Zehnder Pumpen ZP SPEEDCONTROL COMFORT User manual

CONTROLLER
ZP SPEEDCONTROL COMFORT
OPERATING MANUAL
en
For safe and proper application, please carefully read the operating manual and further
product-accompanying documents. The operating manual has to be handed over to the
fi nal user and kept until product disposal.
Processing status: V 1.1 May 2020

en2
ZP SPEEDCONTROL COMFORT en English
You have purchases a high-quality product and we congratulate you on this decision.
Prior to delivery, this product was checked for proper condition within the framework of
quality controls. Please read and observe this operating manual so that you can enjoy the
product for a long time.
The following guidance will make it easier for you to deal with this operating manual:
Useful tips and additional information which facilitate the work
Step-by-step handling instructions
References to further information in this operating manual
Indication of a possibly hazardous situation that can result in property damage if not
avoided
Warning against a hazard area which can lead to personal injuries
Warning of hazardous electrical voltage
i

1. 
We continuously work on the further development of all our products. Therefore modi-
fi cations of the scope of delivery in terms of shape, engineering and equipment are
subject to change without notice.
That is why no claims can be made due to information and fi gures provided in this op-
erating manual.
i
!

en3
ZP SPEEDCONTROL COMFORT en English
Table of Contents
1 General aspects .................................................................................................... 5
1.1 Introduction.......................................................................................................5
1.2 Warranty ...........................................................................................................5
2 Safety .....................................................................................................................6
2.1 Symbols in this operating manual .................................................................... 6
2.2 Intended use.....................................................................................................7
2.3 Selection and qualifi cation of persons ..............................................................8
2.4 Personal protective equipment ......................................................................... 8
2.5 Basic hazard potential ......................................................................................9
2.6 Unauthorised modifi cation and spare parts production ....................................9
2.7 Hazards caused by non-observation of safety instructions ............................10
2.8 Safety-conscious work ................................................................................... 10
2.9 Responsibility of the operating company / owner ........................................... 11
3 Transport and storage ........................................................................................ 11
3.1 Transport ........................................................................................................ 11
3.2 Temporary storage and conservation ............................................................. 11
4 Product description ............................................................................................ 12
4.1 Operating principle in case of assembly mounting (Master / Slave) .............. 13
4.2 Scope of delivery ............................................................................................ 13
4.3 Application examples...................................................................................... 14
4.3.1 Individual mounting ..................................................................................... 14
4.3.2 Assembly mounting .....................................................................................14
4.3.2.1 With direct (immediate) connection to the drinking water line ..................14
4.3.2.2 Indirect connection to the collection tank ................................................. 15
5 Installation ........................................................................................................... 16
5.1 Preparations ...................................................................................................16
5.2 Hydraulic installation ...................................................................................... 17
5.3 Suction line ..................................................................................................... 19
5.4 Pressure line .................................................................................................. 20
5.4.1 Note on installation of the membrane expansion tank ................................ 20
5.5 Electrical connection of the controller ZP SPEEDCONTROL COMFORT .....22
5.5.1 Connection of the external release (e.g. fl oat switch) .................................24
5.5.2 Connection of the potential-free alarm contact (fault indication relay) ........ 24
5.5.3 Linking of two controllers in case of assembly mounting ........................... 25

en4
ZP SPEEDCONTROL COMFORT en English
6 Commissioning ................................................................................................... 26
6.1 Initial commissioning ...................................................................................... 26
6.2 Control panel of the ZP SPEEDCONTROL COMFORT ................................ 27
6.3 Display of operating conditions ...................................................................... 28
6.3.1 Special features of the operating display in case of assembly mounting.... 29
6.3.2 Switching the display indication...................................................................30
6.4 Indication of parameters................................................................................. 31
6.4.1 Sequence of parameters in the menu .........................................................32
6.5 Expert settings................................................................................................35
6.6 Error messages..............................................................................................37
6.6.1 Additional error messages in case of assembly mounting ..........................40
6.7 Counter and alarm log.................................................................................... 42
6.8 Handing over the plant to the user .................................................................43
6.9 Operation........................................................................................................43
7 Maintenance and repair ...................................................................................... 44
8 Technical data .....................................................................................................45
8.1 Type plate .......................................................................................................46
8.2 Dimensions [mm] ...........................................................................................46
9 Environmental notes .......................................................................................... 47
10 Declaration of conformity .................................................................................. 47

