Wilo fluidcontrol Assembly Instructions Manual

Wilo-Fluidcontrol / - EK

D Montageanleitung
GB Assembly Instructions
F Notice de montage
NL Inbouw- en gebruikshandleiding
E Instrucciones de instalación y funcionamiento
I Istruzioni di montaggio, uso e manutenzione

2 049 542 / ed04-0804

H Beépítési és üzemeltetési útmutató
GR Οδηγίες εγκατάστασης και λειτουργίας

6

5

3

2

4

1

12

Fig. 1

10 11 9 8

Fig. 2

Fig. 2

220-240 V
50 - 60 Hz

M

1

L1

Fig. 4

N

U

V

Fig. 5

7

Einbau- und
Betriebsanleitung

Installation and
operating instructions

Notice de montage et
de mise en service

Inbouw- en
gebruikshandleiding

……..6

……12

……18

……24

D

GB

F

NL

Instrucciones de instalación y
funcionamiento

Istruzioni di montaggio, uso e
manutenzione

Beépítési és
üzemeltetési útmutató

Οδηγίες εγκατάστασης
και λειτουργίας

……30

……36

……42

……48

E

I

H

GR

ENGLISH

1 General

Installation and service by qualified personnel only!

1.1 Application

The electronic control system Wilo-Fluidcontrol (... EK) can be screw-attached
to water supply and pressure booster pumps. It enables the automatic
operation of these pumps without use of a separate pressure vessel.

Product Information

1.2

1.2.1 Technical Data

Flow medium
Max. capacity
Max. working pressure
Switch on pressure
Max. water temperature:
Power supply:

F.L.C.
Enclosure:
Connections suction/discharge

clean water free of suspended matter
10 m3/h
10 bar

1.5 - 2.7 bar
60° C
Single phase

max. 10 A
IP 65
1" BSP

1~ 220-250V,
50-60 Hz

The shut-off head generated by the applicable pump must be approx. 0.5 bar
higher than the 2.2 bar switch-off pressure.

State all name plate data when ordering spare parts.

2 Safety Notes

These instructions contain basic rules on safety which must be strictly adhered
to on installation and operation. It is therefore imperative for the Installer and
the Operator to read these instructions prior to installation and commissioning.
Please observe, not only the general safety references listed under the main
heading SAFETY NOTES, but also those added to and specially highlighted
under the ensuing headers.

12 (55)

ENGLISH

2.1 Safety symbols contained herein

Safety notes contained herein which, if not strictly adhered to, may cause injury
to persons are specially highlighted by general danger symbol:

Warnings from electrical causes by the special symbol:

Safety references which, if not complied with, may result in damage to the plant
or its function are marked by the word:

ATTENTION!

2.2 Trade Qualifications

Only suitably qualified personnel may work on this equipment.

2.3 Hazards arising from non-compliance with safety notes

Non compliance with safety notes may cause bodily harm to persons or
damage to the plant. Failure to comply with safety notes may invalidate any
damage claims. Non-compliance may, for example, lead to the following
hazardous consequences:

● failure of vital plant functions,

● hazards to persons due to electrical and/or mechanical causes.

2.4 Safety notes for the Operator

Local regulations regarding the prevention of accidents must be observed.
Hazards from electrical energy must be excluded (conforming to local or
general regulations such as EC, BSI, UL, VDE, etc.).

2.5 Safety rules for inspections and installation work.

It is the Operator's responsibility to ensure that inspection and installation
works are carried out by authorized and qualified personnel only, after
having made themselves fully conversant with these instructions.

Work on this plant must on principle be carried out with the plant switched off
and completely pressure-relieved.

The safety valve must not be removed.

2.6 Arbitrary alterations and spare part procurement

Any alterations to the plant are only permitted with the manufacturers' consent.
Original and manufacturer authorized spare parts serve safety. The use of
other parts can invalidate any claims for consequential damages.

13 (55)

ENGLISH

2.7 Non-permissible operating conditions

Operational safety of the plant is conditional on it being used in accordance
with Chapter 1 of these instructions. Operational criteria must not exceed or
fall short of the limits stated in catalogue/data sheets.

3 Transport and Storage

ATTENTION!

During transport and intermediate storage it is necessary
to protect the WILO-Fluidcontrol from moisture and
mechanical damage.

The stock location must be dry and be frost-free.

4 Description of the Product

4.1 Description of the Device (Fig. 1 & 2)

1. Suction port with integrated non-return valve

2. Delivery port

3. Pressure gauge (0-10 bars) for control – possible mounting on right or left
side.

4. Electric box with electronic board including a protection against dry
running with motor stop and connection box for pump and network.

