Wilo Yonos MAXO-Z User manual

Pioneering for You
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Wilo-Yonos MAXO-Z
2189869 • Ed.01/2017-03
en Installation and operating instructions

en
2 WILO SE 2017-03
Table of contents
1 Guidance information............................................................................................................................................................... 4
1.1 About these instructions ..................................................................................................................................................................................4
1.2 Original instructions ..........................................................................................................................................................................................4
1.3 Safety information.............................................................................................................................................................................................4
2 Description of the pump .......................................................................................................................................................... 4
2.1 Overview .............................................................................................................................................................................................................4
2.2 Description of the pump...................................................................................................................................................................................4
2.3 Type key..............................................................................................................................................................................................................5
2.4 Technical data ....................................................................................................................................................................................................5
2.5 Min. inlet pressure..............................................................................................................................................................................................5
3 Safety......................................................................................................................................................................................... 5
3.1 Intended use.......................................................................................................................................................................................................5
3.2 Misuse..................................................................................................................................................................................................................5
3.3 Operator responsibilities...................................................................................................................................................................................6
3.4 Safety instructions.............................................................................................................................................................................................6
4 Transportation and storage..................................................................................................................................................... 6
4.1 Scope of delivery................................................................................................................................................................................................6
4.2 Accessories .........................................................................................................................................................................................................6
4.3 Transport inspection .........................................................................................................................................................................................6
4.4 Transport and storage conditions ...................................................................................................................................................................6
4.5 Transport.............................................................................................................................................................................................................7
5 Installation................................................................................................................................................................................. 7
5.1 Personnel requisition.........................................................................................................................................................................................7
5.2 Safety during installation..................................................................................................................................................................................7
5.3 Preparing the installation..................................................................................................................................................................................7
5.4 Permissible installation .....................................................................................................................................................................................7
5.5 Outdoor installation...........................................................................................................................................................................................7
5.6 Aligning ...............................................................................................................................................................................................................7
5.7 Installation ..........................................................................................................................................................................................................8
6 Connect.................................................................................................................................................................................... 11
6.1 Personnel requisition...................................................................................................................................................................................... 11
6.2 Requirements .................................................................................................................................................................................................. 11
6.3 Connection options ........................................................................................................................................................................................ 11
6.4 Collective fault signal (SSM).......................................................................................................................................................................... 12
6.5 Connect ............................................................................................................................................................................................................ 12
7 Put into operation................................................................................................................................................................... 14
7.1 Venting ............................................................................................................................................................................................................. 14
7.2 Flush.................................................................................................................................................................................................................. 14
7.3 Select operating mode................................................................................................................................................................................... 14
7.4 Adjust operating mode and pump output................................................................................................................................................... 14
8 Troubleshooting...................................................................................................................................................................... 14
8.1 Personnel requisition...................................................................................................................................................................................... 14

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Installation and operating instructions Wilo-Yonos MAXO-Z 3
8.2 Safety during troubleshooting...................................................................................................................................................................... 14
8.3 Error table......................................................................................................................................................................................................... 15
8.4 Fault signals ..................................................................................................................................................................................................... 15
8.5 Warning signals ............................................................................................................................................................................................... 15
9 Spare parts............................................................................................................................................................................... 16
10 Disposal.................................................................................................................................................................................... 16
10.1 Information on the collection of used electrical and electronic products.............................................................................................. 16

en Guidance information
4 WILO SE 2017-03
1 Guidance information
1.1 About these instructions
These instructions enable the safe installation and ini-
tial commissioning of the pump.
▪Read these instructions before commencing work and
keep them in an accessible place at all times.
▪Observe instructions and labelling on the pump.
▪Observe local regulations where the pump is installed.
1.2 Original instructions
The German language version represents the original
instructions. All other language versions are transla-
tions of the original instructions.
1.3 Safety information
1.3.1 Identification of safety instructions
These installation and operating instructions set out
safety instructions for preventing personal injury and
damage to property that are displayed in different
ways:
▪Safety instructions relating to personal injury start with
a signal word and are preceded by a corresponding
symbol.
▪Safety instructions relating to property damage start
with a signal word and are displayed without a symbol.
Signal words
▪Danger!
Failure to observe the safety instructions will result in
serious injury or death!
▪Warning!
Failure to follow the instructions can lead to (serious)
injury!
▪Caution!
Failure to follow the instructions can lead to property
damage and a possible total loss.
▪Notice!
Useful information on handling the product
Symbols
These instructions use the following symbols:
General danger symbol
Danger of electric voltage
Warning of hot surfaces
Warning of magnetic fields
Notes
1.3.2 Personnel qualifications
▪The product must be operated by persons who are in-
structed in the functioning of the complete system.
▪Installation/dismantling must be carried out by a quali-
fied technician who is trained in the use of the neces-
sary tools and mounting materials.
▪Electrical work must be carried out by an authorised
electrician (in accordance with EN50110-1).
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 Description of the pump
2.1 Overview
Fig.1: Overview flange and threaded pipe union pump (single
pump)
1. Pump housing
2. Motor
3. Control module
4. LEDdisplay and fault signal LED
5. Operating button
6. Plug
2.2 Description of the pump
The high-efficiency pump Wilo-Yonos MAXO-Z in the
single pump version with flange or threaded pipe union
is a glandless pump with a permanent magnet rotor and
integrated differential pressure control. The choice of
material of the pumps corresponds to the state of the
art, taking into the account the guidelines of the Ger-
man Environment Agency (UBA).
Power limit
The pump is fitted with a power-limiting function
which prevents overload. This may have an operational
influence on the delivery rate.

