Wilo Circulation Pumps

Glandless Circulators and Accessories,Package Heat Exchanger Assembly

Catalogue Heating, Air-Conditioning, Cooling

Glandless Pumps

Catalogue A1 - 50 Hz - 2007 A1

71

2

35

4

6

8

9

10

13

12

11

Wilo-Jet WJ

B1

1

Wilo-SubTW5/TW5-SE

B1

2

Wilo-SilentMaster

B1

3

Wilo-Sub TWU 3

B1

4

Wilo-RainSystemAF Comfort

B1

5

Wilo-Comfort-Vario CO 1/MVIE

B4

6

Wilo-Comfort-Vario CO 1/MVIE

B4

6

Wilo-EasyStar

A1

7

Wilo-Safe

A1

8

Wilo-Star-Z 15 TT

A1

9

Wilo-DrainLift Con

C3

10

Wilo-Stratos

A1

11

Wilo-Drain TM/TMW 32 Twister

C1

12

Wilo-DrainLift S

C3

13

SeriesCatalogue

Wilo-EMU KS

C1

1

Wilo-RainSystemAF 150

B1

2

Wilo-Comfort-VarioCOR 3/MHIE VR

B4

3

Wilo-Stratos-D

A1

4

Wilo-CronoLine-IL-E

A2

5

Wilo-TOP-Z

A1

6

Wilo-Stratos-Z

A1

7

Wilo-CronoBloc-BL

A3

8

Wilo-CronoBloc-BL

A3

8

Wilo-DrainLift M

C3

9

Wilo-DrainLift WS

C3

10

Wilo-VeroNorm-NP/NPG

A3

11

7

1

2

3

6

5

89

104

11

SeriesCatalogue

Program overview and fields of application

Glandless pumps

Pump type Main field of application

Page

Heating, Air-conditioning, Cooling 36

High-Efficiency Pumps Single-head pumps

Wilo-Stratos ECO S/M S/M 40

Wilo-Stratos M/C C M/C 40

Twin-head pumps Wilo-Stratos-D C C C 40

Energy-saving Pumps Single-head pumps

Wilo-Star-E (EasyStar) S/M 76

Wilo-TOP-E M/C 76

Twin-head pumps Wilo-TOP-ED C 76

Automatic Pumps Single-head pumps

Wilo-Smart S/M S/M S 108

Standard Pumps Single-head pumps

Wilo-Star-RS (ClassicStar) S/M S/M 116

Wilo-AXL (max. 2440/1 min) M/C 116

Wilo-TOP-RL (max. 2660/1 min) M/C C 116

Wilo-SE (max. 2880/1 min) M/C C 118

Wilo-TOP-S (max. 2880/1 min) M/C C 118

Wilo-TOP-D (max. 1400/1 min.) M/C C 118

Wilo-RP (max. 1400/1 min) S/M 120

Wilo-P (max. 1400/1 min) M/C 120

Twin-head pumps Wilo-Star-RSD (ClassicStar) S/M S/M 122

Wilo-TOP-SD (max. 2850/1 min) C C 122

Wilo-SE-TW (max. 2880/1 min) C 122

Wilo-DOP (max. 1400/1 min) C 124

Potable water circulation 245


Wilo-Stratos ECO-Z M 246

Wilo-Stratos-Z M/C M/C C M/C 246

Twin-head pumps Wilo-Stratos-ZD C C C 246


Wilo-Star-Z 15 (CircoStar) S 272

Wilo-Star-Z 20/25 (CircoStar) M M 272

Wilo-TOP-Z (max. 2850/1 min) M/C M/C 272

- Special single-head pumps Wilo-VeroLine-IP-Z M/C M/C M/C M/C 272

Solar thermal 303


Wilo-Stratos ECO-ST S/M 304


Wilo-Star-ST (SolarStar) S/M 314

Legend: Fields of application:

ApplicableS Single- and two-family housesM Multi-family housesC Commercial

New in the program or series expansion or modification

Heating Air-conditioning/cooling sector

Potable water circulation Solar

Floor heating

High-efficiency pumps Wilo-Stratos and Wilo-Stratos ECO.

Energy efficiency class A. Also for one- and two-family homes.

Up to 80 % power savings.*Highly efficient.

The Wilo-Stratos-ECO is the world's first high-efficiency pump. And it is the referencefor the energy label. Allowing power savings of up to 80 %*, it set the standard for theenergy efficiency class A as early as in 2001. The Wilo-Stratos ECO offers this state-of-the-art technology now also for one- and two-family homes.Ingenious? We call it Pumpen Intelligenz.

www.wilo.com

*compared to uncontrolled heating pumps.

3Contents

Wilo Catalogue A1 - Circulating pumps in glandless design

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General Notes and Abbreviations 4

Planning Guide 6

Heating, Air-conditioning, Cooling

Contents 36Wilo-Stratos ECO, Stratos, Stratos-DWilo-Star-E, TOP-E, TOP-EDWilo-SmartWilo-Star-RS, AXL, TOP-RLWilo-SE, TOP-S, TOP-DWilo-RP, PWilo-Star-RSD, SD, SE-TW, DOP

Potable water circulation

Contents 245Wilo-Stratos ECO-Z, Stratos-Z, Stratos-ZDWilo-Star-Z, TOP-Z, VeroLine-IP-Z

Solar thermal

Contents 303Wilo-Stratos ECO-STWilo-Star-ST

Service/AccessoriesSystems

Contents Service/Accessories 325Wilo-TOP Motor Technology, circuit diagramsSwitching plug, servicing apparatusThreaded pipe unions, adapter fittingsWilo thermal insulation shells, ClimaForm, Motor-Modules (MOT)

Contents Systems 343Wilo-Safe-WS, DrainLift Con

Switchgears and Control DevicesPump Management Systems Wilo-Control

Contents Switchgears and Control Devices 351Wilo-S1.../S2.../S4, SK, SR, SD, AS, VR-HVAC, CRn, CR

Contents Pump Management Systems Wilo-Control 421Wilo-IF-Moduls, IR-Monitor, Protect-Modul-CWilo-Control AnaCon/DigiCon/DigiCon-A

4 Subject to change without prior notice 09/2006 WILO AG

General Notes and Abbreviations

Abbreviations and what they mean

Abbreviation Meaning

1~ 1-phase alternating current

1/min Revolutions per minute (rpm)

3~ 3-phase alternating current

Autopilot Automatic adjustment of pump performance during setback phases, e.g. boiler setback mode overnight

blsf Blocking current-proof, no motor protection required

DM 3-phase AC motor

'p-c Control mode for constant differential pressure

'p-T Control mode for differential-pressure control as a function of fluid temperature

'p-v Control mode for variable differential pressure

'T Control mode for differential temperature

EM 1-phase AC motor

EnEV German energy saving act (Energie-Einsparverordnung)

ECM technology

Electronically commutated motor with new wet rotor encapsulation, newly developed glandless drive con-cept for high-efficiency pumps

Ext. Aus Control input Overriding Off

Ext. Min Control input Overriding Min, e.g. for setback mode without autopilot

FI Residual-current device

GA Building automation

GRD Mechanical seal

GTW Special cast iron: white malleable cast iron

d Degree of German water hardness, unit for assessing water hardness

H Delivery head

IF Interface

Inox Stainless steel

Int. MS Internal motor protection: Pumps with internal pro-tection against unacceptably high winding tempera-tures

IR Infrared interface

KDS Capacitor

KLF PTC thermistor sensor

KTL coating Cataphoretic painting: Paintwork with high adhesive strength for long-lasting corrosion protection

KTW Authorisation for products with plastics, for utilisa-tion in potable water applications

LON Local operating network (open, non-manufacturer-dependent, standardised data bus system in LONWORKS networks)

Abbreviation Meaning

MOT Motor module (drive motor + impeller + terminal box/electronics module) for replacement in the TOP .. Series

PLR Pump master computer, Wilo-specific data interface

PT 100 Platinum temperature sensor with a resistance value of 100 : at 0 C

Q (= ) Flow volume

SBM Run signal or collective run signal

SSM Fault signal or collective fault signal

Control input0 - 10 V

Analogue input for external activation of functions

Wilo-Control

Building automation management with pumps and accessories

TrinkwV 2001 German potable water ordinance of 2001(valid from 01.01.2003)

VDI 2035 VDI guideline for the prevention of damage in hot-water heating installations

WRAS Water Regulations Advisory Scheme

WSK thermal winding contacts (in motor for monitoring winding temperature, full motor protection through additional tripping unit)

Operating mode of twin-head pumps:Individual operation of the respective operating pump

+ Operating mode of twin-head pumps:Parallel operation of both pumps

No. of poles for the pumps: 2-pole



V.

5General Notes and Abbreviations


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Wear and tearPumps or parts of pumps are subject to wear in accordance with

state-of-the-art technology (DIN 31051/DIN-EN 13306). This wear

may vary depending on operating parameters (temperature, pressure,

water conditions) and the installation/usage situation and may result

in the malfunction or failure at different times of the aforementioned

products/components, including their electrical/electronic circuitry.

