Wilo Yonos GIGA-N 80 User manual

Pioneering for You
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Wilo-Yonos GIGA-N
6088793 • Ed.01/2020-10
en Installation and operating instructions

en
Installation and operating instructions Wilo-Yonos GIGA-N 3
Table of contents
1 General information ................................................................................................................................................................. 5
1.1 About these instructions ..................................................................................................................................................................................5
1.2 Copyright ............................................................................................................................................................................................................5
1.3 Subject to change..............................................................................................................................................................................................5
2 Safety......................................................................................................................................................................................... 5
2.1 Identification of safety instructions................................................................................................................................................................5
2.2 Personnel qualifications....................................................................................................................................................................................6
2.3 Electrical work ....................................................................................................................................................................................................6
2.4 Transport.............................................................................................................................................................................................................7
2.5 Installing/dismantling........................................................................................................................................................................................7
2.6 During operation ................................................................................................................................................................................................7
2.7 Maintenance tasks.............................................................................................................................................................................................8
2.8 Operator responsibilities...................................................................................................................................................................................8
3 Application/use......................................................................................................................................................................... 9
3.1 Intended use.......................................................................................................................................................................................................9
3.2 Improper use.......................................................................................................................................................................................................9
4 Product description.................................................................................................................................................................. 9
4.1 Design..................................................................................................................................................................................................................9
4.2 Electronic module ..............................................................................................................................................................................................9
4.3 Twin-head pump function/Y-pipe application .......................................................................................................................................... 11
4.4 Other functions ............................................................................................................................................................................................... 15
4.5 Variants ............................................................................................................................................................................................................ 16
4.6 Type key........................................................................................................................................................................................................... 16
4.7 Technical data .................................................................................................................................................................................................17
4.8 Scope of delivery............................................................................................................................................................................................. 18
4.9 Accessories ...................................................................................................................................................................................................... 18
4.10 Permissible forces and torques on the pump flanges................................................................................................................................ 18
5 Transportation and storage................................................................................................................................................... 19
5.1 Delivery............................................................................................................................................................................................................. 19
5.2 Transport.......................................................................................................................................................................................................... 19
5.3 Storage ............................................................................................................................................................................................................. 20
6 Installation and electrical connection .................................................................................................................................. 21
6.1 Personnel qualifications................................................................................................................................................................................. 21
6.2 Operator responsibilities................................................................................................................................................................................ 21
6.3 Preparing the installation............................................................................................................................................................................... 21
6.4 Installing the pump unit on a base ............................................................................................................................................................... 21
6.5 Pipework........................................................................................................................................................................................................... 23
6.6 Aligning the unit.............................................................................................................................................................................................. 24
6.7 Electrical connection...................................................................................................................................................................................... 28
6.8 Protective devices........................................................................................................................................................................................... 34
7 Commissioning........................................................................................................................................................................ 35
7.1 Personnel qualifications................................................................................................................................................................................. 35
7.2 Filling and venting........................................................................................................................................................................................... 35
7.3 Twin-head pump installation/Y-pipe installation ..................................................................................................................................... 36
7.4 Setting of pump output ................................................................................................................................................................................. 36
7.5 Switching on the pump..................................................................................................................................................................................37
7.6 Behaviour after being switched on............................................................................................................................................................... 38
7.7 Setting the control mode............................................................................................................................................................................... 38
8 Operation................................................................................................................................................................................. 39
8.1 Operating elements........................................................................................................................................................................................39
8.2 Display structure ............................................................................................................................................................................................. 39
8.3 Explanation of standard symbols ................................................................................................................................................................. 40
8.4 Symbols in graphics/instructions.................................................................................................................................................................. 40

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4 WILO SE 2020-10
8.5 Display modes ................................................................................................................................................................................................. 41
8.6 Operating instructions ................................................................................................................................................................................... 43
8.7 Menu elements reference.............................................................................................................................................................................. 47
9 Shutdown................................................................................................................................................................................. 53
9.1 Switching off the pump and temporary shutdown.................................................................................................................................... 53
9.2 Shutdown and storage ................................................................................................................................................................................... 53
10 Maintenance/repair ................................................................................................................................................................ 53
10.1 Personnel qualifications................................................................................................................................................................................. 54
10.2 Operation monitoring..................................................................................................................................................................................... 54
10.3 Maintenance tasks.......................................................................................................................................................................................... 55
10.4 Draining and cleaning..................................................................................................................................................................................... 55
10.5 Dismantling...................................................................................................................................................................................................... 55
10.6 Installation ....................................................................................................................................................................................................... 59
11 Spare parts............................................................................................................................................................................... 63
11.1 Spare parts list.................................................................................................................................................................................................64
12 Faults, causes and remedies .................................................................................................................................................. 65
12.1 Mechanical faults ............................................................................................................................................................................................ 66
12.2 Error codes, display......................................................................................................................................................................................... 67
12.3 Acknowledge fault.......................................................................................................................................................................................... 71
13 Factory settings...................................................................................................................................................................... 76
14 Disposal.................................................................................................................................................................................... 77
14.1 Oils and lubricants........................................................................................................................................................................................... 77
14.2 Water-glycol mixture..................................................................................................................................................................................... 77
14.3 Protective clothing .........................................................................................................................................................................................77
14.4 Information on the collection of used electrical and electronic products.............................................................................................. 77

