Zehnder Pumpen ZP SPEEDCONTROL COMFORT User manual

CONTROLLER
ZP SPEEDCONTROL COMFORT
OPERATING MANUAL
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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

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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
!

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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

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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

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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.
!

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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.
!

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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.
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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:

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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.

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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.

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ZP SPEEDCONTROL COMFORT en English
2.9 Responsibility of the operating company / owner
Compliance with the following points is the responsibility of the operating company /
owner:
- The plant has to be operated for the intended use only when it is in proper condition.
 Chapter 2.2 “Intended use”
- The function of the protection devices, e.g. touch protection device of coupling and fan
wheel, must not be impaired.
- Maintenance intervals have to be adhered to and malfunctions have to be immediately
removed. Malfunctions have to be removed on ones own only if measures are
described in this operating manual. Qualifi ed persons are in charge of all other
measures – contact the factory service, if necessary.
- The type plate of the plant has to be checked for completeness and readability.
 Chapter 8.1 “Type plate”
- Personal protective equipment must be suffi ciently available and be worn.
 Chapter 2.4 “Personal protective equipment“
- The operating manual has to be made available at the place of operation in a readable
and complete way.
- Only qualifi ed and authorised personnel may be employed.  Chapter 2.3 ”Selection
and qualifi cation of persons“
3 Transport and storage
3.1 Transport
During transport, it has to be made sure that the plant cannot be knocked into and is not
dropped.
3.2 Temporary storage / conservation
When decommissioning, the water has to be completely drained from the pressure
booster. For intermediate warehousing and conservation, it is suffi cient to store the plant
at a cool, dark and frost-proof place. The controller has to be protected against humidity.
In case of long-term storage (more than 3 months), all blank metal parts that were not
manufactured from stainless steel have to be treated with preserving agent. Then the
preservation has to be checked every 3 months and replaced, if necessary.
After longer storage of pumps, they have to checked prior to putting them into operation
(again). To do so, the freedom of movement of the shaft has to be checked by rotating it
by hand

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ZP SPEEDCONTROL COMFORT en English
4 Product description
The ZP SPEEDCONTROL COMFORT contains an electronic control device with a
frequency converter. In automatic mode, this enables independently of the respective
flow rate, to keep the pressure within the plant constant at a target pressure that had been
set before. The power consumption of the pump is thereby clearly minimised.
The ZP SPEEDCONTROL COMFORT switches on the pump once the measured plant
pressure(P-LINE)fallsbelowthesettargetpressure(P-SET)bymore thantheset differential
pressure (P-DIFFERENTIAL PRESSURE). The control then regulates the speed of the
pump in such a way that the plant pressure (P-LINE) keeps being as constant as possible.
Once the plant pressure (P-LINE) has reached the set target pressure (P-SET) and the
control does not recognise any flow rate, the ZP SPEEDCONTROL COMFORT will stop
the pump after a time period (TIMER STOP) that was set before.
The ZP SPEEDCONTROL COMFORT protects the pump against:
• Dry-running
• Overcurrent
• too high water temperature
• Frost
• Short circuit
• Overvoltage / undervoltage
• ART function (Automatic Reset Test)
Should the device be at standstill, because the protection system against
dry operation has been set in motion, the ART function will try with the pre-
programmed frequency to switch the pressure booster back on again in order to
restore the water supply.
• AIS function (Anti-ice System) - integrated temperature sensor
Below 5°C, the control will automatically switch the pump to frost protection mode
in order to prevent freezing inside the pump.

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ZP SPEEDCONTROL COMFORT en English
!
It is possible to couple two controllers with one another.
4.1 Operating principle in case of assembly mounting (Master / Slave)
With it, a controller is formally defi ned as main device (Master). The second control must
then be set up as secondary device (Slave).
During initial commissioning in automatic mode, the pump will start fi rst that has been set
up as Master. In the subsequent work cycle, the starting pump will swap - now the pump
defi ned as Slave will start at fi rst.
Due to constant change of the starting pumps, an equal load of the pumps as possible
shall be achieved.
Should both pumps be required in case of a large fl ow rate (peak load), the speed of the
second pump will also be adjusted so that the total system will achieve the pre-set target
pressure as good as possible.
4.2 Scope of delivery
• ZP SPEEDCONTROL COMFORT , with 230 V plug, one 4-wire connecting cable
for the pump to be connected and one enclosed 4-wire communication cable for
assembly mounting
Required for a single system on the part of the building site, e.g.:
Connection set CPN ZP SPEEDCONTROL COMFORT
Article No. 20237 consisting of:
• Membrane expansion tank
Fully fl own-section (DIN 4807-T5)
RFLEX DD 12 litres, 10 bar, ¾“
• Flow fi tting
REFLEX Flowjet ¾“
• Swing check valve
in straight form according to
DIN EN 1717 Type EA as well as
DIN EN 13959 and valid DIN/DVGW test number.
Model range RV 281 1“ IG Honeywell Braukmann
• T-piece
1“ x ¾“ x 1“
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Pressure line to
the consumers
Fully own-section
membrane
expansion vessel
(DIN 4807 - T5)
controllable swing check valve
straight form
(DVGW approved)
Drinking water line from water
supplier
Fully own-section
membrane expansion
vessel
(DIN 4807 - T5)
Pressure line to
the consumers
controllable swing
check valve
straight form
(DVGW approved)
Drinking water line
from water supplier
Suction connection
with shut-o valve
ZP SPEEDCONTROL COMFORT en English
4.3 Application examples
4.3.1 Individual mounting
4.3.2 Assembly mounting
4.3.2.1 With direct (immediate) connection to the drinking water line
*) not included in scope of delivery - must be provided on the part of the building site