Wearing parts are all components subject to rotary or dynamic strain,

including electronic components under tension, in particular:

- seals/gaskets (including rotating mechanical seals), seal ring

- bearings and shafts

- stuffing boxes

- capacitors

- relays/contactors/switches

- electronic circuits, semiconductor components, etc.

- impellers

- wearing rings/wearing plates

We do not accept liability for faults or defects arising from natural

wear and tear.

NoteAccording to the German energy saving act EnEV, starting from 1.2.2002, boilers with outputs in excess of 25 kW must be equipped

with either switchgear-equipped heating pumps for automatic per-

formance control or electronically controlled pumps.In accordance with TrinkwV 2001 and DIN 50930-6 only circulating pumps with corrosion-resistant pump housings in stainless steel or

red bronze (CC 491K) are to be used in potable water circulation

systems.

Pump replacementPlease refer to the current Wilo heating pumps replacement guide for

more detailed information on replacing heating pumps.

WILO General Terms of Delivery and ServiceThe latest version of our General Terms of Delivery and Service can be

found on the Internet at

www.wilo.com


Planning GuideGlandless Pumps (General)

Pump selection: General NotesCirculating pumps should always be selected such that the specified

duty point is located on or as near as possible to the point of max.

efficiency (optimum capacity) of the max. speed H/Q pump curve.

Fig.: Pump curve

If the specified duty point is between two possible pump curves, it is

always good practice to choose the smaller pump.

Fig.: Pump selection

The resulting flow volume reduction has no appreciable effect on the

actual heating performance in heating systems. This applies to

pumps for chilled water applications.

Pump selection: Potable water circulation systemsPump selection

- In order to ensure correct configuration of the potable water circula-

tor, the pipeline system must be designed in accordance with both

DIN 1988 and the DVGW Worksheets W 551 to W 553.

- The necessary flow volume should be based on the figures recom-

mended in the standard and the DVGW guideline.

- If the hydraulic duty point lies between two pump curves, then the

next-largest circulator pr speed stage is to be selected in accordance

with DVGW Worksheet W 553.

- The thermal losses in the ascending and circulation pipelines for

potable water are to be reduced to a minimum through the installa-

tion of appropriate insulation.

Because most potable water circulation systems permit periodic

stops of the circulating pump (generally at night), a time switch for

automatic On/Off control should always be part of standard equip-

ment.

The German EnEV requires periodic pump shutdown.

Legionellae blocking circuits in the heat generator and/or in the heat-

ing control unit are to be observed and taken into account during

programming.

Maximum potable water temperatureIn view of the hardness-forming particles contained in water, potable

water circulation systems should not be operated at temperatures in

excess of 65 C.

This limit is required to avoid the formation of lime deposits.

Circulation pipeA gravity brake should always be installed in order to exclude the

possibility of incorrect circulation and for the prevention of gravity

circulation when the pump is switched off.

Control systems for automatic time-sensitive On/Off switching:Wilo-SK switchgear 601 for Wilo-TOP-Z Series pumps

ll

Fig.: Wilo-SK switchgear 601

- Wall-mounted installation, protection class IP 31

- Direct connection for AC pumps (EM) without thermal winding con-

tacts (WSK)

Not for three-phase pumps or for AC pumps with WSK except in con-

junction with Wilo-SK 602 or contactor

- Time switch for On/Off daily programme with 15-minute switch

interval

Special-design time switch with daily/weekly program and battery

backup (120 hrs.), with digital display

Variable speed controlExperience shows that variable speed control is only required in cir-

culating pumps in potable water circulation systems for basic adjust-

ment of performance. Automatic speed control is not required. A

time-sensitive On/Off control should however be provided for each

installation.

Motor protectionBlocking current-proof pumps and pumps with internal protection

against unacceptably high winding temperatures do not require

motor protection. All other pumps contain integrated full motor pro-

tection including trip electronics or are equipped with full motor

protection (thermal winding contacts [WSK]) for utilisation in con-

junction with the Wilo-SK 602/SK 622 tripping units.

max. (1 )min. (3 )

(2 )

Optimal flow rate

max. 1

max. 2

Pump ADuty point

Flow rate

Pump B

7Planning GuideGlandless Pumps (General)


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Pump-performance splittingGeneral notes on twin-head pumps

- Two pump heads mounted in a common housing, hydraulically sepa-

rated by a switchover valve

- Specific design features in accordance with single-head pump series

- Replacement of an equal-performance single-head pump with iden-

tical installation dimensions

- Wide range of applications thanks to standard series 3-/4-speed

control

Pump-performance splittingSplitting the assigned max. design performance to a twin-head pump in parallel operation makes possible - particularly in the heat-ing field - significantly improved adaptability to partial-load condi-tions and optimum economic efficiency.The average partial-load pump performance required for a particular season, i.e. during 85% of

the heating season, can be achieved through the operation of only one pump; the second pump is available for parallel operation on the occasions that full-load requirements need to be met.

Advantages of splitting the performance output between two pumps:

- Reduced operating costs of between 50 % and 70 %

- Increased reliability thanks to the constant availability of a standby

unit ready for operation

The individual pump duty charts for twin-head pumps featured in the

relevant chapters specify the hydraulic performance values for both

individual and parallel operation.

Operating modes for twin-head pumpsTwin-head pumps are suitable for operation in either of two dis-

tinctly different modes:

- Main/Standby operation

- Parallel operation

Rates of flow in pipes and pumpThe rate of flow of the fluid through the pipe system is determined by

the cross-section sizes in the pipeline network.

The values listed below should not be exceeded:

Rates of flow inside the pump [m/s] are shown on all individual Wilo

pump curves in relation to flow performance.

Viscous fluidsAll the pump curves contained in this catalogue apply to the pumping

of water (kinematic viscosity = 1 mm2/s). The hydraulic characteris-

tics of both pump and pipe system will change when handling fluids

with different densities and/or viscosities (e.g. water/glycol mix-

tures)!

Documents for calculating the correction factors for pump selec-tion can be obtained from Wilo on request.Correction factors applicable to the individual pipe system(increased pressure loss, lower specific heat capacity) cannot be fur-

nished by the pump manufacturer.They must be calculated by the

planner in co-operation with the chemical additive suppliers and the

makers of pipes, valves and fittings.

Minimum inlet pressure for the prevention of cavitationTo avoid cavitation (vapour bubble formation within the pump), it is

necessary to maintain at the pump suction port a sufficiently high

positive pressure (suction head) in relation to the vapour pressure of

the fluid being handled.

The minimum suction heads are shown in respective tables for all glandless pumps. These guide values apply to heating systems with feed temperatures of up to 130C that are installed at alti-tudes up to 300 m above seal level.For higher altitudes: 0.1 m/100 m head increase.These minimum heads must be respectively increased when handling

fluids of higher temperatures or lower densities, with there is greater

flow resistance on the pump suction side and in regions of lower

atmospheric pressures.

Main/Standby operation(STANDBY)

Parallel operation(ADDITION)

No. I or No. II pump operating Both pumps operating

The model-specific pump perform-ance is provided by whichever one of the two pumps is acting as the main pump; the second pump remains on standby, ready for time- or fault-actuated switchovers.

The model-specific pump perform-ance will be provided by both pumps operating in parallel. One pump can be switched off during partial-load states.

Nominal connection diameter DN[ mm]

Rate of flow v[m/s]

In building installations

Up to Rp 11/4 or DN 32 up to 1.2

DN 40 and DN 50 up to 1.5

DN 65 and DN 80 up to 1.8

DN 100 and greater up to 2.0

In long-distance heating pipes 2.5 to a max. of 3.5



Notes on installation and operationPermissible ambient temperature: 0 C to +40 C

InstallationGlandless pumps must be installed in dry, well-ventilated, frost-free

spaces. They are not suitable for outdoor installation.

CondensationAll standard series pumps for cold-water operation that are intended

for standard usage down to -10 C/-20 C are fully condensation-

proof.

The grey cast iron pump housing that comes with the following

series:

- Stratos/Stratos-D

- TOP-E/-ED

- TOP-S/-SD

- TOP-D

- TOP-RL

- P/RP (not RP 25/60-2)

- DOP

- AXL/SE/SE-TW

is provided with a special coating for surface finishing

(KTL: cataphoretic painting).

The benefits provided by this coating are:

- optimum corrosion protection against condensation formation on

the pump housings in cold-water installations

- very high scratch and impact resistance

To avoid condensation forming on Wilo-Top-E/-ED pumps, it is

essential to ensure that the fluid temperature is equal to or greater

than the ambient temperature at all times.

Intermittent operationThe series

- Stratos/Stratos-D

- Star-RS/RSD

- TOP-S/-SD

- TOP-D

- TOP-Z

- TOP-RL

- AXL/SE/SE-TW

can also be utilised for intermittent operation.