General information en
Installation and operating instructions Wilo-Yonos GIGA-N 5
1 General information
1.1 About these instructions These installation and operating instructions are an integral part of the device. Read
these instructions before commencing work and keep them in an accessible place at all
times. Strict adherence to these instructions is a requirement for intended use and cor-
rectly operating the device. All specifications and markings on the device must be ob-
served. These installation and operating instructions correspond to the relevant version
of the device and the underlying safety standards that apply at the time of going to
print.
The language of the original operating instructions is German. All other languages of
these instructions are translations of the original operating instructions.
1.2 Copyright These installation and operating instructions have been copyrighted by the manufac-
turer. The contents, of whatever type, may not be reproduced or distributed, or used for
purposes of competition and shared with others.
1.3 Subject to change The manufacturer reserves the right to make technical modifications to the device or
individual components. The illustrations used may differ from the original and are in-
tended as an example representation of the device.
2 Safety This chapter contains basic information for the individual phases of the life cycle. Fail-
ure to observe this information carries the following risks:
ƒInjury to persons from electrical, mechanical and bacteriological factors as well as
electromagnetic fields
ƒEnvironmental damage from discharge of hazardous substances
ƒProperty damage
ƒFailure of important functions of the product
Failure to observe the information contained herein will result in the loss of claims for
damages.
The instructions and safety instructions in the other chapters must also be ob-
served!
2.1 Identification of safety instruc-
tions These installation and operating instructions set out safety instructions for preventing
personal injury and damage to property. These safety instructions are shown differ-
ently:
ƒSafety instructions relating to personal injury start with a signal word, are preceded
by a corresponding symbol and are shaded in grey.
DANGER
Type and source of the danger!
Consequences of the danger and instructions for avoidance.
ƒSafety instructions relating to property damage start with a signal word and are dis-
played without a symbol.
CAUTION
Type and source of the danger!
Consequences or information.
Signal words
ƒDANGER!
Failure to observe the safety instructions will result in serious injuries or death!
ƒWARNING!
Failure to follow the instructions can lead to (serious) injuries!
ƒCAUTION!
Failure to follow the instructions can lead to property damage and a possible total
loss.
ƒNOTICE!
Useful information on handling the product

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6 WILO SE 2020-10
Symbols
These instructions use the following symbols:
Danger – high voltage
General warning symbol
Warning – danger of crushing
Warning – risk of cutting injuries
Warning – hot surfaces
Warning – high pressure
Warning – suspended loads
Personal protective equipment: wear a safety helmet
Personal protective equipment: wear foot protection
Personal protective equipment: wear hand protection
Personal protective equipment: wear mouth protection
Personal protective equipment: wear safety goggles
Useful information
2.2 Personnel qualifications Personnel must:
ƒBe instructed about locally applicable regulations governing accident prevention.
ƒHave read and understood the installation and operating instructions.
Personnel must have the following qualifications:
ƒElectrical work: A qualified electrician must carry out the electrical work.
ƒInstallation/dismantling must be carried out by a qualified technician who is trained
in the use of the necessary tools and fixation materials.
Definition of “qualified electrician”
A qualified electrician is a person with appropriate technical education, knowledge and
experience who can identify and prevent electrical hazards.
2.3 Electrical work ƒHave electrical work carried out by a qualified electrician.
ƒWhen connecting to the mains, comply with the locally applicable laws and regula-
tions of the local energy supply company.

Safety en
Installation and operating instructions Wilo-Yonos GIGA-N 7
ƒBefore commencing work, disconnect the product from the mains and secure it
against being switched on again without authorisation.
ƒGive personnel training on how to establish the electrical connection and the meth-
ods for switching off the product.
ƒObserve the technical information in these installation and operating instructions as
well as on the rating plate.
ƒEarth the product.
ƒObserve the manufacturer’s specifications when connecting to electrical switching
systems.
ƒReplace defective connection cables. Contact customer service.
2.4 Transport ƒWear protective equipment:
–Safety gloves for protection against cuts
–Safety shoes
–Sealed safety goggles
–Safety helmet (when using lifting equipment)
ƒOnly use legally specified and approved lifting gear.
ƒSelect lifting gear based on the available conditions (weather, attachment point,
load, etc.).
ƒAlways attach the lifting gear to the designated attachment points (lifting eyes).
ƒPosition the lifting equipment in a way that ensures stability during use.
ƒWhen using lifting equipment, a second person must be present to coordinate the
procedure if required (e.g. if the operator’s field of vision is blocked).
ƒPersons must not stand underneath suspended loads. Do not move suspended loads
over workplaces where people are present.
Please note the following information during transport and prior to installation:
ƒDo not reach into suction ports, discharge ports or other openings.
ƒAvoid the penetration of foreign objects. To this end, leave the protective covers or
packaging on until they have to be removed for installation.
ƒPackaging and covers may be removed from suction or outlet openings for inspec-
tion purposes. They must be put back on afterwards to protect the pump and ensure
safety.
2.5 Installing/dismantling ƒWear the following protective equipment:
–Safety shoes
–Safety gloves for protection against cuts
–Safety helmet (when using lifting equipment)
ƒComply with laws and regulations on work safety and accident prevention in force at
the site of installation.
ƒThe procedure described in the installation and operating instructions for shutting
down the product/unit must be strictly observed.
ƒDisconnect the device from the mains and secure it against being switched on again
without authorisation.
ƒAll rotating parts must be at a standstill.
ƒClose the gate valve in the inlet and in the pressure pipe.
ƒProvide adequate aeration in enclosed spaces.
ƒClean the device thoroughly. Disinfect devices that use fluids hazardous to health!
ƒMake sure that there is no risk of explosion when carrying out any type of welding
work or work with electrical devices.
2.6 During operation ƒWear protective equipment:
–Safety shoes
–Safety helmet (when using lifting equipment)
ƒThe work area in which the device is used is not a recreational area. No persons are
allowed in the work area during operation.
ƒThe operator must report any faults or irregularities to a line manager immediately.
ƒIf hazardous defects occur, the operator must immediately deactivate the device.
Hazardous defects include:
–Malfunction of safety and monitoring devices
–Damage to housing parts
–Damage to electrical equipment
ƒOpen all gate valves in the piping on both the suction and pressure sides.
ƒCollect any leakage of fluids and operating fluids immediately and dispose of it ac-
cording to the locally applicable guidelines.
ƒTools and other objects should only be kept in their designated places.

