Wilo Star E 21 User manual

Wilo- Star E 21
EC Motor-Driven, High-Efciency, Wet-Rotor, Circulator
Installation and operating instructions
WILO_IOM_STAR_E_21_092823

Fig. 1 - Model numbering information format
Fig. 2 - Proper Mounting
2
HORIZONTAL MOUNTING
(DEFAULT CONFIGURATION) VERTICAL MOUNTING ROTATING THE DISPLAY
Figure 2a Figure 2b Figure 2c

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Fig. 3 - Dimensional Data
Fig. 4- Probe Location
ALL DIMENSIONAL DATA IN INCHES
Installation and operating instructions - Wilo-Star E 21
Special Note: Refer to the boiler
manufacturer’s pump placement.
This is only an example.

Figure 5- Installation and proper orientation
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Figure 5a - Installing the gaskets
Figure 5b - Position of junction box
Fig. 6 - Wiring Diagram

Fig. 7 - Display navigation
5
Fig. 8 - Performance curves for Constant Speed, HD mode, and Auto mode
Installation and operating instructions - Wilo-Star E 21

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1. General
1.1 About this document
These installation and operating instructions are an integral
part of the product. They must be kept readily available at
the place where the product is installed. Strict adherence
to these instructions is a precondition for the proper use
and correct operation of the product. These installation and
operating instructions correspond to the relevant version of
the product and the underlying safety standards valid at the
time of publication.
1.2 Modeling information
Please refer to Fig.1-page 2- Model numbering information
format, for the reference concerning the model description.
2. Safety
These instructions contain important information which
must be followed when installing and operating the pump.
It is therefore imperative that they be read by both the
installer and the operator before the pump is installed or
operated.
Both the general safety instructions in this section and the
more specic safety points in the following sections should
be observed.
2.1 Instruction symbols used in this operating manual
Symbols
General danger symbol
Hazards from electrical causes
NOTE: ...
Signal words:
DANGER! Imminently hazardous situation.
Will result in death or serious injury if not avoided.
WARNING! Risk of serious injury. ‘Warning’ implies
that failure to comply with the safety instructions can
potentially result in severe personal injury.
CAUTION! Risk of damage to the pump if improperly
installed.
NOTE: Useful information on the handling of the product.
It alerts the user to possible problems.
2.2 Personnel qualication
The personnel installing the pump must have the
appropriate qualication for this work.
2.3 Possible risks incurred by failure to comply with the
safety instructions
Failure to comply with the safety instructions could result
in personal injury or damage to the pump or installation.
Failure to comply with the safety instructions could also
invalidate any claim for damages.
In particular, failure to comply with these safety
instructions could give rise, for example, to the following
risks:
• Failure of the pump is sufcient,
• Personal injury due to electrical, mechanical and
environmental causes,
• Damage to property.
2.4 Safety precautions for the operator
The relevant accident precaution regulations must be ob-
served. Dangers caused by electrical energy must be eli-
minated. Local or general regulations [e.g. NEC, etc.] and
directives from local codes, must be observed.
2.5 Safety precautions for inspection and
installation
The operator must ensure that all inspection and
installation work is carried out by authorized and qualied
specialists who have carefully studied these instructions.
Work on the pump/unit must be carried out only with
the pump disconnected from the electrical supply and
at complete standstill. For proper mounting options
concerning the pump installation please refer to Fig.2
-page 2-Proper Mounting.
2.6 Unauthorized alterations
Alterations to the pump or installation may only be made
in agreement with the manufacturer.
2.7 Improper use
The proper operation of the pump or installation can only
be guaranteed if it is used in accordance with the operating
instructions. All values must neither exceed, nor fall below,
the limit values given in the catalogue or data sheet.
3. Shipment and interim storage
When receiving the material, check that there has been no
damage during shipment. If shipping damage has occurred,
take all necessary steps with the carrier within the allowed
time.
CAUTION! Outside inuences may cause damages !
If the delivered material is to be installed later on, store it in
a dry place and protect it from impact.
4. Installation and electrical connection
Installation and electrical work must be carried out
in compliance with any local codes and by qualied
personnel only.
WARNING! Bodily injury!
Existing regulations for the prevention of accidents must
be observed.
WARNING! Electrical shock hazard!
It is strongly suggested to have a trained technician install
and set the Star E 21 pump for operation.
4.1 Unpacking
Unpack the pump and dispose of the packaging in an
environmentally responsible manner.
Scope of supply:
• One circulating pump, Model, Star E 21 (provided by
Wilo).
• Two gaskets need to be placed into the ange ends of
the pump (provided by Wilo).