en5
ZP SPEEDCONTROL COMFORT en English
1 General aspects
1.1 Introduction
This operating manual is valid for the controller ZP SPEEDCONTROL COMFORT.
This operating manual enables safe handling of the controller ZP SPEEDCONTROL
COMFORT. This operating manual is an integral part of the electronic pressure regulator
and must be kept in close vicinity of the plant and be accessible to the personnel at any
time.
In case of any queries about the ZP SPEEDCONTROL COMFORT and this operating
manual, please get in touch with: Zehnder Pumpen GmbH
Zwönitzer Strasse 19
D-08344 Grünhain-Beierfeld
Tel.: [phone] / 52-100
Facsimile: -150
[email protected]
1.2 Warranty
Basically, the statutory regulations apply to the warranty.
Within this warranty period, we will at our discretion, either by means of repair or
replacement, correct free of charge all defects due to material or manufacturing defects
of the unit.
The warranty excludes all damage attributable to improper use or wear and tear. We do
not assume any liability for consequential damages which occur due to a failure of the
device.
For warranty claims it is required to submit a copy of the purchase receipt and to prove
proper initial commissioning.
In case of non-observation to the operating manual - in particular the safety instructions -
as well as unauthorised modifi cation of the device or the installation of non-original spare
parts the warranty claims will automatically become void. The manufacturer assumes no
liability for any damage resulting from this!
iIn case of defects or damages, please initially get in touch with your dealer.
They will always be your fi rst point of contact!
Smooth operation is ensured by observing the following notes.
Non-observance can lead to failure of electronics, malfunctions and to shorter service
life. The operating company bears the responsibility.
!

en6
Warning signs and
signal word Signification
DANGER
Personal injuries
Indication of a dangerous situation which, if not avoided, immediately
leads to death or severe injuries.
WARNING Indication of a dangerous situation which, if not avoided, might lead to
death or severe injuries.
CAUTION Indication of a dangerous situation which, if not avoided, might lead to
moderate or slight injuries.
DANGER
All live components are protected against unintentional contact. Prior to
opening housing covers, plugs and cables, they have to be disconnected
from the power supply. Works on electrical components may be carried
out only by qualified staff.
! ATTEN-
TION
Material dam- ages
Indication of a situation, if not avoided, might lead to damages of compo-
nents, the plant and/or its functions or a thing in its surrounding.
ZP SPEEDCONTROL COMFORT en English
2 Safety
These operating manual contain basic instructions which have to be observed during
set-up, operation and maintenance. For this reason, these operating manual must by all
means be read before installation and commissioning by the installation technician as
well as by the competent specialist staff / user, and must be permanently available at the
location of the plant. Not only the general safety instructions mentioned in this chapter
on safety have to be observed, but also the special safety instructions mentioned in the
other chapters.
2.1 Symbols in this operating manual
In these operating manual, safety warnings are marked by symbols.
-
Furthermore, the following must be defi nitely observed and kept in legible condition:
- Instructions attached directly to the machine, such as the rotation arrow.
- Marks for fl uid connections.
!

en7
ZP SPEEDCONTROL COMFORT en English
2.2 Intended use
The controller ZP SPEEDCONTROL COMFORT is a frequency controller that is traversed
by conveyed medium and is intended for automatic water supply purposes, such as:
• Pressure boost
• Rainwater utilization plants
• Irrigation
The controller is connected to the 230V power supply. Pumps with a max. nominal current
of 9 A at 1~ 230 V AC motor or a max. nominal current of 10 A at 3~ 230 V three-phase
AC current can be connected.
It is possible to connect two controllers with one another to become a control unit.
Switching-ON and control pressure can be adjusted.
Clear to slightly contaminated water without aggressive and abrasive components only
must be used as pumping medium.
The controller is permitted for the operation:
• with 230 Volt 50 Hertz alternating voltage on the input
• up to a water temperature of 40 °C
• in the area of residential, commercial and industrial areas; not suitable for open-air
installation, installation in wet cells and explosive environments
• maximum system pressure is 15 bar
When determining the maximum system pressure of the pressure boost, it is
absolutely necessary to observe the maximum permitted pressure of the pump
•
•
The frequency controller ZP SPEEDCONTROL COMFORT has to be operated only
in connection with an membrane expansion tank.
!
Use in swimming pools, garden ponds and their protected area is permissible only, if built
in keeping with VDE 0100/49 D. The ZP SPEEDCONTROL COMFORT must not be placed
or submersed in water.
!
The following pumping media are not suitable:
• corrosive, combustible and explosive media
• Waste water from urinal installations and lavatories
!
Install the controller free of frost and fl ood-proof.
According to the Guideline EN 61800-3
(Electromagnetic compatibility of variable-speed
electrical drives), the controller ZP SPEEDCONTROL
COMFORT belongs to Class C2.
i