Safety en
Installation and operating instructions Wilo-Yonos MAXO-Z 5
2.3 Type key
Example: Yonos MAXO-Z 40/0.5-12
YonosMAXO Pump designation
‐Z Single pump for domestic hot water circula-
tion systems
40 Flange connection DN40
0.5-12
0.5: Minimum delivery head inm
12: Maximum delivery head inm
at Q=0m³/h
2.4 Technical data
Fig.2: Technical data
Instruction Value
Permissible fluid temperature 0 to 80°C (short term (2h)):
+110°C)
Permitted ambient temperat-
ure
0 to +40°C
Maximum relative humidity 95%
Mains voltage 1~ 230V +/-10% 50/60Hz
Residual current ∆I ≤ 3.5mA
Electromagnetic compatibility
Emitted interference in acc.
with:
EN61800-3:2004+A1:2012/
residential area (C1)
Interference resistance in acc.
with:
Instruction Value
EN61800-3:2004+A1:2012/
industrial environment (C2)
Emissions-sound-pressure
level
< 52dB(A)
For further instructions see rating plate and catalogue.
2.5 Min. inlet pressure
Nominal dia-
meter Fluid temperature
0 to +50°C up to +95°C up to +110°C
RP1 0.3bar 1.0bar 1.6bar
RP1¼ 0.3bar 1.0bar 1.6bar
DN40 0.5bar 1.2bar 1.8bar
DN50 0.5bar 1.2bar 1.8bar
DN65 0.7bar 1.5bar 2.3bar
NOTICE
Effective up to 300m above sea-level. For higher
positions +0.01bar/100m.
3 Safety
3.1 Intended use
Use
Circulators from the Yonos MAXO-Z series may only be
used for pumping liquids in domestic hot water circula-
tion systems.
Permitted liquids
▪Drinking water acc. to EC Drinking Water Directive.
▪Drinking water and water according to the drinking wa-
ter ordinance for Germany (TrinkwV).
CAUTION
Material damage!
Chemical disinfectants can result in damage to ma-
terial.
Permitted temperatures
0°C to +80°C
3.2 Misuse
WARNING!Misuse of the pump can lead to dangerous
situations and damage.
▪Never use non-specified fluids.
▪Highly flammable materials/fluids should always be
kept at a safe distance from the product.

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6 WILO SE 2017-03
▪Never allow unauthorised persons to perform work.
▪Never operate the pump outside of the specified limits
of use.
▪Never carry out unauthorised conversions.
▪Use exclusively authorised accessories and authorised
spare parts.
▪Never operate with phase angle control.
3.3 Operator responsibilities
The operator must:
▪provide the installation and operating instructions in a
language which the personnel can understand.
▪have all work carried out by qualified personnel only.
▪make sure that personnel are relevantly trained for the
specified work.
▪verify the area of responsibility and individual respons-
ibilities of personnel.
▪train personnel with regards to the operating principles
of the system.
▪eliminate risk from electrical current.
▪equip hazardous components (extremely cold, ex-
tremely hot, rotating, etc.) with an on-site guard.
▪have defective gaskets and connection pipes replaced.
▪keep highly flammable materials at a safe distance from
the product.
All information that appears on the product must be
followed and kept permanently legible:
▪Warnings
▪Rating plate
▪Direction of rotation arrow/symbol for direction of flow
▪Identification of connections
This device can be used by children from 8years of age
as well as people with reduced physical, sensory or
mental capacities or lack of experience and knowledge
if they are supervised or instructed on the safe use of
the device and they understand the dangers that can
occur. Children are not allowed to play with the device.
Cleaning and user maintenance is not allowed to be
carried out by children without supervision.
3.4 Safety instructions
Electrical current
DANGER
Electric shock!
The pump is operated electrically. An electric shock
may be a danger to life!
▪Only allow work on electrical components to be carried
out by qualified electricians (according to EN50110-1).
▪Before all work deactivate power supply and guard
against accidental switch-on. Work on the control
module may only be started after 5minutes have
elapsed, due to the dangerous residual contact voltage.
▪Never open control module and never remove operator
controls.
▪Operate pumps exclusively with intact components and
connection pipes.
Magnetic field
DANGER
Magnetic field!
The permanent magnet rotor inside the pump can
pose mortal danger for people with medical implants
(e.g pacemakers) during dismantling.
▪Never remove the rotor.
Hot components
WARNING
Hot components!
Pump housing and glandless pump motor can get
hot and cause burns when touched.
▪During operation only touch the control module.
▪Allow the pump to cool down before commencing any
work.
▪Keep highly flammable materials away.
4 Transportation and storage
4.1 Scope of delivery
▪Pump
▪8x washer M12 (only flange-end pump)
▪8x washer M16 (only flange-end pump)
▪2x flat gasket (only threaded pipe union pump)
▪Concise Installation and operating instructions
4.2 Accessories
Separately available:
▪Thermal insulation shell
4.3 Transport inspection
Following delivery immediately check for damage and
integrity. Where necessary make a complaint immedi-
ately.
4.4 Transport and storage conditions
▪Only carry by motor or pump housing ➜ Fig.3.
▪Store in original packaging.