Operating pressureThe max. system pressure (operating pressure) and the flange ver-

sions for the pumps are listed in the relevant tables. All flanges on

glandless pumps (except Stratos, Stratos-Z, Stratos-D and

Stratos-ZD) have pressure-measurement connections R 1e8.

ConnectionsScrew-end pumpsScrew-end pumps are equipped with connecting threads in accord-

ance with DIN EN ISO 228 Part 1. Seals are included in the scope of

delivery. Threaded pipe unions with threads in accordance with

DIN 2999 must be ordered separately.

Flange-end pumpsThe pump flanges are designed in accordance with DIN 2531 or

DIN 2533 and/or in accordance with DIN EN 1092-2. Detailed infor-

mation on the respective Data Sheets.

Combination flange pumpsFlange-ended pumps with combination flanges can be mounted with

mating flanges PN 6 and PN 16 in accordance with DIN or DIN EN up to

and including DN 65. Installation linking combination flanges to one

another is not permissible. Bolts of tensile strength class 4.6 or higher

must be used for the flanged connections. The washers supplied must

be mounted between the bolt head and the combination flange.

Recommended bolt lengths:

MotorGlandless pump motors with protection class:

- Wilo-Stratos Series IP 44

- Wilo-EasyStar Series IP 42

- Wilo-ClassicStar Series IP 44

- Wilo-TOP product range IP 44

- Other pump product rangeIP 42

- Insulation class F

- Emitted interference: EN 61000-6-3

- Immunity to interference: EN 61000-6-2

Electrical connection- All Wilo pumps are designed to run on European standard voltage

230/400 V (10 %) in accordance with DIN IEC 60038.

- As of 1.1.1995, all Wilo pumps are labelled with the CE mark in

accordance with EU machinery directives.

- When pumps are utilised in installations with pumping media tem-

peratures above 90C, a corresponding heat-resistant connection

line must be used.

Electronic performance controlHeating pumps are, due to their high annual operating hours, among

the largest power-consuming appliances in buildings.

Automatic pump performance control helps drastically reduce power

consumption in heating pumps. Reductions of up to 50% can be

achieved. With high-efficiency pumps, it is possible to achieve power

savings of up to 80% over standard pumps.

Automatic pump performance control will hydraulically optimise

operations in all load conditions, particularly the partial-load periods

so typical for heating systems.

A further significant effect connected with the prevention of a rise in

pump pressure is the avoidance of flow noise in thermostatic valves.

DIN 2999(pipe thread sealed in thread)

DIN EN ISO 228/1(sealing pipe thread with flat

gasket at the front)

Female thread of pipe Rp 11/2 Female thread of pipe G 11/2Male thread of pipe R 11/2 Male thread of pipe G 11/2

Thread Starting torque Minimum bolt length

DN 32/DN 40 DN 50/DN 65

Flanged connection PN 6

M12 40 Nm 55mm 60mm

Flanged connection PN 10

M16 95 Nm 60mm 65mm

9Planning GuideGlandless Pumps (General)


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German energy-saving ordinance EnEVWithin the framework of statutory measures for CO2 reduction in

connection with the power consumption of heating circulating

pumps, the German legislature has established in the EnEV that cir-

culating pumps fitted after 01 Feb. 2002 with nominal thermal out-

put ratings starting at 25 kW must be configured in such a way that

electrical power consumption is automatically adjusted in at least

three stages to the delivery demands required by operation.

Although EnEV prescribes the application of automatic pump per-

formance controls starting with a nominal thermal output of 25 kW,

by far the greater savings potential for power and CO2 can be found

in single- and two-family houses, i.e. in systems that fall below the

25 kW minimum.

Pump performance control does not replace the need for correct

dimensioning of the circulating pump! The pump performance

installed must also be checked when the pump is replaced. Controlled

pumps that are slightly overdimensioned do not pose any risk if they

are correctly set to the nominal load requirement.

Standards/guidelines- CE mark (all Wilo pumps)

- Certification in accordance with:

- ISO 9001,

- ISO 14001,

- VDA 6.1

Pump curvesThe pump curves apply to water at + 20C and with a kinematic vis-

cosity of 1 mm2/s.

The pump curves take into account the standard European voltages

of 230/400 V.

Pump controlWhen operating Wilo pumps with control units or module accesso-

ries, it is essential to adhere to the electrical operating conditions as

set out in VDE 0160.

When operating glandless and glanded pumps in conjunction with

frequency-converter models not supplied by Wilo, it is necessary to

use output filters to reduce motor noise and prevent harmful voltage

peaks and to adhere to the following limit values:

- Glandless pumps with P2 d 1.3 kW and glanded pumps with P2 d 1.1 kWRate of voltage rise du/dt < 500 V/s

Voltage peaks < 650 V

For noise reduction on glandless pump motors, it is recommended

that sine filters (LC filters) be used rather than du/dt filters

(RC filters).

- Glanded pumps with P2 > 1.1 kW

Rate of voltage rise du/dt < 500 V/s

Voltage peaks < 850 V

Installations with large cable lengths (l > 10 m) between converter

and motor may cause increases of the du/dt and levels (resonance).

The same may happen for operation with more than 4 motor units at

one voltage source.

The output filters must be selected as recommended by the con-

verter manufacturer or filter supplier, respectively.

The pumps must be operated at a max. of 95 % of their rated motor

speed if the frequency converter causes motor losses.

The following limit values at the pump connection terminals must not

be undershot if TOP-S/-SD, TOP-D and TOP-Z Series glandless

pumps are operated in conjunction with a frequency converter:

Umin = 150 V

fmin = 30 Hz

Minimum flow volumeLarger pumps require a minimum flow volume to ensure trouble-free

operation. Operation against closed gate valves, flow volume Q = 0,

can lead to overheating inside the dry well and damage to the shaft

seal.

- Constraints on pump operation when Q = 0:

Permitted operating temperature 10 K less than Tmax

- to P2 = 1 kW unproblematic

- starting with P2 > 1 kW continuous operation, a minimum flow

volume of

Q = 10 % QNom is required

Further information in special cases on request.

Motor protectionService life and operational reliability of a circulating pump depend to

a great extent on the choice of the correct motor protection device.

Motor protection switches are unsuitable for utilisation in conjunc-

tion with multi-speed pumps due to their different nominal current

ratings at different speed settings which require correspondingly dif-

ferent fuse protection.

All circulating pumps are either

- blocking current-proof

- provided with internal protection against unacceptably high winding

temperatures

- provided with full motor protection in the form of thermal winding

contacts (WSK) and a separate Wilo tripping unit (e.g. Wilo-SK 602/

SK 622)

- equipped with full motor protection and a fully integrated trip

mechanism (Wilo-Stratos Series, Wilo-TOP Series, except TOP-D,

see pump data).

No further motor protection by the customer is required except

where this is stipulated for blocking current-proof motors and

motors with internal protection against unacceptably high winding

temperatures by the energy supply company.



Sound pressure levelThe construction of the glandless pumps is the reason for their low-

noise operation. Its air-borne noise values with measuring-surface

sound pressure level Lp (A) [dB] depend on the motor power output

and are determined under normal operating conditions.

Fig.: Sound pressure level of glandless pumps, determined in accordance with DIN EN ISO 3745

Heat insulation with heating applicationsAll Wilo-Stratos/Stratos-Z, Wilo-TOP-E/-S/-Z/-D and Stratos ECO

single-head pumps are standard-equipped with thermal insulation

shells for the prevention of thermal losses at the pump housing.

Material: EPP, polypropylene foam

Thermal conductivity: 0.04 W/m K in accordance with DIN 52612

Flammability: Class B2 in accordance with DIN 4102; FMVSS 302

When insulating the pump on-site, care must be taken to cover the

pump up to the top edge of the pump housing only (the motor must

be left uncovered).

Thermal insulation for air-conditioning/cooling applicationsIf pumps from the following series:

- Stratos, Stratos-D, Stratos-Z

- TOP-S/-SD

- TOP-D

- TOP-Z

- TOP-RL

- SE/SE-TW

are utilised in air-conditioning/cooling applications, no vapour-proof

insulation is permitted to cover the drain labyrinth between the pump

housing and the motor. This is to ensure that any condensate having

possibly accumulated in the motor can drain off freely through the

condensate drain openings in the motor housing.

The Wilo-ClimaForm vapour-proof insulation that is obtainable as an

accessory for the Stratos, TOP-S, TOP-RL and SE series for insulating

pump housings in cold water applications guarantees this automati-

cally, thanks to its specific construction.