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8 WILO SE 2020-10
Thermal hazards
Most of the pump and drive surfaces can become hot during operation.
The surfaces in question also remain hot after switching off the unit. These surfaces
may only be touched with extreme caution. Wear protective gloves if it is essential to
touch hot surfaces.
Make sure that the drained water is not too hot for more intensive contact with skin.
Install appropriate equipment to safeguard against contact with components that may
become hot.
Hazard due to articles of clothing or other objects being caught
To avoid the dangers presented by the rotating parts of the device:
ƒDo not wear loose or frayed clothing or jewellery.
ƒDo not dismantle devices for protecting against accidental contact with moving
parts (e.g. coupling guard).
ƒOnly put the device into operation once this protection is in place.
ƒThe devices for protecting against accidental contact with moving parts may only be
removed when the system is at a standstill.
Hazards due to noise
Observe the applicable health and safety regulations. If the device is operated under
normal operating conditions, the operator must measure the sound pressure.
Sound pressure levels of 80dB(A) and above must be noted in the work regulations!
The operator must also introduce the following preventative measures:
ƒInform the operating personnel
ƒProvide hearing protection
For a sound pressure level of 85dB(A) and above, the operator must:
ƒMake it a mandatory requirement to wear hearing protection
ƒDemarcate the noisy areas
ƒTake measures to reduce noise (e.g. insulation, noise barriers)
Leakages
Observe local standards and regulations. Avoid pump leakages to protect persons and
the environment against hazardous (explosive, toxic or hot) substances.
Ensure that a dry run of the pump is not possible. A dry run can damage the shaft seal
and thereby cause leakages.
2.7 Maintenance tasks ƒWear the following protective equipment:
–Sealed safety goggles
–Safety shoes
–Safety gloves for protection against cuts
ƒOnly carry out the maintenance tasks described in these installation and operating
instructions.
ƒOnly original parts from the manufacturer may be used for maintenance and repairs.
Use of parts other than original parts releases the manufacturer from any liability.
ƒCollect any leakage of fluid and operating fluid immediately and dispose of it ac-
cording to the locally applicable guidelines.
ƒStore tools at the designated locations.
ƒAfter completing work, reattach all safety and monitoring devices and check that
they function properly.
2.8 Operator responsibilities The operator must:
ƒProvide the installation and operating instructions in a language which the personnel
can understand.
ƒMake sure that personnel are suitably trained for the specified work.
ƒEnsure that safety and information signs mounted on the device are always legible.
ƒTrain personnel with regard to the operating principles of the system.
ƒEliminate any risk from electrical current.
ƒEquip hazardous components (extremely cold, extremely hot, rotating, etc.) with an
on-site guard.
ƒDemarcate and cordon off the hazardous area.
ƒDefine personnel responsibilities to ensure safe working practice.