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Installation and operating instructions Wilo-Yonos MAXO-Z 7
▪Storage of pump on a horizontal bearing surface.
▪Protect against damp and mechanical load.
▪Dry pump thoroughly following use (e.g.function test)
and store for a maximum of 6months.
▪Permissible temperature range: -20°C to +40°C
4.5 Transport
Fig.3: Transport
▪Only carry motor or pump housing.
▪If necessary use hoisting gear with sufficient bearing
capacity.
5 Installation
5.1 Personnel requisition
Carry out installation using qualified specialists only.
5.2 Safety during installation
WARNING
Hot fluids!
Hot liquids can cause scalding. Before the installa-
tion or removal of the pump or the dismantling of
the housing screws observe the following:
1. Close shut-off device or drain unit.
2. Cool down the unit completely.
5.3 Preparing the installation
1. Complete all welding and brazing tasks.
2. Flush unit.
3. Provide shut-off devices upstream and downstream of
the pump. Laterally align the shut-off device above the
pump so that the leakage water does not drip on the
control module.
4. Make sure that the pump can be installed free of mech-
anical stresses.
5. Allow a 10cm distance around the control module so
that it does not overheat.
5.4 Permissible installation
Fig.4: Permissible installation
5.5 Outdoor installation
When installing outdoor also observe:
▪Install pump in a pump chamber.
▪Utilise cover as protection against environmental influ-
ences (e.g.rain).
▪Observe permissible environmental conditions and pro-
tection classes.
5.6 Aligning
The motor head must be aligned according to installa-
tion position.

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8 WILO SE 2017-03
Fig.5: Align motor
1. Check permissible installation positions ➜ Fig.4.
2. Detach motor head and carefully turn ➜ Fig.5.
Do not remove motor from pump housing.
CAUTION
Material damage!
Damage to the gasket causes leakage.
▪Do not remove gasket.
5.7 Installation
5.7.1 Flange-end pump installation
Screws and tightening torques
Flange-end pump
PN6
DN32 DN40 DN50 DN65
Screw diameter M12 M12 M12 M12
Strength class ≥4.6 ≥4.6 ≥4.6 ≥4.6
Tightening torque 40Nm 40Nm 40Nm 40Nm
Screw length ≥55mm ≥55m
m
≥60m
m
≥60mm
Flange-end pump
PN10
DN32 DN40 DN50 DN65
Screw diameter M16 M16 M16 M16
Strength class ≥4.6 ≥4.6 ≥4.6 ≥4.6
Tightening torque 95Nm 95Nm 95Nm 95Nm
Screw length ≥60mm ≥60m
m
≥65m
m
≥65mm
▪Never interconnect 2combination flanges.
Installation steps
WARNING
Hot surface
The pipes might be hot. Injury may occur from
burns!
▪Wear protective gloves.
Fig.6: Close the shut-off device
1. Close the shut-off devices in front of and behind the
pump.

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Installation and operating instructions Wilo-Yonos MAXO-Z 9
Fig.7: Insert pump
2. Insert the pump in the pipe together with 2suitable
flat gaskets in such a way that the flange can be
screwed to the pump inlet and outlet. The arrow on the
pump housing must point in the direction of flow.
Fig.8: Pump installation
3. Screw together flange with suitable screws and the
supplied washers. Observe aforementioned tightening
torques!
Fig.9: Opening shut-off devices
4. Open the shut-off devices in front of and behind the
pump.
5. Check impermeability.
5.7.2 Install threaded pipe union pump
WARNING
Hot surface
The pipes might be hot. Injury may occur from
burns!
▪Wear protective gloves.
1. Install suitable threaded pipe union.

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10 WILO SE 2017-03
Fig.10: Closing shut-off devices
2. Close the shut-off devices in front of and behind the
pump.
Fig.11: Pump installation
3. Insert the supplied flat gaskets into the pump.
4. Screw together the pump with the union nuts. In do-
ing so hold it exclusively against the flat faces on the
pump housing.
Fig.12: Opening shut-off devices
5. Open the shut-off devices in front of and behind the
pump.
6. Check impermeability.