Wilo-ClimaForm:

- Water vapour diffusion resistance t 7000- Normal flammability, in accordance with DIN 4102-B2, Part 1

- Quality-monitored in accordance with DIN 18200

Quality and safety marks

For pump types:

Star-E 25/ ..., -E 30/ ...,

Stratos ECO

Star-RS 25/ ..., -RS 30/ ...,

RSD 30/ ..., Star-Z 20/1, -Z 25/6, Star-ZE 25/ ...,

Rp 25/60-2

Certificate of conformity/acceptance test certificateAvailable upon request at additional charge for all glandless circulat-

ing pumps of the series

- Stratos, Stratos-D, Stratos-Z

- TOP-E/-ED

- TOP-S/-SD

- TOP-D

- TOP-Z

- TOP-RL

- P/RP (not RP 25/60-2)

- DOP

- SE/SE-TW

- Certificate of conformity 2.1Contents: Certification that the product supplied conforms to the

order, without details of test results.

- Certificate of conformity 2.2Contents: Certification that the product supplied conforms to the

order, with details of series test results.

- Acceptance test certificate 3.1BContents: Certification that the product supplied conforms to the

order, with details of test results actually measured on the product.

The required test procedure and scope must be specified with the

order.

60

50

40

20

30

10

010 20 50 100 200 500 1000 2000 5000

WRate motor output P2

Lp (A) [dB], 2-pole standard pumps (max. 2900 1/min.) and Stratos seriesLp (A) [dB], 4-pole standard pumps (max. 1450 1/min.) and TOP-E series

3000

[dB]

11



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1) For installation positions for Wilo-Stratos/-Stratos-Z/-Stratos-D/-Stratos-ZD, refer to Planning Guide High-Efficiency Pumps

Non-standard versionsPumps for other voltages or 60 Hz frequency possible on request (at

additional charge).

Other materials and design versions (RG, PN 16) for pumps are listed

in the pump tables.

The glandless circulating pumpWith this design, all of the rotating components inside the canned

motor run in the fluid being pumped. Shaft sealing by means of a

stuffing box or mechanical seal as required with conventional pumps

is not required. The pumped fluid lubricates the shaft bearings and

cools the electric-motor components.

The electrical section of the pump motor (stator with winding) is

separated from the encapsulated rotor compartment by means of an

encapsulated motor cartridge (TOP-Wilo Series) or by a can sealed

with O-rings.

Installation positions for glandless pumps1)

Installation positions not permitted

Permitted without limitationAll energy-saving pumps,

stepless control

Permitted without limitationAll standard and potable water circulators,

1-, 3- or 4-speed stages

Additional terminal box positions for single and twin-head pumps

Pump types

Energy-saving pumps

Star-E 20 (25, 30) TOP-E 25 (30)/1-7TOP-E 30/1-10TOP-E 40/1-4TOP-E 50/1-6

TOP-ED 32/1-7TOP-ED 40/1-7TOP-ED 50/1-6

Standard and potable water circulators

Star-RS, Star-ZRP 25/60-2

Stratos ECO-Z Star-RSD

Install pumps under voltage-free conditions. Valid for all operating conditions.TOP-ED twin-head pumps can not be utilised for additional installation units because of the tilted alignment of the terminal boxes.If in doubt, please contact Wilo.

Impeller

Winding

Rotor

Bearings

Spacer can

Pumping medium

Hydraulic seal


Planning GuideConnection Notes Wilo-TOP and Wilo-Stratos

Connection of Wilo-TOP... and -Stratos ... to Wilo switchgears present on-site


Newpump

type

Switchgear connectionpossible as per circuit diagram

Accessories: Modules

Wilo-IF-ModuleAC

Existing Wilo switchgear

Wilo-TOP-SWilo-TOP-Z

Wilo-TOP-RLWilo-SE

Wilo-TOP-SDWilo-SE-TW

or2 x Wilo-TOP-S2 x Wilo-TOP-Z

2 x Wilo-TOP-RL2 x Wilo-SE

Wilo-TOP-D Wilo-TOP-EStratos

Stratos-Z

Wilo-TOP-EDStratos-D

Stratos-ZDor

2 x TOP-E2 x Stratos

2 x Stratos-Z

Wilo-TOP-EStratos

Stratos-Z

Wilo-TOP-EDStratos-D

Stratos-ZD or2 x TOP-E2 x Stratos

2 x Stratos-Z

1~ 3~ 1~ 3~ 1~ 3~ 1~ 1~ 1~ 1~

IS WSKSSM

IS SSM IS WSKSSM

IS SSM IS WSK IS WSK

SK 601 A B C 1) D 1) A B G 1) D 1) U W Y 1) Z E E Yes Yes

SK 602/622 F G H I F G H I V X Y1 Z1 J J Yes Yes

SK 632 K L K L K L Yes Yes

S2R 0,2-1Switchgear not suitable with pumps of the Wilo-TOP series. Alternatively use exchange motor for faulty pump.

S2R 2,5

S2R 3D M N o P Q or R Yes Yes

S4R 2,5Switchgear not suitable with Wilo-TOP series. Alternatively use exchange motor for faulty pump.

S4R 2.5D

AS 08/1.5(P) S T

2 Pcs.AS 08/1.5(P)

S T

AS 08/1.5(P)plus S2R 3D

N + S P + T

AR/DR/CR T T

IS: Internal protection against unacceptably high winding temperatures, WSK: Thermal winding contacts, SSM: Collective fault signal

= Connection not possible, 1) Only in conjunction with contactor or Wilo-SK 602/622; SK602/622 also can be used as On/Off switch or contactor

Circuit diagram A Mains 1~230 V/N/50 Hz

Circuit diagram BMains 1 ~230 V/N/50 Hz

Circuit diagram CMains 3 ~400 V/N/50 Hz

1) Wilo-TOP-S/-Z/-SD/-RLWilo-SE/SE-TW

1) 3) Wilo-TOP-S/-Z/-SD 1) 3) Wilo-TOP-S/-Z/-SD

1) Automatic restart after power failure2) After an overload fault trip of the pump (TOP or Stratos), confirm fault first at the pump, then at the switchgear3) SK 622 additionally with terminals for collective operation and fault signals

Ensure correct grounding when replacing a three-phase pump (3~400 V) with an AC pump (1~230 V).

Consult your Wilo representative prior to installation of Wilo pumps in conjunction with non-listed Wilo switchgears or switchgears not supplied by Wilo.For circuit diagrams for Wilo circulating pumps, refer to the Service/Accessories chapter or to the pump data.

N

SK 601

NL PE

PE PEL1 N N 2

L

PE

PE

L1

U

L2

V

L3

W

N

PE L1 N

N

N

15

L N WSK

1

10

2

10 11WSK

SK 602SK 622

SK 601

N PE

PE PEL1 N N 2

PE

PE

L1

U

L2

V

L3

W

N

PE L1 L2 L3 N

N

N

15

L2L1 L3

1

10

2

10 11WSK

SK 602SK 622

SK 601

N PE

PE PEL1 N N 2

13




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Circuit diagram DMains 3 ~400 V/N/50 Hz