Application/use en
Installation and operating instructions Wilo-Yonos GIGA-N 9
Children and persons younger than 16years or with reduced physical, sensory or mental
capacities or limited experience are prohibited from handling the device! Persons under
the age of 18 must be supervised by a technician.
3 Application/use
3.1 Intended use The glanded pumps in the Wilo-Yonos GIGA-N series are intended for use as circulators
in building services.
The Wilo-Yonos GIGA-N pumps may be used for:
ƒHot-water heating systems
ƒCooling and cold water circulation systems
ƒIndustrial circulation systems
ƒHeat carrier circuits
ƒIrrigation
The pumps are only approved for the fluids specified in the “Technical data” section.
Installation within a building
Typical installation locations are technical rooms within the building with other do-
mestic installations. No provision has been made for direct installation of the pump in
rooms used for other purposes (residential and work rooms). The installation location
must be dry, well ventilated and frost-resistant.
Installation outside a building (outdoor installation)
ƒInstall the pump in a housing as weather protection. Observe ambient temperatures.
Permissible ambient temperature for outdoor installation, see “Technical data” table.
ƒProtect the pump against the effects of weather such as direct sunlight, rain and
snow.
ƒTake suitable measures to prevent the formation of condensation water
Intended use also includes compliance with this manual. Any other use is regarded as
non-compliant with intended use.
3.2 Improper use WARNING!Misuse of the pump can lead to dangerous situations and damage.
ƒNever use with fluids that have not been approved by the manufacturer.
ƒNon-permitted substances in the fluid can destroy the pump. Abrasive solids (e.g.
sand) increase pump wear.
ƒHighly flammable materials/fluids should always be kept at a safe distance from the
device.
ƒNever allow unauthorised persons to carry out work.
ƒNever operate the pump beyond the specified limits of use.
ƒNever carry out unauthorised conversions.
ƒUse authorised accessories and genuine spare parts only.
4 Product description
4.1 Design The Wilo-Yonos GIGA-N pump is a single-stage back pull-out centrifugal pump with
spiral housing for horizontal installation. Power and dimensions conform to EN733.
The drive has an integrated electronic speed control. This allows optimisation of the
pump output for the demands of the installation and particularly cost-efficient pump
operation.
4.1.1 Hydraulics The pump consists of a radially divided spiral housing (optionally with replaceable neck
rings) and cast-on pump support feet. The impeller is a closed radial impeller. The pump
shaft is supported by grease-lubricated radial ball bearings.
4.1.2 Drive AC motors with integrated frequency converters are used as drives.
4.1.3 Seal The fluid pump is sealed via a mechanical seal in accordance with EN12756.
4.2 Electronic module Depending on the differential pressure and the control mode setting, the electronic
module controls the speed of the pump according to a setpoint which can be adjusted
within the permissible control range.

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10 WILO SE 2020-10
The continuous adjustment of the hydraulic output follows the changing power de-
mand of the system. Changing requirements arise particularly when thermostatic valves
or mixers are used.
The basic advantages of the electronic control system are:
ƒEnergy savings and reduced operating costs at the same time
ƒReduced number of differential pressure valves required
ƒReduction of flow noise
ƒPump can be adapted to changing operating requirements
1 2 3 4 5
7 68
2
5
3
1864
7
11 ... 22 kW:
1.5 ... 7.5 kW:
Fig.1: Electronic module, overview
1 Cover attachment points
2 Operating button
3 Infrared window
4 Control terminals
5 Display
6 DIP switch
7 Power terminals (mains terminals)
8 Interface for IF module
4.2.1 Control modes
NOTICE
For details of setting the control mode and associated parameters, see the “Opera-
tion” and “Control mode” chapters.
Selectable control modes are:
Constant differential pressure (
>
p-c)
The control system keeps the delivery head constant at the adjusted differential pres-
sure setpoint HS. Control is independent of the volume flow and is applied until the
maximum characteristic curve is reached.

Product description en
Installation and operating instructions Wilo-Yonos GIGA-N 11
Q
s
Hmax
H
Hs
Hmin
Fig.2: Control mode >p-c
Q = Volume flow
H = Differential pressure (min./max.)
HS = Differential pressure setpoint
Constant rotation speed (constant speed)
Q
H
H
Q
nmin
nmax
s
Hs
Fig.3: Constant speed
The speed of the pump can be kept to a constant speed between nmin and nmax. “Con-
stant speed” mode deactivates all other control modes.
PID control
If other sensors are used or if the distance between the sensors and the pump is very
large, the standard control modes are not applicable. In these cases, the “PID-Control”
function (Proportional Integral Differential control) is available.
By selecting a good combination of individual control elements, the operator can ensure
fast-reacting, constant control without lasting setpoint deviations. The output signal of
the selected sensor can accept any intermediate value. The relevant actual value
reached (sensor signal) will be shown as a percentage on the status page of the menu
(100% = maximum measurement range of the sensor).
NOTICE
The displayed percent value only corresponds indirectly to the current
delivery head of the pump(s).
The maximum delivery head can even been reached at a sensor signal of <100%.
4.3 Twin-head pump function/Y-pipe
application
NOTICE
The properties described in this section are only available if the internal MP interface
(MP = Multi Pump) is used.