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Pressure line
Cistern
connector
Inlet
Overow
Suction line
Fully own-section
membrane
expansion vessel
(DIN 4807 - T5)
controllable swing
check valve
straight form
Charging pump
in the cistern
ZP SPEEDCONTROL COMFORT en English
*) not included in scope of delivery - must be provided on the part of the
building site
4.3.2.2 Indirect connection to the collection tank

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Safety instructions
The electric connection must be made via a socket with grounding
(mandatory provision according to DIN VDE 100)
Should the power supply not take place by a mandatory FI
operator protection circuit breaker with a rated residual current
with max. 30 mA, then the pump must be connected to the socket
via a separate FI operator protection circuit breaker (mandatory
provision according to EN 60 335-2)
Basically, a separate FI circuit breaker with own supply cable to
the controller is recommended so that potential interaction with
other parts of the electrical installation can be excluded
Extension cables must have at least the same cable cross section
as the connecting cable of the pump
ZP SPEEDCONTROL COMFORT en English
5 Installation
5.1 Preparations
Check whether according to the packaging the plant is suitable for the power system (230
V / 50 Hz). Make sure that all safety rules are observed. Check to make sure that the
requirements in  Chapter 2.2 “Intended use“ are complied with.
1. Remove the controller from the package.
2. Check for perfect external condition (transport damage).

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Do not use
a KFR valve
ZP SPEEDCONTROL COMFORT en English
5.2 Hydraulic installation
The controller can be mounted directly to the pressure socket of the pump.
We recommend to make the connection between pump and controller readily removable,
e.g. with a connecting coupling. That way, an inspection or maintenance can be easily
carried out.
During mounting, the following has to be basically observed:
• the pump/controller system requires a shut-off on the pressure and suction side
• the swing check valve has to be preferably mounted on the suction side. Alternatively,
it can also be mounted between pump and controller.
In case of assembly mounting, each pump must be equipped with a shut-off and swing
check valve.
!

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ZP SPEEDCONTROL COMFORT en English
1. Controller ZP SPEEDCONTROL COMFORT
2. Pump
3. Connecting coupling, pump-side with union nut, fl at sealing
(the controller has an 1¼“ connection thread)
4. Connecting coupling, pressure-side with union nut, fl at sealing
(the controller has an 1¼“ connection thread)
The controller ZP SPEEDCONTROL COMFORT must be mounted with a readily remov-
able pump connecting coupling (not included in the scope of delivery) so that it can be
easily removed at later maintenance and service works.
Mounting the controller using a readily removable connecting couplings
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Connecting the suction line
• The suction line has to be installed from vacuum-resistant
material
• The inside diameter of the suction line must be at least as big
as the inside diameter of the suction connector
• The suction connection by the customer at the pump should
preferably sealed using thread sealing
Alternatively, Teflon tape can be used
• In the suction line, a controllable swing check valve in straight
form according to DIN EN 1717 Type EA as well as DIN EN
13959 and a valid DIN/DVGW test number must be installed.
The model range RV 281 from Honeywell has proven itself
ZP SPEEDCONTROL COMFORT en English
5.3 Suction line
!
The swing check valve should be built in directly upstream the pump. Suction-side fine
filters must be installed upstream the swing check valve

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Connecting the pressure line
• The pressure outlet of the ZP SPEEDCONTROL has to be
preferably provided with a flat-sealing connecting coupling.
That way, the pump can be easily mounted and dismounted
later (e.g. for maintenance purposes).
• The inside diameter of the pressure line must be at least ¾“
• Seal the construction-side pressure line and connect it with the
connecting coupling of the pressure socket
Softening
equipment
Softening
equipment
ZP SPEEDCONTROL COMFORT en English
It is recommended to use a block fi tting on the pressure-side for maintenance and
service purposes.
i
5.4.1 Note on installation of the membrane expansion tank
! No check valve or pressure reducer may be built in between the membrane
expansion tank and the ZP SPEEDCONTROL COMFORT.
5.4 Pressure line
In case of an application as water supply or pressure boost with automatic switch-
off , a membrane expansion tank according to DIN 4807-5 must be provided. The
membrane expansion tank is absolutely necessary for the function of the frequency
control. No consumers may be built in between pump and membrane.
!