Circuit diagram EMains 1~230 V/N/50 Hz

Circuit diagram FMains 1~230 V/N/50 Hz

1) 2) 3) Wilo-TOP-S/-Z/-SD 1) Wilo-TOP-E/-EDWilo-Stratos/-Z/-D/-ZD


Circuit diagram GMains 3~400 V/N/50 Hz

Circuit diagram HMains 3~400 V/N/50 Hz

Circuit diagram IMains 3~400 V/N/50 Hz

1) 3) Wilo-TOP-S/-Z/-SD 1) Wilo-TOP-S/-Z/-SD 1) 2) 3) Wilo-TOP-S/-Z/-SD

Circuit diagram JMains 3~400 V/N/50 Hz or 1~230 V/N/50 Hz

Circuit diagram KMains 3~400 V/N/50 Hz

Circuit diagram LMains 3~400 V/N/50 Hz

1) 2) 3) Wilo-TOP-E/-EDWilo-Stratos/-Z/-D/-ZD

1) Wilo-TOP-S/-Z/-SD 1) 2) Wilo-TOP-S/-Z/-SD




PE

PE

L1

U

L2

V

L3

W

N

PE L1 L2 L3 N

N

N

15

L2L1 L3 SSM

1

10

2

10 11WSK

SK 602SK 622

SK 601

N PE

PE PEL1 N N 2

N

SK 601

NL PE

PE PEL1 N N 2

L SSM

PE

PE

L1

U

L2

V

L3

W

N

PE L N

N

N

15

L N

1

10

2

10 11WSK

SK 602SK 622

PE

PE

L1

U

L2

V

L3

W

N

PE L N

N

N

15

1

10

2

10 11WSK

SK 602SK 622

L N WSK

PE

PE

L1

U

L2

V

L3

W

N

PE L1 L2 L3 N

N

N

15

L2L1 L3

1

10

2

10 11WSK

SK 602SK 622 PE

PE

L1

U

L2

V

L3

W

N

PE L1 L2 L3 N

N

N

15

L2L1 L3 SSM

1

10

2

10 11WSK

SK 602SK 622

PE

PE

L1

U

L2

V

L3

W

N

PE L1 L2 L3 N

N

N

15

L N SSM

1

10

2

10 11WSK

SK 602SK 622 PE

PE

L1

U

L2

V

L3

W

PE L1 L2 L3

N 15

L2 L3L1

10 10 11WSK

SK 632PE

PE

L1

U

L2

V

L3

W

PE L1 L2 L3

N 15

L2 L3L1

10 10 11WSK

SK 632

SSM




Circuit diagram MMains 1~230 V/N/50 Hz

Circuit diagram NMains 1~230 V/N/50 Hz

Circuit diagram OMains 3~400 V/N/50 Hz


1) Wilo-TOP-S/-Z/-SD 1) Wilo-TOP-S/-Z/-SD

Circuit diagram PMains 3~400 V/N/50 Hz

Circuit diagram QMains 3~400 V/N/50 Hz

Circuit diagram RMains 1~230 V/N/50 Hz

1) 2) Wilo-TOP-S/-Z/-SD 1) 2) Wilo-TOP-E/-EDWilo-Stratos/-Z/-D/-ZD

1) 2) Wilo-TOP-E/-EDWilo-Stratos/-Z/-D/-ZD

Circuit diagram S Mains 1~230 V/N/50 Hz

Circuit diagram T Mains 3~400 V/N/50 Hz

Circuit diagram U Mains 1~230 V/N/50 Hz

1) Wilo-TOP-S/-Z/-SD 1) 2) Wilo-TOP-S/-Z/-SD 1)




PE

PE

L1

U

L2

V

L3

W

N

PE L N

N 15

L N

10 11 WSK

S2R 3D

1

2

PE

PE

L1

U

L2

V

L3

W

N

PE L N

N 15

L N WSK

10 11WSK

S2R 3D

1

2

PE

PE

L1

U

L2

V

L3

W

PE L1 L2 L3

N 15

L2 L3L1

10 11WSK

S2R 3D

1

2

N

N

PE

PE

L1

U

L2

V

L3

W

PE L1 L2 L3

N 15

L2 L3L1 SSM

10 11WSK

S2R 3D

1

2

N

N

PE

PE

L1

U

L2

V

L3

W

PE L1 L2 L3

N 15

NL1 SSM

10 11WSK

S2R 3D

1

2

N

N

PE

PE

L1

U

L2

V

L3

W

PE L1

N 15

NL1 SSM

10 11WSK

S2R 3D

1

2

N

N

PE

PE

L1

U

L2

V

L3

W

PE L

N 15 10 WSK

AS 08N

N

N L WSK/SSM

PE

PE

L1

U

L2

V

L3

W

PE L1 L2 L3

N 15

L3L1 L3 SSM

10WSK

AS 08/1,5AR/DR/CR N

N

SK 601

TOP-D

NL1 PE

PE PEL1 N N 2

U1 V1 W1

W2 U2 V2

15




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Circuit diagram V Mains 1~230 V/N/50 Hz

Circuit diagram W Mains 1~230 V/N/50 Hz

Circuit diagram X Mains 1~230 V/N/50 Hz

1) 1) 3) 1) 3)

Circuit diagram Y Mains 3~400 V/N/50 Hz

Circuit diagram Y1Mains 3~400 V/N/50 Hz

Circuit diagram Z Mains 3~400 V/N/50 Hz

1) 3) 1) 1) 3)

Circuit diagram Z1Mains 3~400 V/N/50 Hz

1) 3)

TOP-D U1 V1 W1

W2 U2 V2

PE

PE

L1

U

L2

V

L3

W

N

PE L1 N

N

N

15

1

10

2

10 11WSK

SK 602SK 622

TOP-D U1 V1 W1

W2 U2 V2

PE

PE

L1

U

L2

V

L3

W

N

PE L1 N

N

N

15

1

10

2

15 10

10 11WSK

WSK

SK 602SK 622

SK 601

N PE

PE PEL1 N N 2

TOP-D U1 V1 W1

W2 U2 V2

PE

PE

L1

U

L2

V

L3

W

N

PE L1 N

N

N

15

1

10

2

15 10

10 11WSK

WSK

SK 602SK 622

TOP-D U1 V1 W1

W2 U2 V2

PE

PE

L1

U

L2

V

L3

W

N

PE L1 N

N

N

15

1

10

2

10 11WSK

SK 602SK 622

L2 L3

SK 601

N PE

PE PEL1 N N 2

TOP-D U1 V1 W1

W2 U2 V2

PE

PE

L1

U

L2

V

L3

W

N

PE L1 N

N

N

15

1

10

2

10 11WSK

SK 602SK 622

L2 L3

PE

PE

L1

U

L2

V

L3

W

N

PE L1 N

N

N

15

1

10

2

15 10

10 11WSK

WSK

SK 602SK 622

L2 L3

SK 601

N PE

PE PEL1 N N 2

TOP-D U1 V1 W1

W2 U2 V2

PE

PE

L1

U

L2

V

L3

W

N

PE L1 N

N

N

15

1

10

2

15 10

10 11WSK

WSK

SK 602SK 622

L2 L3

TOP-D U1 V1 W1

W2 U2 V2


Planning GuideIdentification Code

Nameplate designation for Wilo-Stratos Series

Standard versionSeries abbreviations for Wilo-Stratos products

Type:Wilo-...

Design

StratosStratos-DStratos-Z

Stratos-ZD

High-efficiency pumpsstepless speed control:Individual pumpTwin-head pumpIndividual pump for potable water circulation systemsTwin-head pump for pota-ble water circulationsystems

Nameplate designation for Wilo-TOP-Programme series

Standard versionSeries abbreviations for Wilo-TOP products

Type:Wilo-...

Design

TOP-ETOP-ED

Energy-saving pumps,stepless speed control:Single-head pumpTwin-head pump

TOP-S/-RL, SETOP-SD, SE-TW

Standard pumps2 or 3 speed stages:Single-head pump

Twin-head pump

TOP-D

Standard pumps1 speed stage:Single-head pump

TOP-Z

Circulating pumps for potable water circulation systems3 speed stages: Single-head pump

Typ Stratos 40/1-8Art.-No.2030570/0601

1~230 V50 Hz

Class F IP 44 PN 6/10Tmax.110C SW 3.06

Made by WILO WILO AG Nortkirchenstr.10044263 Dortmund Germany

S/N70000100008

310 1,37

18 0,17

Insulation classProtection class IPPN = nominal pressure d. PumpTmax = max. fluid temperatureSW = Software Version

VoltageFrequency

Maximum power consumptionMaximum current I

Series/Pump type

Art. No./Date of Manufacture 06 01

Month Year

Sequential numbering

Typ TOP-E50/1-6Art.-No.-2039649/0601

1~230 V50 Hz

SW 4.00

Made by WILOWILO AG Nortkirchenstr.100 44263 Dortmund Germany

Class F IP 43

S/N20000100004

PN 6/10 Tmax 110C

390 1,70

70 0,35

Insulation classProtection class IPPN = nominal pressureof the pumpmax. fluidstemperature Tmax

VoltageFrequencyThree-phase current 3~400V or 3~230V with switching plug 230VSW = Software Version

Maximum current IMaximum power consumption

Series/Pump type

Art. No./Date of Manufacture 06 01

Month

Year

Sequential numbering

17



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Non-standard versionsSeveral pumps can be supplied in the following non-standard versions at additional charge, if desired

(the type of the special version is marked on the name plate):

- PN 10 Maximum permitted pump operating pressure- RG Red bronze version

Example:Star-RS 25/4 RG = Star-RS 25/4 with red-bronze housing

Nameplate designation Wilo-Star, Wilo-Stratos ECO

Standard versionSeries abbreviations for Wilo-Star and Wilo-Stratos ECO products.

Type:Wilo-...