en8
Mandatory signs Signification Explanation
Wear safety
shoes
Safety shoes provide good non-slip properties, particularly when wet,
as well as a high pierce resistance, for example in case of nails, and
the protect your feet against falling objects, e.g. during transport
Wear a safe-
ty helmet
Safety helmets protect against head injuries, e.g. in case of falling
objects or impacts
Wear safety
gloves
Safety gloves protect your hands against slight bruises, cut
injuries, infections and hot surfaces, particularly during transport,
commissioning, maintenance, repair and disassembly
Wear protec-
tive clothing
Protective clothing protects your skin against slight mechanical impacts
and infections in case of wastewater leakage
Wear safety
goggles
Safety goggles protect your eyes against wastewaters, particularly
during commissioning, maintenance, repair and decommissioning
ZP SPEEDCONTROL COMFORT en English
2.3 Selection and qualification of persons
All activities on the plant have to be carried out by qualifi ed persons, unless the activities
in this operating manual are explicitly indicated for other persons (owner, user).
Qualifi ed persons are those who know the relevant provisions, valid standards and
accident prevention regulations due to their vocational training and experience. They
are able to recognise and avoid potential hazards. The staff for operation, maintenance,
inspection and installation must have the corresponding qualifi cation for this work.
Works on electrical components may be carried out only by qualifi ed persons trained for
these purposes by observing all valid provisions of the accident prevention regulations.
The operating company / owner have to ensure that only qualifi ed personnel take action
on the plant. Moreover, the operating company / owner have to ensure that the content of
the operating manual is understood completely by the staff .
2.4 Personal protective equipment
For various activities on the plant, personal protective equipment is required, if necessary.
Personal protective equipment has to be provided to the personnel and their use has to
be checked by supervisory staff .
If personal protective equipment must be used, this is indicated by the following symbols:

en9
ZP SPEEDCONTROL COMFORT en English
2.5 Basic hazard potential
If hot or cold machine parts could lead to hazards, these parts have to be protected
against touch by the user.
Touch protection for moving parts (such as coupling) must not be removed from plants in
operation.
Leakage (of the shaft seal, for example) of hazardous material conveyed (e.g. explosive,
toxic, hot) must be removed in such a way that no danger is caused to persons and the
environment. Legal regulations have to be observed.
Hazards caused by electric energy must be excluded (for details here, please refer to the
country-specifi c regulations and the regulations of the local energy supply companies).
Basically, work on the machine may be carried out only at standstill. The procedure to shut
down the machine described in the operating instructions must be observed by all means.
In case of contact with waste water or contaminated pump components, e.g. when
removing blockages, can result in infections. Protective equipment must be worn.
 Chapter 2.4 “Personal protective equipment“
Pumps or pump assemblies, which convey media hazardous to health, must be
decontaminated.
Immediately after completing the works, all safety and protection devices have to be fi tted
again and/or have to be made functional again, e.g. the touch protection device for the
coupling and the fan wheel.
Before recommissioning, the points listed in the chapter on initial commissioning have to
be observed.
2.6 Unauthorised modification and spare parts production
Up to the market launch, the plant was submitted to comprehensive quality controls and
all components were checked under high load. Installation of non-approved parts will
aff ect the safety and void the warranty. When replacing parts, only original parts or parts
released by the manufacturer have to be used.

en10
ZP SPEEDCONTROL COMFORT en English
The non-observation of the safety instructions may endanger persons as well as the
environment, and may have consequences for the environment and machine. The non-
observation of the safety instructions will result in the loss of all claims for damages.
2.7 Hazards caused by non-observation of safety instructions
In detail, the non-observation of safety instructions may cause the following hazards, for
example:
- Malfunction of important functions of the machine / plant
- Malfunction of the mandatory methods of maintenance and repair
- Danger to persons caused by electrical, mechanical and chemical eff ects
- Danger to the environment caused by leakage of dangerous substances
2.8 Safety-conscious work
In addition to the safety instructions in this operating manual, the accident prevention
regulations and possibly internal work, operational and safety instructions of the operating
company / owner must be observed.