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• One, optional ow check valve (recommended for
parallel pumping systems, provided by Wilo).
• Installation and operation instructions (provided by
Wilo).
• Three wire nuts and three cable ties (provided by Wilo).
4.2 Installation
It is recommended that full port isolation ball valves be
placed on the supply and return lines for the pump so that
the pump can be serviced without having to drain the
system. Make sure that the pump is pumping away from the
bladder tank. Pumping toward the tank during extremely
low speeds, in rare cases, can cause the pump to become
air bound and stop the ow of water. It is recommended
that the system includes an air vent device at highest point
of the system.
• Install the pump in a vertical or horizontal position.
Refer to Fig.2a Horizontal Mounting and 2b Vertical
Mounting-Page 2
• Adjust the display to the proper orientation. The default
orientation for the display view is in the horizontal
position. In a vertical installation, remove the four hex
head bolts (4 mm) and turn the pump counterclockwise
90° and reinsert the hex bolts and tighten in a crisscross
pattern evenly until tight. Refer to Fig.2c-Page 2-
Rotating the Display.
• The installation and connection dimensions (connection
anges and pump footprint) are given in Fig.3-Page
3-Dimensional Data
• It is strongly recommended to capture sediment by using
permanent magnet separator upstream of the pump.
Using the supplied O-ring gaskets, install them on the
supply and return body anges of the pump, Tighten the
ange bolts evenly to the pump. Only use the O-ring
gaskets provided, any other gaskets used will void the
warranty. Refer to Fig. 5a-Page 4-Installing the Gaskets
The flow check option should be used when parallel
pumping is the primary piping conguration. When used,
please insert the ow check into the discharge neck until
it locks into place. Make sure the check moves freely. Refer
to Fig.2c-Page 2 - Rotating the Display.
WARNING! Risk of injury due to hot surfaces!
The pump must be positioned so that someone cannot
come into contact with the hot pump surfaces while in
operation.
If you are using differential temperature as the method of
control, zip-tie the probes to the supply and return piping.
Fig.4 -Page 3-Probe Location. If you have issues (e.g. not
enough wire length available to attach the probe to the
return piping), it is recommended to switch the control
mode from the Delta-T mode to the Auto mode.
This pump’s basic function is to pump hot or cold water or
water with 50% ethylene or propylene glycol.
NOTE: If introducing propylene or ethylene glycol into the
system, it is important to dose downstream of the pump.
DANGER! Risk of explosion!
The pump must not be used to pump ammable liquid such as
rapeseed oil and gasoline. Allowed liquids should be thin, clean,
non-corrosive and non-explosive and should not contain any
solid particles, ber or mineral oil.
4.3 Application areas:
Heating, Ventilation and Air-Conditioning:
• Boilers
• Induction heating
• Heat exchangers
• Temperature control systems
• Cooling circuits
5. Technical data
5.1 Technical data
- Ambient temperature range: 0°F -104°F
- Max relative humidity: 95%
- Degree of protection: IP42
- Max ow: 14.5 Gallons Per Minute
- Max dBA: 42
- Max system pressure: 145 PSI (10 BAR)
- Fluid temperature range: 36°F -230°F
WARNING CONCERNING CONDENSATION
To avoid condensation in the control box and stator, the
temperature of the pumped liquid must be always higher than
ambient temperature . In cooling circuits it is recommended to
insulate the pump housing. DO NOT INSULATE THE MOTOR!
5.2 Motor Information
The Star E 21 pump is equipped with permanent-
magnet motor and differential temperature controller,
capable of automatically & continuously adjusting motor
performance to meet the actual needs of system.
5.3 Accessories
Original accessories are available for the Wilo-Star E 21.
The accessories must be ordered separately.
6. Electrical connections
Wire the pump from the boiler pump relay to the conduit
box. Note: Please follow the appropriate national and local
electrical codes. Two 3/4” knock-outs are available for
wiring; one on the side and one on the back. Liquid-tite,
BX, or Rigid conduit are the preferred methods to protect
the wiring. Fig. 6-page 4-Wiring diagram.
DANGER! Danger of death!
National Electrical Codes (NEC), local codes and
regulations must be followed.
WARNING! Electrical shock hazard!
All electrical work must be conducted by a qualied
electrician! Make sure that the supply voltages are
Installation and operating instructions - Wilo-Star E 21
Liquid Temperature <185°F 194°F 230°F
Minimum Inlet Pressure 0.725 PSI 4.1 PSI 14.5 PSI
1.68 Ft. of Hd 9.5 Ft. of Hd 33.5 Ft. of Hd