Design

Star-E

Energy-saving pumpsStepless speed control:Single-head pump

Star-RSStar-RSDStar-RSL

Standard pumps3 speed stages:Single-head pumpTwin-head pumpVenting pump

Potable water circulators:

Star-Z Single-head pumps, 1 or 3 speed stages

Stratos ECO Individual pump in high-effi-ciency design

Stratos ECO-Z

Individual pump in high-effi-ciency design for potable water circulation systems

Art.-No. 4032954/0503Star-RS 25/4

1 ~ 230 V50 Hz27-68 WImax 0,28 APN 10TF 110IP 44

WILO AGNortkirchenstr.100 44263 Dortmund Germany

VoltageFrequencyPower consumptionMaximum current IPressure stage PNMaximum fluid temperature TmaxProtection class

Series/Pump type

Art. No./Date of Manufacture 05 03 Month

Year



Type keyHigh-efficiency pumpsExample: Wilo-Stratos 30/1-12

Energy-saving pumpsExample: Wilo-Star-E 25/1-5 SSM,

Wilo-TOP-E 50/1-6

Standard pumps, max. 2800 1/minExample: Wilo-Star-RS 25/6

Wilo-TOP-S 50/4

Standard pumps, max. 1400/1 minExample: Wilo-RP 25/80 r,

Wilo-TOP-D 40

StratosScrew-end or flange-end pump stepless elec-

tronic control

Stratos-DFlange twin-head pump stepless elec-

tronic control

Stratos-ZScrew-end or flange-end pump for potable water circulation systems

stepless elec-tronic control

Stratos-ZD

Flange twin-head pump for potable water circulation systems


Stratos ECO

Screw-end pump in Economy ver-sion, specially for 1-6-family houses


Stratos ECO-Z

Screw-end pump in Economy ver-sion for potable water circulation systems

30/ Nominal connection diameter

1-12 Nominal delivery head range (m)

BMSVersion with Building Management System

STVersion with special hydraulics for utilisation in solar thermal installa-tions

L Venting pump

Star-EScrew-end pump stepless elec-

tronic control

Star-EPScrew-end pump with RG housing for floor heating


Star-ELScrew-end pump with connection for automatic ventilation


Star-ZEScrew-end pump for potable water circulation systems


TOP-EScrew-end or flange-end pump stepless elec-

tronic control

TOP-EDFlange twin-head pump stepless

electronic control


1-6 Nominal delivery head range (m)

SSM Version with collective fault signal

Star-RSScrew-end pump 3 speed stages,

manually reversi-ble

Star-RSDScrew-end twin-head pump 3 speed stages,


Star-ZScrew-end pump for potable water circulation systems

1/3Speed stages,manually reversi-ble

Star STScrew-end pump for solar thermal 3 speed stages,


Star-ACScrew-end pump for air-condition-ing/cooling

3 speed stages, manually reversi-ble

TOP-SScrew-end or flange-end pump 2 or 3 speed

stages, manually reversible

TOP-RL SE

Screw-end or flange-end pump 3 speed stages, manually reversi-ble

TOP-ZScrew-end or flange-end pump for potable water circulation systems

3 speed stages, manually reversi-ble

TOP-SDFlange twin-head pump 2 or 3 speed

stages, manually reversible

SE-TWFlange twin-head pump 3 speed stages,



6Nominal delivery head (m) at Q = 0 m3/h

EM Version with single-phase AC motor

DM Version with three-phase AC motor

L Venting pump

RPScrew-end pump 3/4Speed stages,


PFlange-end pump 4 speed stages,


TOP-D Screw-end or flange-end pump 1 speed stage

DOPFlange twin-head pump 4 speed stages,


25 Nominal connection diameter

/80 Nominal impeller diameter

r 4-stage manual switching

19

Planning GuideEnergy efficiency classification


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Energy efficiency classification

Within the framework of the Kyoto Convention, European govern-

ments in particular are pursuing the goal of drastically reducing CO2emissions. Energy-specific designations, particularly for high-con-

sumption household devices such as washing machines and refriger-

ators, is prescribed as an important control element for providing the

end consumer with an aid for making decisions in favour of energy-

saving appliances.

Because of the fact that heating circulating pumps are numbered

among the biggest energy consumers in household use because of

their long running times, leading European heating pump manufac-

turers have voluntarily declared their intention of henceforth attach-

ing energy consumption labels to their heating pumps. This makes it

possible for users and end consumers to recognise, on the basis of an

already familiar classification system, to recognise whether a heating

circulating pump being utilised is especially energy-efficient.

The energy efficiency classification of heating pumps is carried out

through the application of a measurement technology procedure

that provides the Energy Efficiency Index (EEI). The smaller the EEI,

the less electrical energy the pump consumes and the better the

energy classification.

Tab.: Breakdown of the Energy Efficiency Index into 7 different Energy Classes

The following tables identify the associated Energy Class for all of the

heating pumps to be labelled, which can be seen to be incorporated

into the energy label on the packaging. In accordance with the letter-

ing system familiar from household appliances, A is the best possible

and G is the worst possible of the Energy Classes.

When comparing hydraulically similar pumps with different Energy

Classes, it should be recognised that adjacent Energy Classes differ

by approximately 22 percentage points in energy expenditure. A

pump of Energy Class A requires accordingly on average only around

33% of the electrical energy used by a Class D pump.

Even though the energy requirements of a Class A pump are them-

selves very high, high-efficiency Energy Class A pumps are neverthe-

less available for the entire performance spectrum ranging from

single-family houses to large buildings.

Fig.: Comparison of the energy consumptions of pumps with the same hydraulic output

Fig.: Energy label for heating circulating pumps,Example: Energy Class A

Energy Class Energy Efficiency Index

A EEI < 0.4

B 0.4 d EEI < 0.6

C 0.6 d EEI < 0.8

D 0.8 d EEI < 1.0

E 1.0 d EEI < 1.2

F 1.2 d EEI < 1.4

G 1.4 d EEI

0%

20%

40%

60%

80%

100%

120%

140%

160%

180%

A B C D E F G

Energy class

Rela

tive

pow

er c

onsu

mpt

ion


Planning GuideEEI Classifications

EEI Classification Single-head pumps/ twin-head pumps (area of application: single- and two-family houses)

Nominal diameterWilo-Stratos

ECO...EEI

ClassWilo-Star-E...

(EasyStar)

EEI Class

Wilo-Smart...EEI

ClassWilo-Star-RS...

(ClassicStar)

EEI Class

Wilo-Star-RSD...(ClassicStar)

EEI Class

DN 15 (Rp ) 15/1-3 15/4 B

15/1-5 15/6 C

DN 25 (Rp 1)

25/1-3 A 25/1-3 B 25/4 B 25/2 C

25/1-5 A 25/1-5 B 25/6 B 25/4 B

25/6 C

DN 30 (Rp 1 )30/1-3 A 30/1-3 B 30/4 B 30/2 C 30/4 D

30/1-5 A 30/1-5 B 30/6 B 30/4 B 30/6 D

EEI Classification Single-head pumps (area of application: multifamily houses, commercial applications)

Nominal diameterWilo-Stratos... EEI

ClassWilo-TOP-E... EEI

ClassWilo-TOP-S... EEI

ClassWilo-RP/P... EEI

Class

DN 25 (Rp 1)

25/1-6 A 25/1-7 C 25/5 EM/DM D/D RP 25/80 r EM/DM G/G

25/1-8 A 25/7 EM/DM D/D RP 25/100 r EM/DM F/E

25/10 EM/DM D/D

DN 30 (Rp 1 )

30/1-6 A 30/1-7 C 30/4 EM/DM D/D RP 30/80 r EM/DM G/F

30/1-8 A 30/1-10 C 30/5 EM/DM D/D RP 30/100 r EM/DM F/F

30/1-12 A 30/7 EM/DM D/D

30/10 EM/DM D/D

DN 32 32/1-12 A

DN 40

40/1-4 A 40/1-4 C 40/4 EM/DM D/D P 40/100 r EM/DM F/D

40/1-8 A 40/1-10 B 40/7 EM/DM D/C P 40/160 r E

40/1-12 A 40/10 EM/DM D/C

40/15 EM/DM D/D

DN 50

50/1-8 A 50/1-6 C 50/4EM/DM D/D P 50/125 r D

50/1-9 A 50/1-7 B 50/7EM/DM E/D P 50/160 r E

50/1-12 A 50/1-10 B 50/10 EM/DM D/C P 50/250 r E

50/15 C

DN 65

65/1-9 A 65/1-10 B 65/7 EM/DM F/D P 65/125 r D

65/1-12 A 65/10 EM/DM F/D P 65/160 r D

65/13 C P 65/250 r E

65/15 C

DN 80

80/1-12 A 80/1-10 B 80/7 EM/DM F/D P 80/125 r D

80/10 D P 80/160 r C

P 80/250 r E

DN 100100/1-12 A 100/1-10 B 100/10 D P 100/160 r E

P 100/200 r E

21

Planning GuideEEI Classifications


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EEI Classification Single-head pumps (range of applications: multifamily houses, commercial applications) (Continued)

Nominal diameterWilo-TOP-D... EEI Class Wilo-TOP-RL... EEI Class Wilo-AXL... EEI Class Wilo-SE... EEI Class

DN 25 (Rp 1) 25/7.5 E 80-25-130 D 125-N D

DN 30 (Rp 1 )

30 EM/DM G/F 30/4 D 110-N D

30/6.5 E

30/7.5 E

DN 32

DN 4040 EM/DM E/E 40/4 D 150-N D

200-N D

DN 5050 EM/DM E/E

DN 65 65 EM/DM E/E

DN 80 80 EM/DM E/E

DN 100 100 EM/DM E/E

DN 125 125 D

EEI Classification Twin-head pumps (area of application: multifamily houses, commercial applications)

Nominal diameterWilo-

Stratos-D....

EEI Class

Wilo-TOP-ED...EEI

ClassWilo-TOP-SD...