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12 WILO SE 2020-10
Fig.4: Example – differential pressure sensor
connection in y-pipe installation
Both pumps are controlled by the master pump.
If one of the pumps malfunctions, the other will run according to the master’s control
settings. In case of a total failure of the master, the slave pump operates at emergency
operation speed. The emergency operation speed can be set in menu <5.6.2.0> (see
section “Operation during interruption of communication”).
The master display shows the status of the double pump. On the slave, the display
shows ‘SL’.
In the example, the master pump is the left-hand pump in the direction of flow. Con-
nect the differential pressure sensor to this pump!
The measuring points of the differential pressure sensor must be on the suction and
discharge side of the double-pump system in the common collector pipe.
Interface module (IF module)
Fig.5: Insert IF module
For communication between pumps and the building management system, one IF mod-
ule (accessories) is required, which is plugged into the terminal room.
The master-slave communication uses an internal interface (terminal: MP).
For pumps in Y-pipe applications in which the electronic modules are connected to
each other via the internal interface, only the master pumps require an IF module.
Communication Master pump Slave pump
PLR/interface converter IF module PLR No IF module necessary
LONWORKS network IF module LON No IF module necessary
BACnet BACnet IF module No IF module necessary
Modbus Modbus IF module No IF module necessary
CAN bus IF module CAN No IF module necessary
Table1: IF modules
NOTICE
The procedure and further information for commissioning and configuring the IF
module on the pump can be found in the installation and operating instructions of
the IF module used.
4.3.1 Operating modes
Main/standby operation
Only one pump ever runs at a time. Each of the two pumps provides the configured flow
rate. The other pump is available in case of malfunction or runs after pump cycling.

Product description en
Installation and operating instructions Wilo-Yonos GIGA-N 13
4.3.2 Behaviour in twin-head pump op-
eration
Pump cycling
t
Δp
Pump 1 Pump 2
Fig.6: Pump cycling, schematic representation
With twin-head pump operation, pump cycling occurs periodically (the intervals can be
set; factory setting = 24 hours).
Pump cycling can be triggered:
ƒInternally, time-controlled (menu <5.1.3.2> + <5.1.3.3>)
ƒExternally (menu <5.1.3.2>) by a positive beam on the “AUX” contact
ƒManual (menu <5.1.3.1>)
Manual or external pump cycling is possible 5seconds after the last pump cycling at the
earliest.
Activating external pump cycling simultaneously deactivates internal time-controlled
pump cycling.
Schematised description of pump cycling operation (see diagram):
ƒPump 1 is running (black line)
ƒPump 2 is switched on at minimum speed and soon afterwards reaches the setpoint
(grey line)
ƒPump 1 is switched off
ƒPump 2 continues to run until the next pump cycling
NOTICE
In constant speed mode, a slight increase in flow can be expected. Pump cycling is
dependent on the ramp time and generally lasts 2sec. In control mode, there may be
minor fluctuations in the delivery head. However, pump1 adjusts itself to the
changed conditions. Pump cycling is dependent on the ramp time and generally lasts
4sec.
Behaviour of the inputs and outputs
104,0 [V] 0 1,0 1,5
105,22 2,8 3,2
[1/min]
0
nmax
nmin
[%]
off
0
100 pmax
pmin
[m]
0
208,0 [mA] 0 2,0 3,0
2010,44 5,6 6,4
Fig.7: Behaviour of the inputs and outputs
Actual value input In1, setpoint input In2.
ƒAt the master: acts on the whole unit
"External off"
ƒSet at the master (menu <5.1.7.0>): Depending on the setting in menu <5.1.7.0>,
acts only on the master or on the master and the slave
ƒSet at the slave: Acts only on the slave
Fault and run signals
Single (ESM) or collective fault signal (SBM):
A collective fault signal (SSM) can be connected to the master to create a central con-
trol centre. In this case, contact may only be made to the master. The display is for the
whole unit.
The contact must be made to each pump for individual fault signals.
This signal can be programmed on the master (or using the IR-Monitor/IR-Stick) as an
individual fault signal (ESM) or collective fault signal (SSM) in menu <5.1.5.0>.
The functions of EBMs/SBMs – “Readiness”, “Operation”, “Mains on” – can be set in
menu <5.7.6.0> on the master.
NOTICE
“Readiness” means: The pump is able to run, there is no fault.
“Operation” means: Motor running.
“Mains on” means: Mains voltage is available.

en Product description
14 WILO SE 2020-10
NOTICE
If the “Operation” function has been selected for EBMs/SBMs, each pump kick ex-
ecuted causes a message to appear for a few seconds.
Operating possibilities at the slave pump
The only settings that are possible at the slave are “External off” and “Disable/enable
pump”.
NOTICE
If an individual motor is disconnected from the power supply in dual-pump opera-
tion, the integrated dual-pump management is out of operation.
4.3.3 Operation during interruption of
communication When communication is interrupted between two pumps in twin-head pump operation,
both displays show the error code “E052”. Both pumps behave as single pumps for as
long as the interruption lasts.
Both electronic modules report the malfunction via the ESM/SSM contact.
The slave pump runs in emergency operation (constant speed) mode according to the
emergency operation speed previously set on the master (see menu items <5.6.2.0>).
The factory setting for the emergency operation speed is about 60% of the pump’s
maximum speed.
ƒFor 2-pole pumps: n = 1850rpm
ƒFor 4-pole pumps: n = 925rpm
After acknowledging the fault display, the status display will be shown on both pump
displays for as long as communication is interrupted. This resets the ESM/SSM contact
at the same time.
The slave pump display flashes and shows the symbol ( – Pump running in emer-
gency operation).
The (former) master pump still follows the control instructions. The (former) slave pump
follows the emergency operation settings. Emergency operation can only be exited by
triggering the factory setting, resolving the interruption in communication or by
switching “mains off/on”.
NOTICE
The differential pressure sensor is switched to the master!
During communication interruptions, the (former) slave pump cannot run in control
mode. When the slave pump is running in emergency operation mode, changes can-
not be made to the electronic module.
After the communication interruption has been resolved, the pumps will resume
regular twin-head pump operation, as before the malfunction.
Slave pump behaviour
Exiting emergency operation at the slave pump:
ƒFactory settings restored
During a communication interruption on the (former) slave, if emergency operation is
discontinued because the factory settings have been restored, the (former) slave will
start up with the factory settings of a single pump. It will then run in Δp-c operating
mode at about half the maximum delivery head.