5. Hydraulic chamber with diaphragm.

6. Compensating chamber with spring.

7. Adjusting screw for starting pressure of the pump.

8. Reset button (Störungs-quittierung/Reset).

9. Indicator light of the voltage (Netz/Power on).

10. Indicator light for pump running (Pumpe in Betrieb/Pump on).

11. Indicator light for activating the safety device (Störung/Failure)

12. Pressure gauge axis

The WILO-Fluidcontrol is offered as ancilliary equipment for WILO water
supply pumps.

The unit must be screwed onto the pump or into the discharge pipe. It is of
Inline design, with both connections axially in line.

On ready standby, with all outlet fitting closed and under max. system pressure,
the yellow LED is on (pos. 9).

The unit contains a small buffer space filled with water which can be varied by
means of a spring-tensioned diaphragm. If an outlet tap in the system is
opened water will flow out of the small buffer volume into the discharge pipe,
lifting the float.

14 (55)

ENGLISH

The green diode (pos. 10) indicates normal pump operation.
The switch unit contains the electronic as well as the terminal block for power

supply and pump motor. The signal/operating elements at the switchbox cover
are (Fig. 2)

● Yellow LED: Mains power is on, the pump is on ready standby, (pos. 9)

● Green LED: Pump runs, (pos. 10)

● Red LED: Any fault leading to pressure loss in the

pipe system, (pos. 11)

● Reset button: After fault rectification the reset button (pos. 8) must be kept

pushed until the system is fully pressurized. This is also valid for renewed
start-up, otherwise the pump will again fail due to insufficient system
pressure.

4.2 Scope of Supply

● Wilo-Fluidcontrol (EK-series + integrated socket + 1.5 m connecting

cable).

● Installation and Operating Instructions.

5 Siting/Installation

5.1 Installation

For installation and mounting requirements refer to the pump installation and
operating instructions.

The arrow at the housing indicates direction of flow.
The WILO-Fluidcontrol must only be mounted into a vertically run discharge

pipe.

● The WILO-Fluidcontrol to be screwed onto the discharge port of the pump

using
suitable connecting fittings, to be sealed with hemp or Teflon band.

● If the water column between pump and highest outlet tap exceeds 15 m,

the unit must be installed at a higher level in the discharge pipe ensuring
a maximum vertical head onto the unit of not more than 15 m. In such
case no outlet tap must be located at a level below that of the WILO­Fluidcontrol (Fig. 3).

● In order to avoid noise transmission from the pump onto the pipe system

it is recommended to provide and install a flexible connector at the
discharge side of theWILO-Fluidcontrol.

15 (55)

ENGLISH

5.2 Electrical Wiring

All electrical site works to be carried out by qualified and
locally licenced electricians strictly in accordance with locally

● Check available power supply,

● take note of pump name plate data requirements,

● power wiring 3 x 1.5 mm". (Minimum cable size 6 mm, maximum 9 mm

OD).

● To ensure water tightness and pull-force relief from the cable glands the

power
cable must be of sufficient outside diameter (e.g. 05 VV-F 3 (7) G 1,5
oder AVMH-I 3 (7) x 1,5).

● All electrical wiring to be executed according to Fig.4.

● Supply side fuse: see as for pump; maximum however 10 A, inert.

ruling regulations.

● Strictly adhere to local earthing regulations.

● If required (see VDE 0100), a ground fault circuit interruptor (GFCI)switch

must be provided and installed by others.

6 Commissioning

For possibly required prestart and commissioning procedures for the pump
refer to the separate installation and Operating Instruction for the pump.

Before initial start-up it must be ensured that sufficient suction capability is
available and that the pump is primed and filled.

On initial start-up the pump will run for 8 seconds, after that a renewed start-up
can be effected by keeping the reset button pushed.

7 Maintenance

Warning!
Electrical Shock Hazard!

Prior to maintenance or repair work turn off the pump and
ensure that it is not turned on by unauthorised personnel.

16 (55)

ENGLISH

8 Faults, Causes

Fault Unit-related Cause Unit-unrelated Cause

Pump does not start - defect printed circuit board

- defect diaphragm

Pump does not stop - defect printed circuit board

- jammed flow controller - stuck
reset button

- Pump does not generate sufficient
pressure

Pump runs irregularly - defekt printed circuit board

- Pump does not generate sufficient
pressure (air)

Pump is jammed - defect printed circuit board

- pump generates pressure < start
pressure

- defect diaphragm

- refer to Installation & Maintenance
Instr. of the pump

- Power failure

- Pump capacity too low

- Pump mechanically jammed

- WILO-Fluidcontrol wrongly
connected

- Lack of water at suction side

- Leakage loss greater than 0.6
l/min

- Leakage loss greater than 0.6
l/min

- Lack of water at suction side

- Pump capacity too low

If the fault cannot be located or rectified, please contact your nearest
Wilo representative.