EEI Class

Wilo-DOP...EEI

ClassWilo-

SE-TW...EEI Class

DN 25 (Rp 1)

DN 30 (Rp 1 ) 30/5 EM/DM D/D 125-N-TW D

DN 3232/1-8 A 32/1-7 C 32/7 EM/DM E/D

32/1-12 A

DN 40

40/1-8 A 40/1-7 C 40/3 EM/DM E/D 40/100 r EM/DM F/E 150-N-TW E

40/1-12 A 40/1-10 B 40/7 EM/DM D/D 40/160 r F 200-N-TW E

40/10 EM/DM E/C

40/15 EM/DM E/D

DN 50

50/1-8 A 50/1-6 C 50/7 EM/DM F/C DOP 50/100 r D

50/1-12 A 50/1-7 B 50/10 EM/DM E/D 50/160 r E

50/1-10 C 50/15 D

DN 65

65/1-12 A 65/1-10 B 65/10 EM/DM F/D 65/125 r D

65/13 D 65/160 r D

65/15 D

DN 8080/1-12 A 80/1-10 B 80/7 EM F 80/125 r D

80/10 D 80/160 r E

DN 100 100/160 r D

DN 125


Planning GuideHigh-Efficiency Pumps

Wilo-Stratos/Stratos-Z/Stratos-D/Stratos-ZD

Planning guide:Wilo-Stratos/Stratos-Z/Stratos-D/Stratos-ZDWilo-Stratos is the first high-efficiency pump of glandless design

world-wide to feature the following advantages:

- up to 80 % energy savings compared to standard pumps

- for all heating, air-conditioning and cooling systems in the tempera-

ture range of -10 C to +110 C

- automatic adjustment of pump performance to the continually

changing hydraulic system load conditions

- preventing flow noise

- reliability and comfort during installation and operation

Fields Of applicationThe Wilo-Stratos series features high-efficiency pumps used in cir-

culation systems for the heating, ventilating, air conditioning of

commercial residential and functional buildings:

- Large residential buildings

- Apartment blocks

- Residential complexes

- Hospitals

- Schools

- Administrative office buildings

- Real-estate developments

Temperature rangeFluid temperature range of -10 C to +110 C without restrictions at

ambient temperatures of 0 C to a max. of + 40 C.

Heating applicationIn nearly all circulation systems, correctly sized controlled glandless

pumps ensure adequate heat supply at all times at significantly

reduced energy costs, while at the same time preventing noise gen-

eration.

Since the introduction of the German energy-saving ordinance (EnEV) of 01.01.2002, heating circulating pumps with nominal thermal outputs of 25 kW or more are required to include control units.On account of its corrosion-resistant red bronze pump housing,

Wilo-Stratos-Z are particularly suitable for systems subject to the

possible ingress of oxygen, such as e.g. floor heating systems made

of plastic piping.

Thermal insulation for heatingIn order to prevent thermal losses through the pump housing, Wilo-

Stratos/-Stratos-Z series single-head pumps are standard-equipped

with thermal insulation shells. The PP material used, foamed polypro-

pylene, has the following properties:

- Environmental compatibility: easily recyclable

- Heat resistance: up to 120 C

- Transmission coefficient: 0.04 W/mK according to DIN 52612

- Flammability: Class B2 4102in accordance with DIN (normal flamma-

bility)

In Germany, normally flammable materials can, in accordance with

fire protection regulations, be used in boiler rooms as long as a mini-

mum distance of 20 cm from the burner is maintained.

Air-conditioning/cooling applicationWilo-Stratos pumps are not subject to the usual restrictions on con-

ventional speed-controlled pumps regarding the dependency of fluid

temperature on ambient temperature.

Condensation takes place on cold surfaces if the fluid temperature is

lower than the ambient air temperature. Wilo-Stratos pumps can

nonetheless be used in such cases. They are constructed in such a

way that damage to electrical parts caused by condensation water is

prevented.

1 drain labyrinth for condensation water

Thermal insulation for air-conditioning/coolingIf vapour-proof insulation is installed on-site, care must be taken

that the drain labyrinth between pump housing and motor is left free

to ensure that any condensate having possibly accumulated in the

motor can drain off freely through the condensate drain openings in

the motor housing.

The Wilo-ClimaForm vapour-proof insulation that is obtainable as an

accessory for the Wilo-Stratos series for insulating pump housings in

cold water applications guarantees this automatically, thanks to its

specific construction.

Corrosion-proof pump designCorrosion-proof designs are required for e.g. radiant cooling or heat-

ing ceiling panels. For these applications, the pump housing is coated.

Alternatively, the Wilo-Stratos-Z can be used as the ultimate design

with a corrosion-resistant red bronze pump housing.

1

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Utilisation of potable water circulation (Wilo-Stratos-Z/Stratos-ZD)Pumps used in potable water circulation systems are subject to

specific requirements which are satisfied by the Wilo-Stratos-Z/

Stratos-ZD series:

- The fluids involved are potable water and water for food businesses

in accordance with the TrinkwV 2001 (German Potable Water Ordi-

nance). The design of the pumps take into account calcification in

such a way as to permit total carbonate hardness of 20d at a max.

fluid temperature of +80 C.

- All plastic parts that come into contact with the conveyed media

conform to the KTW recommendations.

- The differential-pressure control modes 'p-c and 'p-v allow auto-matic adjustment of pump performance in variable volumetric-flow

potable water circulation systems with thermostatically controlled

line shutoff valves.

- The manual control mode allows optimum manual adjustment of

pump performance to the constant volumetric-flow circulation sys-

tem. This can be performed for example with the Wilo-IR-Monitor.

The criterion for this is the temperature of the potable water in the

circulation pipe which upon entry into the potable water accumulator

is permitted to be a max. of 5 K below the accumulator temperature

High-Efficiency PumpsThe pump overall efficiency is determined by the hydraulic and motor

efficiencies. Both components have been doubled in the Wilo-

Stratos in comparison with the glandless pump previously used in

building engineering and thus significantly improved.

The applied ECM technology drastically reduces the annual power

consumption, achieving significant cost savings in comparison to

conventional pumps.

ECM technologyThe new ECM technology is the basis for the outstanding efficiency

of the Wilo-Stratos. It consists of:

EC motorEC stands for electronically commutated motor. Its basis is a syn-

chronous motor with a permanent magnet rotor. The rotating stator

flux is generated by electronic commutation, meaning that the stator

windings are specifically activated for the reciprocal action of the

electrical and magnetic poles.

Advantage: The magnetic field required in the rotor does not first

have to be generated with losses.

Advantage: Particularly in the partial-load range (up to 98% of the

operating time), the difference in efficiency in compari-

son with an asynchronous motor will be even greater

than it already is anyway in the full-load range.

Advantage: This motor can be operated at higher speeds than with

an asynchronous motor. This leads to a reduction in size

and weight of the pump with comparable hydraulics.

Wet rotor encapsulationThe rotor of the glandless pump motor runs in the pumping medium.

This fluid serves to lubricate the bearings and cool the motor.

The current-carrying stator is separated from the pumping medium

by a can, this being known as the wet rotor encapsulation.

This wet rotor encapsulation directly influences efficiency

- through the size of the necessary gap between stator and rotor,

- through the magnetic resistance of the selected can material.

- In this respect the efficiency improvement on the Wilo-Stratos

results from:

- reduction of the air gap and

- utilisation of an innovative can material with smaller losses to the

magnetic flux between stator and rotor.

Hydraulic optimisationOptimised hydraulic conditions are provided by a 3D spiral housing,

an 3D impeller and a smooth surface in the pump housing (cata-

phoretic painting).

The suction throat seal between impeller and pump housing reduces

radial gap losses. Axial losses are reduced by the lip seal at the front

of the impeller.

Planning GuideHigh-Efficiency PumpsWilo-Stratos/Stratos-Z/Stra-tos-D/Stratos-ZD

Annual power consumption of a heating pump (DN 30) with setback operation*

Comparison of different pump types

High-efficiency pump Stratos 30/1-12

Energy-saving pump TOP-E 30/1-10

Standard pump TOP-S 30/10

* Load profile with 5500 operating hours per year:

1832

0 1000 2000Power consumption [kWh/a]

1216

396

2% (110 hrs.) at 100% QN(peak load)25% (1375 hrs.) at 65% Q N(partial load)40% (2200 hrs.) at 30% Q N(low load)33% (1815 hrs.) setback operation

Wilo-Stratos with EC motor

Wilo-TOP-E with AC motor

Comparison of motor components




Automatic performance controlThe volumetric flow conveyed through a circulating pump is depend-

ent on the thermal output/cooling output requirement of the system

being supplied.

This requirement varies in accordance with

- climatic changes

- user behaviour

- external heat influence

- influence of hydraulic control devices, etc.

The circulating pump designed for max. load status is adapted by

means of a continuous setpoint/actual-value comparison to the rele-

vant system operating state. This automatic control functions serves

to adapt the pump performance and thus also the power consump-

tion continuously to the actual requirement/demand.

The sum total of all the measures described here enable the Wilo-

Stratos high-efficiency pumps to achieve energy savings of up to

80% in comparison with conventional standard pumps.

