltage, e.g. with storage charge
pumps, the manufacturer of the control system must confirm
that the pump can be operated with sinusoidal AC voltage.
• The current type and voltage must correspond to the details on
the name plate.
• It is recommended to safeguard the pump with a residual-cur-
rent-operated protection switch.
Labeling: FI - or
When dimensioning the residual-current-operated protection
switch, take the number of pumps connected and their nominal
motor currents into account.
• Connect the Wilo-Connector (Fig. 4a to 4e).
• Mains connection: L, N, PE.
• Maximum back-up fuse: 10 A, slow-blow
• Earth the pump according to the regulations.
Dismantle the Wilo-Connector in accordance with Fig. 5.
A screwdriver is required for this.
• The electrical connection must be made in accordance with
VDE 0700/part 1 via a fixed connected load. The latter is pro-
vided with a plug device or an all-pole switch with a contact
opening width of at least 3 mm.
• To ensure drip protection and strain relief at the PG screwed
connection, a connected load with an adequate outer diameter
is necessary (e.g. H05VV-F3G1.5).
• When pumps are used in systems with water temperatures
above 90°C, a suitably heat-resistant connected load must be
installed.
• The connected load is to be installed in such a way that it can
under no circumstances come into contact with the piping
and/or the pump and motor housing.
• The switching of the pump via triacs/solid-state relays is to be
checked on an individual basis.

Installation and operating instructions Wilo-Stratos PICO 15
English
• Switching frequency:
• On/off switching operations via mains voltage ≤100/24 h
•≤20/h for a switching frequency of 1 min. between switching
on/off via mains voltage.
Note: The inrush current of the pump is < 5A. If the pump is
switched „On“ and „OFF“ via a relay, it must be sure that the
relay is designed to switch an inrush current of minimum 5A. If
necessary, the boiler-/regulation manufacturer need to give a
statement.
8 Commissioning
WARNING! Risk of injury and damage to property!
Incorrect commissioning can lead to injuries to persons and
damage to property.
• Commissioning by qualified personnel only!
• Depending on the operating status of the pump or system
(fluid temperature), the entire pump can become very hot.
Touching the pump can cause burns!
8.1 Operation
The pump is operated using the red operating knob.
Turn
Select menu items and set the parameters.
Press briefly
Select menu items and confirm parameters you have entered.
8.2 Filling and venting
Fill and vent the system correctly. The pump rotor chamber
normally vents automatically after a short time in operation.
However, if direct venting of the rotor chamber is required, the
venting routine can be started.

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16 WILO SE 11/2015
To do this, press and turn the red button to select the symbol
for venting and press it to activate. Then turn the red button to
activate the function (ON appears in the display). The duration
of the venting routine is 10 minutes; it is shown with a count-
down in the display. Noises may be heard during the venting
routine. The process can be stopped if desired by turning and
pressing the red button (OFF appears in the display).
Note: The venting function removes accumulated air from the
rotor chamber of the pump. The venting function does not vent
the heating system.
8.3 Setting the delivery head
To set the delivery head press the red button to select the sym-
bol for the pump output. Press it again and turn the red button
to increase or reduce the value of the delivery head.
Confirm setting by pressing the red button.
Factory setting: Stratos PICO ... 1-4: 2.5 m
Stratos PICO ... 1-6: 4 m
8.4 Setting the control mode (Fig. 2a, 2b)
Press and turn the red button to select the symbol of the con-
trol mode. Press and turn it again to select between the control
modes.
Variable differential pressure (Δp-v): Fig. 2a
Constant differential pressure (Δp-c): Fig. 2b
Confirm setting by pressing the red button.
Note: When the Dynamic Adapt function is active and Δp-c is
activated at the same time, the Dynamic Adapt function is
deactivated.
This is indicated by the Dynamic Adapt symbol flashing five
times; "auto" goes out, and Dynamic Adapt is disabled.
Factory setting: Control mode Δp-v

Installation and operating instructions Wilo-Stratos PICO 17
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8.5 Activation of the Dynamic Adapt function
Press and turn the red button to select the symbol for the
Dynamic Adapt function. Press and turn again to activate or
deactivate Dynamic Adapt.
The word "auto" indicates that Dynamic Adapt is activated.
If the word "auto" is not lit up, the function is deactivated.
Confirm setting by pressing the red button.
Note: If the control mode Δp-c is active while Dynamic Adapt is
activated, the control mode automatically switches to Δp-v.
This is indicated by the Δp-v symbol flashing give times.
Factory setting: Dynamic Adapt OFF
8.6 Activation of the setback operation
Press and turn the red button to select the symbol for the set-
back operation. Press and turn it again to activate (ON) or deac-
tivate (OFF) the setback operation.
Confirm setting by pressing the red button.
Factory setting: Setback operation OFF
8.7 Key lock (hold function)
Select the symbol for venting; this allows activation of the key
lock by pressing and turning the red button. Hold the red button
down for 10 seconds. The message "Hold" appears on the dis-
play. By turning, the key lock can now be activated (ON) or
deactivated (OFF).
If the key lock is activated, the pump settings cannot be
changed. After 10 seconds the display shows power consump-
tion and the power consumption meter again. If the red button
is pressed, "Hold" appears on the display.
To deactivate the key lock, repeat the steps as for activation.
Factory setting: Key lock OFF

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18 WILO SE 11/2015
NOTE: Key lock is not deactivated by switching off the pump.
The power consumption meter cannot be reset to the factory
settings when key lock is activated. Key lock is not activated
automatically, e.g. after a set period of time has passed.
8.8 Operation
Note: All settings and displays are retained if the mains supply
is interrupted.
Resetting the power consumption meter
• In pump standby mode, press the red button for 10 seconds.
The power consumption meter sets itself to zero after the
current meter reading on the display has flashed five times.
Restoring the factory settings
• When the pump is in standby mode, press the red button for
20 seconds, all LED elements light up for 2 seconds. The factory
setting (delivery condition) of the pump is restored and the
power consumption meter in the display is at zero.
9 Maintenance
DANGER! Danger of death!
A fatal shock may occur when working on electrical equip-
ment.
• The pump should be electrically isolated and secured against
unauthorised switch-on during any maintenance or repair
work.
• Any damage to the connecting cable should always be recti-
fied by a qualified electrician only.
WARNING! Danger due to strong magnetic field!
Inside the machine there is always a strong magnetic field
that can cause injury and damage to property in the event of
incorrect dismantling.