Product description en
Installation and operating instructions Wilo-Yonos GIGA-N 15
NOTICE
In the absence of a sensor signal, the (former) slave will run at maximum
speed.
To prevent this, the (former) master differential pressure sensor’s signal can be
looped through. In normal double pump operation, the presence of sensor signals on
the slave has no effect.
ƒMains off/mains on
During a communication interruption on the (former) slave, if emergency operation is
discontinued due to “mains off, mains on”, the (former) slave will start up with the
latest emergency operation settings received from the master (for example, constant
speed with preset speed or “off”).
Master pump behaviour
Emergency operation at the master pump discontinued:
ƒFactory settings restored
During a communication interruption on the (former) master, if the factory settings
are restored, it will start up with the factory settings of a single pump. It will then run
in Δp-c mode at about half the maximum delivery head.
ƒMains off/mains on
During a communication interruption on the (former) master, if emergency operation
is discontinued via mains off/mains on, the (former) master will start up with the
most recent settings it has received from the twin-head pump configuration.
4.3.4 Disabling or enabling a pump This function is only available with twin-head pump operation. A particular pump can
generally be enabled or disabled for operation in menu <5.1.4.0>. A disabled pump can-
not be operated until the disabling has been manually lifted.
The setting can be made directly at each pump or over the infrared interface. If a pump
(master or slave) is disabled, the pump is no longer ready for operation.
In this state, errors are identified, displayed and reported. If a fault occurs in the enabled
pump, the disabled pump does not start up. However, the pump kick is still performed if
it is activated. The interval to the pump kick starts when the pump is disabled.
NOTICE
If a pump head is disabled and “parallel operation” operating mode is ac-
tivated:
It cannot be guaranteed that the desired duty point will be achieved with just one
pump head.
4.4 Other functions
4.4.1 Pump kick
NOTICE
If the pump is at a standstill for prolonged periods, the impeller may seize
up in the pump housing.
The pump kick reduces this risk. This is intended to ensure pump operation after a
long standstill. If the “pump kick” function is deactivated, smooth starting of the
pump can no longer be guaranteed.
A pump kick takes place after a configurable time has elapsed since a pump or pump
head stopped operating. The interval can be set manually in menu <5.8.1.2> on the
pump for a period of between 2h and 72h, in 1h steps. Factory setting: 24h.
The reason for the standstill is irrelevant. The pump kick is repeated until the pump is
switched back on via a control mechanism.
For double pump function (“Main/standby operation” mode), this also applies to the
standby pump. If the time interval before pump cycling set in menu <5.8.1.2> expires, a
pump kick takes place at the standby pump.

en Product description
16 WILO SE 2020-10
The “pump kick” function can be disabled via menu <5.8.1.1>. As soon as the pump is
switched on via the control system, the countdown to the next pump kick is interrup-
ted.
A pump kick lasts 5seconds, during which time the motor turns at the set speed. The
speed can be set between the minimum and maximum permissible pump speeds in
menu <5.8.1.3>. Factory setting: minimum speed.
NOTICE
If the “Operation” function has been chosen for EBM/SBM, each pump kick produces
a signal. The signal is visible for a few seconds each time.
NOTICE
In the event of a malfunction too, the system will also attempt to perform a pump
kick.
The time remaining until the next pump kick can be seen on the display in menu
<4.2.4.0>. This menu is only available when the motor is stopped. The number of pump
kicks is shown in menu <4.2.6.0>. With the exception of warnings, all faults detected
during a pump kick will cause the motor to be switched off. The corresponding error
code is shown on the display.
4.4.2 Overload protection The pumps are equipped with an electronic overload protection function which
switches off the pump in the event of an overload.
The electronic modules are equipped with a non-fading memory for data storage pur-
poses. The data is retained no matter how long the module is disconnected from the
power supply. When the voltage supply is re-established, the pump continues to run
with the default values prior to disconnection from the power supply.
4.4.3 Switching frequency The switching frequency can be changed via menu <4.1.2.0>, the CAN bus or the IR-
Stick.
NOTICE
At high ambient temperatures, the thermal load on the electronic module
can be reduced by lowering the switching frequency. Carry out
switchovers or changes only when the pump is at a standstill (not when
the motor is running).
Lower switching frequencies result in increased noise levels.
4.5 Variants If menu <5.7.2.0> “pressure value correction” is not available for a pump, the pump in
question is a variant version.
In that case, the following functions are unavailable:
ƒPressure value correction (menu <5.7.2.0>)
ƒEfficiency-optimised activation and deactivation in twin-head pumps
ƒFlow rate trend display
4.6 Type key Example: Yonos GIGA-N 40/200-15/2-R1-P5
Yonos Product family
GIGA Series
NConstruction
40 Nominal diameter DN of pressure port
200 Nominal diameter of the impeller in mm
15 Rated power P2 in kW
2Number of poles
R1 Version without differential pressure measurement