Automatic air ventingAir venting from the rotor space is effected automatically by the filter

and flow channel system. As the pumping medium flows into the

rotor space, a filter plug in the shaft and a filter disc in the bearing

plate reduce infiltration by miniscule abrasive particles.

The seal between impeller and bearing plate prevents dirt from accu-

mulating in the A-bearing gap on the motor side.

Advantage: The automatic venting of the rotor space is

accelerated, thus reducing the times of dry-

running and of air venting noise.

Advantage: Damage to the radial bearing or to the can

is reduced through this filtering-out process.

Motor protectionThe standard series integrated protection device reliably protects the

pump, in all settings, against overtemperature, excess current draw

and rotor locking.

Advantage: No external motor protection switch is required.

The instructions for electrical power connections pub-

lished by the local power supply companies are to be

taken into account.

If a motor protection switch is present in the electrical

installation in cases of replacements and can not be

bypassed, for example, then it is to be set to the max.

current allowed by the specifications listed on the

nameplate.

Manual operation

Control buttonThe Wilo-Stratos is operated by means of tried-and-tested Red But-

ton technology (1single-button operation). The important basic

functions can be set easily and safely, directly at the pump.

All-way (non-position-dependent) displayImportant information during pump operation can at all times be

obtained from the front-readable pump display screen with its posi-

tion-independent display.

Extension of the manual operating facilities for wireless communica-

tion can be obtained from the Wilo-IR-Monitor Operating and Service

Unit.

Fig.: All symbols can be read in horizontal or vertical set-up installation

3-D spiral

Suction throat seal

Lip seal

3-D impeller

Smooth inside surface

Lip seal

Impeller

A-bearing

Bearing plate

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Control modes

Control mode 'p-cIn the 'p-c control mode, the electronics circuitry maintains the dif-ferential pressure generated by the pump constant at the setpoint

value Hs over the permitted flow-rate range.

Fig.: Control mode 'p-c

Control mode 'p-vIn the 'p-v control mode, the electronic circuitry varies the differen-tial pressure to be maintained by the pump on a linear basis between

Hs and 1e2 Hs. The setpoint differential-pressure value H varies with the flow volume Q.

Fig.: Control mode 'p-v

Control mode 'p-TIn the 'p-T control mode (programmable only with the IR-Monitor) the electronics circuitry varies the setpoint differential pressure value

to be maintained by the pump as a function of the measured fluid

temperature. This temperature-prompted differential-pressure con-

trol mode can be used in constant-volume (e.g. one-pipe systems)

and variable-flow systems with varying feed temperature. Con-

versely, the 'p-T control mode supports condensing-boiler technol-ogy, provided the pump is installed in the return pipe of the system.

Fig.: Control mode 'p-T

Operating modes

Auto operating mode (setback function)

Fig.: Measurement of an electronic pump with automatic setback mode

The patented setback feature, by means of fuzzy control, further

optimises the power input requirements of the pump during periods

of low-load demand on heating systems. During periods where there

is no pump performance (e.g. reduction of feed temperature by

weather-/time-prompted heating controller) the pump performance

is set back to a reduced constant speed.

Advantage: This operating mode offers further savings of up to

25 % compared with previous stepless heating circu-

lating pumps.

Manual control modeThis operating mode deactivates the control function in the elec-

tronics module. The pump speed can be manually set to a constant

value (setting range, see pump motor data).

H max

H

H min

Hs

Q

H max

H

H min

Hs

Q

Hs1/2

H s min

H s

Hs var.

QQ min Q max

H s

T medT min T max

H s max

Pow

er c

onsu

mpt

ion

[%]

0

20

40

60

80

100

120

130

12:00 18:00 0:00 6:00 12:00 18:00 0:00 6:00 12:00 18:00

Time

0

10

20

30

40

50

60

65

Power consumption

Feed temperature

Feed

tem

pera

ture

[C

]




DDC operating modeIn this mode the actual/setpoint level assessment required for control

is referred to a remote controller. The Wilo-Stratos receives an ana-

logue signal (0 - 10V) from the external controller as the manipulated

variable. The current speed is shown on the pump display, manual

operation of the pump is deactivated.

Required accessory: IF-Modul Stratos (also see chapter Pump

Management Systems).

Remote setpoint adjustmentThe setpoint value for internal differential-pressure control ('p-c, 'p-v) is preset for the Wilo-Stratos by way of an analogue signal 0 - 10 V.

Required accessory: IF-Modul Stratos (also see chapter Pump Man-

agement Systems).

BA linkupThe Wilo-Stratos pump features standard and optional interfaces for

linkups to external monitoring units (e.g. BA building automation or

DDC stations).

Collective fault signal SSMA standard-equipped potential-free normally closed contact in

accordance with VDI 3814 is provided for collective fault signalling.

Contact rating: 250 VAC, 1A

Contacts are closed under the following conditions:

- the pump has zero current,

- no apparent fault is present,

- total breakdown of the control module

Contacts open under the following conditions:

- the pump is activated and one of the following faults exists:

Motor overtemperature

Control module overtemperature

excess current draw

Locking of shaft

Short circuit and fault to ground

Faulty contact between motor/module

Mains undervoltage

Mains overvoltage

Accessories

IF-Modul Stratos LON (also see chapter Wilo-Control Pump Management Systems).Retrofittable module with serial LON interface for connection to LON

networks and double pump interface for communication with

another IF-Modul PLR.

IF-Modul Stratos PLR(also see chapter Wilo-Control Pump Management Systems).Retrofittable module with serial PLR interface for connection to BA

building automation via Wilo interface converter or on-site coupling

modules and double pump interface for communication with another

IF-Modul PLR.

IF-Modul Stratos Ext. Aus(also see chapter Wilo-Control Pump Management Systems).Retrofittable module with control input Overriding Off, control

input 0 - 10 V and double pump interface for communication with

another IF-Modul PLR.

IF-Modul Stratos Ext. Min.(also see chapter Wilo-Control Pump Management Systems).Retrofittable module with control input Overriding Min. (setback

mode without autopilot), control input 0 - 10 V and double pump

interface for communication with another IF-Modul PLR.

IF-Modul Stratos SBM(also see chapter Wilo-Control Pump Management Systems).Retrofittable module with collective run signal SBM, control input

0 - 10 V and double pump interface for communication with another

IF-Modul SBM.

n[1/mn]

n max

n min

Off10U[V]1 32

H max

H min

Aus

H[m]

10U[V]1 32

Off

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Twin-head pump managementThe new high-efficiency pumps are suitable to operate under auto-

matic twin-head pump management without the use of external

switchgears: Required accessory: 2 pc. IF-Modul Stratos (for possible

module combinations, see catalogue section Wilo-Control Pump

Management Systems).

The following operating modes are possible thanks to intelligent

twin-head pump management with one Wilo-Stratos-D twin-head

pump or two Wilo-Stratos single-head pumps.

- Standby operationThe model-specific pump performance is provided by one pump, the

other pump remains available on standby for time changeover

(24hours of pure operating time) or fault-actuated switchover.

- Efficiency-optimised peak-load operationFor the peak duty operating mode the specified hydraulic duty is cov-

ered by the two units of the twin-head pump operating in parallel.

During low load operation (the base-duty pump only operating) the

trailing pump is ready for standby operation. It is automatically addi-

tionally started on efficiency-optimised operation if load conditions

require a higher pump performance. From this point onwards both

pumps will be synchronously run up to their max. speed (rated motor

speed).

A time-sensitive pump alteration feature (24 hours of pure operating

time) allocates the basic-load function to the different pumps in

alteration. This operating mode (load-sensitive On/Off control)

achieves further energy savings compared to the conventional peak-

load operation.

Infrared monitoringWilo-Stratos pumps are equipped with a powerful IR interface for

wireless remote operation control and fault diagnosis.

All the basic functions of the Stratos pumps can be manually adjusted

easily and directly at the pump (1-button operation).

Numerous additional functions and information are available with the

Wilo-IR-Monitor Operating and Service Unit. The main operating

function of the IR-Monitor corresponds to those at the pump itself. It

is however supplemented by some important additional functions

which essentially exceed those available at the pump.

The Wilo-IR-Monitor operating and service unit for:

- inaccessibly installed pumps

- comprehensive information

- special settings/control modes for special requirements

- protection against unauthorised access

- Rotation test unit for all kinds of pumps and IEC standards motors

Application in compact manifoldsIn narrow and low-clearance situations the control module can be put

in a vertical position by turning the motor. Dimension b4 serves as

the minimum clearance (x) for application of thermal insulation shells

(see chapter Dimensions, Weights).

Fig.: Simplified illustration, installation dimensions of additional fittings must be allowed for.

0

200

400

600

800

1000

1200

1400

05 10 15 20 25 30 35 40

Q [m 3/h]

P1[

W]

Activation of peak-load operation

Q*

Synchronised operation (2 pumps)

Q* = Efficiency-optimised

Wilo Circulation Pumps

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