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suitable for the motor used.
7. Modes and functions
7.1 Mode description
Delta-T Mode (Default) – Variable speed, maintains
constant ΔT, and provides exact GPM ow required. Attach
the WHITE wire probe to the supply piping using the
provided zip-ties. The BLUE wire probe should be zip-tied
to the boiler return line. Fig. 4 -page 3-Probe Location.
Press and hold down the “Set” button until the screen
ashes “Delta-T mode”. Press the “Set” button again,
and you will see the 20°F default setting ashing. Use the
“Up” and “Down” arrow to either decrease or increase the
desired differential temperature. Press the “Set” button
to accept the change and to exit the setting. Fig. 7 -page
5-Display navigation.
Constant Speed Mode – Press and hold down the “Set”
button until the screen ashes “Delta-T mode”. Press the
“Down” arrow to change the mode from Delta-T mode to
“Constant Speed Mode”. Press the “Set” button again, and
you will see the “Speed 4” default setting ashing. Use
the “Up” and “Down” arrow to either decrease or increase
the desired speed curve. Press the “Set” button to accept
the change and to exit the setting. This mode runs the
pump at a xed speed when a thermostat has called for
the boiler to run. Four speeds are available for this mode.
Please refer to the performance curves Fig. 8 -page
5-Performance curves for Constant Speed, HD mode, and
Auto mode
HD Mode (Head Dened) – This mode runs the pump at a
variable speed while limiting the Maximum head in relation
to the ow. Three performance curves are available for
this mode. Please refer to the performance curves Fig. 8 -
page 5-Performance curves for Constant Speed, HD mode,
and Auto mode
Auto Mode – adjusts the speed of the circulator in
accordance with the resistance in the system. As zone
valves open or close, the circulator will automatically
adjust its speed to meet the most efcient point on the
curve. To get to this setting, press and hold down the
“Set” button and use the “Up” and “Down” arrow to get
to the Auto mode and press “set” to accept and exit the
mode. This mode does not use the temperature probes for
monitoring. Please refer to the performance curves Fig. 8 -
page 5-Performance curves for Constant Speed, HD mode,
and Auto mode
SP Heat Mode – Set Point Heat Mode adjusts the speed of
the circulator by slowing down the circulator if the supply
temperature increases over setpoint. To get to this setting,
press and hold down the “Set” button and use the “Up”
and “Down” arrow to get to the SP Heat mode and press
“Set” to accept and exit the mode.
SP Cool Mode – Set Point Cool Mode adjusts the speed of
the circulator by speeding up the circulator if the supply
temperature increases over setpoint. To get to this setting,
press and hold down the “Set” button and use the “Up”
and “Down” arrow to get to the SP Cool mode and press
“Set” to accept and exit the mode.
BP Mode – Boiler Protection Mode adjusts the speed of
the circulator by monitoring the return line temperature.
The pump slows down as return temperature increases.To
get to this setting, press and hold down the “Set” button
and use the “Up” and “Down” arrow to get to the BP Mode
and press “Set” to accept and exit the mode.
Set Up Mode –This mode is used to change the languge
and read-out units. To get to this setting, press and hold
down the “Set” button and use the “Up” and “Down”
arrow to get to the Set-up mode and press “Set” to
accept and exit the mode.
8. Maintenance
The Wilo Star E 21 is a maintenance free pump.
WARNING! Electrical shock hazard!
Dangers caused by electrical energy must be excluded.
All electrical work must be performed after the electrical
supply has been secured against unauthorized switching.
WARNING! Risk of scalding!
At high water temperatures and system pressure close
isolating valves before and after the pump.
First, allow pump to cool down.