Product description en
Installation and operating instructions Wilo-Yonos GIGA-N 17
Example: Yonos GIGA-N 40/200-15/2-R1-P5
P5
Option:
empty = with spacer coupling
P5 = without spacer coupling (with standard coupling)
4.7 Technical data
Property Value Remarks
Speed range 750 ... 2900rpm
380 ... 1450rpm
Depending on pump type
Nominal diameters DN 32, 40, 50, 65, 80, 100, 125, 150 (dis-
charge side)
Pipe connections Flanges PN16 EN1092-2
Permissible min./max. fluid temper-
ature
-20 °C ... +140 °C Depending on the fluid
Ambient temperature min./max. 0 ... +40°C Lower or higher ambient temperatures
on request
Storage temperature min./max. -20 °C ... +60 °C
Max. permitted operating pressure 16bar
Insulation class F
Protection class IP55
Electromagnetic compatibility
Emitted interference in acc. with:
Interference resistance in acc. with:
EN IEC 61800-3:2018/IEC
61800-3:2017
Industrial environment (C2)
Sound-pressure level1) LpA, 1m < 83 dB(A) | ref. 20µPa Depending on pump type
Permissible fluids2)
Heating water according to VDI2035
Cooling/cold water
Water-glycol mixture up to 40% vol.
Standard version
Standard version
Standard version
Electrical connection
3~380 V -5%/+10%, 50/60Hz
3~400V ±10%, 50/60Hz
3~440V ±10%, 50/60Hz
Supported mains types3): TN, TT
Internal electric circuit PELV, galvanically isolated
Speed control Built-in frequency converter
Relative humidity
At Tambient = 30 °C: <90%, non-con-
densing
At Tambient = 40 °C: <60%, non-con-
densing
1) Average value of the sound-pressure levels on a spatially rectangular measuring surface at a distance of 1m from the
pump surface in accordance with DIN EN ISO 3744.
2) For more information about permissible fluids, see the “Fluids” section on the next page.
3) Electronic modules for IT networks are optionally available for motor power from 11 ... 22kW. Compliance with the
specified values according to EN 61800-3 can only be guaranteed for the standard version of TN/TT networks. Non-ob-
servance can result in EMC faults.
Table2: Technical data
Pumped fluids Take account of the fact that water-glycol mixtures or fluids with a different viscosity
from pure water increase the power consumption of the pump. Only use mixtures with
corrosion protection inhibitors. Observe relevant manufacturer specifications!
ƒThe fluid must be sediment-free.
ƒThe use of other fluids requires approval from Wilo.
ƒMixtures with a proportion of glycol of >10% influence the flow calculation.
ƒIn systems built according to the state of the technology, under normal system con-
ditions it can be assumed that the standard seal/standard mechanical seal is com-
patible with the fluid.
Special circumstances may require special seals, for example:
–Solid materials, oils or EPDM-corrosive substances in the fluid,
–air in the system etc.

en Product description
18 WILO SE 2020-10
NOTICE
The flow value that is shown on the IR-Monitor/IR-Stick display or output to the
building management system must not be used to control the pump. This value is
merely an indicator of general trends.
A flow value is not output by every pump type.
Always read and follow the material safety data sheet for the fluid being pumped!
4.8 Scope of delivery ƒWilo-Yonos GIGA-N pump
ƒInstallation and operating instructions
4.9 Accessories Accessories have to be ordered separately.
ƒIR-Monitor
ƒIR-Stick
ƒPLR IF module for connecting to PLR/interface converter
ƒLON IF module for connecting to the LONWORKS mains network
ƒBACnet IF module
ƒModbus IF module
ƒCAN IF module
ƒDPS sets
NOTICE
IF module may only be inserted when the pump is de-energised (voltage-free).
4.10 Permissible forces and torques on
the pump flanges
Z
Y
X
Y
X
Z
Fig.8: Permissible forces and torques on the
pump flanges–pump made of grey cast iron
DN Forces F [N] Torques M [Nm]
FXFYFZΣ Forces F MXMYMZΣ Torques M
Pressure port
32 315 298 368 578 385 263 298 560
40 385 350 438 683 455 315 368 665
50 525 473 578 910 490 350 403 718
65 648 595 735 1155 525 385 420 770
80 788 718 875 1383 560 403 455 823
100 1050 945 1173 1838 613 438 508 910
125 1243 1120 1383 2170 735 525 665 1068
150 1575 1418 1750 2748 875 613 718 1278
Suction port
50 578 525 473 910 490 350 403 718
65 735 648 595 1155 525 385 420 770
80 875 788 718 1383 560 403 455 823
100 1173 1050 945 1838 613 738 508 9100
125 1383 1243 1120 2170 735 525 665 1068
150 1750 1575 1418 2748 875 613 718 1278
200 2345 2100 1890 3658 1138 805 928 1680
Values in acc. with ISO/DIN5199–class II (2002)–AppendixB, Family no. 1A.
Table3: Permissible forces and torques on the pump flanges
If not all working loads reach the maximum permitted values, one of these loads may
exceed the normal limit value. This is under the condition that the following additional
conditions are fulfilled:
ƒAll force and torque components are limited to 1.4times the maximum permitted
value.