Technical modifications reserved!

17 (55)

WILO AG
Nortkirchenstraße 100
44263 Dortmund
Germany
T [phone]
F [phone]
www.wilo.com

Algeria

Bad Ezzouar, Dar El
Beida
T [phone]
chabane.hamdad@
salmson.fr

Armenia

375001 Yerevan
T [phone]
[e-mail]

Bosnia and
Herzegovina

71000 Sarajevo
T [phone]
zeljko.cvjetkovic@
wilo.ba

Georgia

0177 Tbilisi
T [phone]
[e-mail]

Macedonia

1000 Skopje
T [phone]
valerij.vojneski@
wilo.com.mk

Moldova

2012 Chisinau
T [phone]
[e-mail]

Rep. Mongolia

Ulaanbaatar
T [phone]
[e-mail]

Tajikistan

734025 Dushanbe
T [phone]
[e-mail]

Turkmenistan

744000 Ashgabad
T [phone]
[e-mail]

Uzbekistan

700046 Taschkent
[e-mail]

January 2008

Wilo – International (Subsidiaries)

Wilo – International (Representation offices)

Argentina

WILO SALMSON
Argentina S.A.
C1270ABE Ciudad
Autónoma de Buenos
Aires
T [phone]
[e-mail]

Austria

WILO Handelsges.
m.b.H.
1230 Wien
T [phone]
[e-mail]

Azerbaijan

WILO Caspian LLC
1065 Baku
T [phone]
[e-mail]

Belarus

WILO Bel OOO
220035 Minsk
T [phone]
[e-mail]

Belgium

WILO SA/NV
1083 Ganshoren
T [phone]
[e-mail]

Bulgaria

WILO Bulgaria Ltd.
1125 Sofia
T [phone]
[e-mail]

Canada

WILO Canada Inc.
Calgary, Alberta T2A 5L4
T [phone]
[e-mail]

China

WILO China Ltd.
101300 Beijing
T [phone]
[e-mail]

Croatia

WILO Hrvatska d.o.o.
10090 Zagreb
T [phone]
[e-mail]

Czech Republic

WILO Praha s.r.o.
25101 Cestlice
T [phone]
[e-mail]

Denmark

WILO Danmark A/S
2690 Karlslunde
T [phone]
[e-mail]

Estonia

WILO Eesti OÜ
12618 Tallinn
T [phone]
[e-mail]

Finland

WILO Finland OY
02330 Espoo
T [phone]
[e-mail]

France

WILO S.A.S.
78390 Bois d'Arcy
T [phone]
[e-mail]

Great Britain

WILO (U.K.) Ltd.
DE14 2WJ Burton­Upon-Trent
T [phone]
[e-mail]

Greece

WILO Hellas AG
14569 Anixi (Attika)
T [phone]
[e-mail]

Hungary

WILO Magyarország
Kft
2045 Törökbálint
(Budapest)
T [phone]
[e-mail]

Ireland

WILO Engineering Ltd.
Limerick
T [phone]
[e-mail]

Italy

WILO Italia s.r.l.
20068 Peschiera
Borromeo (Milano)
T [phone]
[e-mail]

Kazakhstan

WILO Central Asia
050002 Almaty
T [phone]
[e-mail]

Korea

WILO Pumps Ltd.
621-807 Gimhae
Gyeongnam
T [phone]
[e-mail]

Latvia

WILO Baltic SIA
1019 Riga
T [phone]
[e-mail]

Lebanon

WILO SALMSON
Lebanon
12022030 El Metn
T [phone]
[e-mail]

Lithuania

WILO Lietuva UAB
03202 Vilnius
T [phone]
[e-mail]

The Netherlands

WILO Nederland b.v.
1948 RC Beverwijk
T [phone]
[e-mail]

Norway

WILO Norge AS
0901 Oslo
T [phone]
[e-mail]

Poland

WILO Polska Sp. z.o.o.
05-090 Raszyn
T [phone]
[e-mail]

Portugal

Bombas Wilo-Salmson
Portugal Lda.
4050-040 Porto
T [phone]
[e-mail]

Romania

WILO Romania s.r.l.
077040 Com. Chiajna
Jud. Ilfov
T [phone]
[e-mail]

Russia

WILO Rus ooo
123592 Moscow
T [phone]
[e-mail]