9Installation and operating instructions - Wilo-Star E 21
Error Shown Description Remedies
Sensor 1 missing Supply sensor disconnected Reconnect sensor
Sensor 2 missing Return sensor disconnected Reconnect sensor
Sensor 1 shorted Supply sensor shorted Replace sensor
Sensor 2 shorted Return sensor shorted Replace sensor
Under-voltage protection Under voltage Power inspection
Over-voltage protection Over voltage Power inspection
Over-current protection Locked rotor possibility Replace pump
Under-load protection Dry running of the pump Fill with water
Lose-phase protection Locked rotor or motor failure Replace pump
Over-heating protection PCB overheating Pump will reduce current and speed until
PCB temperature is acceptable. If speed
falls below 1650RPM, pump will stop on
safety. Cycle AC power OFF/ON to restart.
9. Faults, causes and remedies
WARNING! Electrical shock hazard!
Temp in °F Resistance KΩ Temp in °F Resistance KΩ Temp in °F Resistance KΩ Temp in °F Resistance KΩ
-22 173.7550 50 20.0690 122 3.5835 194 0.9180
-13 129.4075 59 15.7608 131 2.9891 203 0.7910
-4 97.4205 68 12.5131 140 2.4901 212 0.6830
5 73.2141 77 10.0000 149 2.0891 221 0.6000
14 55.8015 86 8.0703 158 1.7491 230 0.5210
23 42.7122 95 6.5443 167 1.4810 239 0.4580
32 32.9977 104 5.3202 176 1.2580 248 0.4000
41 25.5513 113 4.3522 185 1.0729 257 0.3490
10. Ohms Table
A good quality test meter capable of measuring
up to 5000kΩ(1kΩ=1000Ω) is required to measure
the sensor resistance. In addition to this, the actual
temperature must be measured with a good quality
digital thermometer. First measure the temperature
using thermometer and then measure the resistance
of the sensor. The wires from the sensor must not
connect to the circulator while this test is performed.
The wire terminals are easily removed by pulling them
from the circulator. Using the chart above, estimate the
temperature measured by the sensor. The sensor and
thermometer reading should be close. If the test meter
reads a very high resistance, there may be a broken wire,
a poor wiring connection or a defective sensor. If the
resistance is very low, the wire may be shorted, there may
be moisture in the sensor or the sensor may be defective.
To test for a defective sensor, measure the resistance
directly at the sensor location.
OHMS TABLE
11. Accessories
Accessories may be ordered via the local WILO USA LLC.
distributor.
To avoid any questions or wrong orders, all data of the name
plate should be mentioned when ordering, including date codes.
CAUTION! Danger of material damage!
Pump performance can only be guaranteed when original
accessories are used.
• Only use original accessories.

WILO USA LLC
[phone]
www.wilo-usa.com
[email protected]
WILO Canada Inc.
[phone]
www.wilo-canada.com
[email protected]
WILO Mexico
[phone]
www.wilo-mexico.com
[email protected]