Transportation and storage en
Installation and operating instructions Wilo-Yonos GIGA-N 19
ƒThe forces and torques acting on each flange meet the requirements of the com-
pensation equation.
Fig.9: Compensation equation
Σ Feffective and Σ Meffective are the arithmetic sums of the effective values of both pump
flanges (inlet and outlet). Σ Fmax. permitted and Σ Mmax. permitted are the arithmetic sums of the
maximum permitted values of both pump flanges (inlet and outlet). The algebraic signs
of Σ F and Σ M are not taken into consideration in the compensation equation.
5 Transportation and storage
5.1 Delivery The pump is secured to a pallet ex works and is protected against dirt and moisture.
Check the shipment immediately on receipt for defects (damage, completeness). De-
fects must be noted on the freight documentation. Any defects must be notified to the
transport company or the manufacturer immediately on the day of receipt of shipment.
Subsequently notified defects can no longer be asserted.
5.2 Transport
DANGER
Risk of fatal injury due to suspended loads!
Never allow anyone to stand under suspended loads! Danger of (serious) injuries
caused by falling parts. Loads may not be carried over work places where people are
present!
The safety zone must be marked so that there is no danger when the load (or part of
it) slips away or if the lifting device snaps or is ripped off.
Loads must never be suspended for longer than necessary.
Accelerations and braking during the lifting operation must be performed in a way
that rules out any danger to people.
WARNING
Hand and foot injuries due to lack of protective equipment!
Danger of (serious) injuries during work. Wear the following protective equipment:
• Safety shoes
• Safety gloves for protection against cuts
• Sealed safety goggles
• Safety helmet must be worn if lifting equipment is used!
NOTICE
Use only properly functioning lifting equipment!
Use only properly functioning lifting equipment to lift and lower the pump. Ensure
that the pump does not become jammed during lifting and lowering. Do not exceed
the maximum bearing capacity of the lifting equipment! Check that lifting equip-
ment is functioning properly before use!
CAUTION
Property damage due to incorrect transport
To ensure proper alignment, all equipment is pre-assembled. If dropped or if im-
properly handled, there is a risk of misalignment or deficient performance due to de-

en Transportation and storage
20 WILO SE 2020-10
formations. The pipes and valves will not withstand loads and should not be used to
secure loads in transit.
• Only use permitted lifting gear for transport. Ensure the stability of the load since,
with this particular pump design, the centre of gravity is shifted to the top (top-
heavy).
•Never attach lifting gear to shafts in order to lift the unit.
• Do not use the transport lugs on the pump or motor to lift the entire unit. They are
only meant for transporting the individual components during installation or dis-
mantling.
Only remove the outer packaging at the place of utilisation to ensure that the pump is
not damaged during transport.
CAUTION
Risk of damage due to incorrect packaging.
If the pump is transported again at a later date, it must be packaged so that it cannot
be damaged during transport. Use the original packaging for this, or choose equival-
ent packaging.
5.2.1 Attaching the unit
Fig.10: Attaching the unit
ƒComply with applicable national safety regulations.
ƒUse legally specified and approved lifting gear.
ƒSelect the lifting gear based on the prevailing conditions (weather, attachment
point, load, etc.).
ƒOnly attach the lifting gear to the attachment point. Fix in place with a shackle.
ƒNever feed the lifting gear over or through transport lugs without protection.
ƒNever feed the lifting gear over sharp edges without protection.
ƒUse lifting equipment with sufficient bearing capacity.
ƒThe stability of the lifting equipment must be ensured during operation.
ƒWhen using lifting equipment, ensure a second person is present to coordinate the
procedure if required (e.g. if the operator’s field of vision is blocked).
ƒWhen lifting, make sure that the load limit of the lifting gear is reduced when pulling
at an angle. The safety and efficiency of the lifting gear is best guaranteed when all
load-bearing elements are loaded vertically. If necessary, use a lifting arm, to which
the lifting gear can be vertically attached.
ƒEnsure the load is lifted vertically!
ƒPrevent the suspended load from swinging!
5.3 Storage
NOTICE
Improper storage can lead to damage to the equipment.
Damage caused by improper storage is not covered by the guarantee or warranty.
ƒRequirements at the storage location:
–dry
–clean
–well-ventilated
–free from vibrations
–free from humidity
–free from rapid or extreme changes in temperature
ƒStore the product where it is protected against mechanical damage.
ƒProtect the bearings and couplings from sand, gravel and other foreign materials.
ƒLubricate the unit to prevent rust and bearing seizure.
ƒManually rotate the drive shaft several times once a week.
Storage for more than three months
Additional precautionary measures:
ƒAll rotating parts must be coated with a suitable protective medium to protect them
from rust.