Saudi Arabia

WILO ME - Riyadh
Riyadh 11465
T [phone]
[e-mail]

Serbia and
Montenegro

WILO Beograd d.o.o.
11000 Beograd
T [phone]
[e-mail]

Slovakia

WILO Slovakia s.r.o.
82008 Bratislava 28
T [phone]
[e-mail]

Slovenia

WILO Adriatic d.o.o.
1000 Ljubljana
T [phone]
[e-mail]

South Africa

Salmson South Africa
1610 Edenvale
T [phone]
errol.cornelius@
salmson.co.za

Spain

WILO Ibérica S.A.
28806 Alcalá de
Henares (Madrid)
T [phone]
[e-mail]

Sweden

WILO Sverige AB
35246 Växjö
T [phone]
[e-mail]

Switzerland

EMB Pumpen AG
4310 Rheinfelden
T [phone]
[e-mail]

Taiwan

WILO-EMU
Taiwan Co. Ltd.
110 Taipeh
T [phone]
nelson.wu@
wiloemutaiwan.com.tw

Turkey

WILO Pompa Sistemleri
San. ve Tic. A.S¸.
34530 Istanbul
T [phone]
[e-mail]

Ukraina

WILO Ukraina t.o.w.
01033 Kiew
T [phone]
[e-mail]

Vietnam

Pompes Salmson
Vietnam
Ho Chi Minh-Ville
Vietnam
T [phone]
[e-mail]

United Arab Emirates

WILO ME - Dubai
Dubai
T [phone]
[e-mail]

USA

WILO-EMU USA LLC
Thomasville,
Georgia 31792
T [phone]
[e-mail]

USA

WILO USA LLC
Melrose Park,
Illinois 60160
T [phone]
mike.easterley@
wilo-na.com

WILO AG
Nortkirchenstraße 100
44263 Dortmund
Germany
T 0231 4102-0
F 0231 4102-7363
[e-mail]
www.wilo.de

G1 Nord

WILO AG
Vertriebsbüro Hamburg
Beim Strohhause 27
20097 Hamburg
T 040 5559490
F 040 55594949
[e-mail]

G2 Ost

WILO AG
Vertriebsbüro Berlin
Juliusstraße 52–53
12051 Berlin-Neukölln
T 030 6289370
F 030 62893770
[e-mail]

G3 Sachsen/Thüringen

WILO AG
Vertriebsbüro Dresden
Frankenring 8
01723 Kesselsdorf
T 035204 7050
F 035204 70570
[e-mail]

G4 Südost

WILO AG
Vertriebsbüro München
Landshuter Straße 20
85716 Unterschleißheim
T 089 4200090
F 089 42000944
[e-mail]

G5 Südwest

WILO AG
Vertriebsbüro Stuttgart
Hertichstraße 10
71229 Leonberg
T 07152 94710
F 07152 947141
[e-mail]

G6 Rhein-Main

WILO AG
Vertriebsbüro Frankfurt
An den drei Hasen 31
61440 Oberursel/Ts.
T 06171 70460
F 06171 704665
[e-mail]

G7 West

WILO AG
Vertriebsbüro Düsseldorf
Westring 19
40721 Hilden
T 02103 90920
F 02103 909215
[e-mail]

Kompetenz-Team
Gebäudetechnik

WILO AG
Nortkirchenstraße 100
44263 Dortmund
T 0231 4102-7516
T 01805 R•U•F•W•I•L•O*

7•8•3•9•4•5•6

F 0231 4102-7666

Kompetenz-Team
Kommune
Bau + Bergbau

WILO EMU GmbH
Heimgartenstraße 1
95030 Hof
T 09281 974-550
F 09281 974-551

Werkskundendienst
Gebäudetechnik
Kommune
Bau + Bergbau
Industrie

WILO AG
Nortkirchenstraße 100
44263 Dortmund
T 0231 4102-7900
T 01805 W•I•L•O•K•D*

9•4•5•6•5•3

F 0231 4102-7126

Erreichbar Mo–Fr von
7–17 Uhr.
Wochenende und feier­tags 9–14 Uhr elektroni­sche Bereitschaft mit
Rückruf-Garantie!

– Kundendienst-

Anforderung
– Werksreparaturen
– Ersatzteilfragen
– Inbetriebnahme
– Inspektion
– Technische Service-

Beratung
– Qualitätsanalyse

Wilo-International

Österreich

Zentrale Wien:
WILO
Handelsgesellschaft mbH
Eitnergasse 13
1230 Wien
T [phone]
F [phone]

Vertriebsbüro Salzburg:
Gnigler Straße 56
5020 Salzburg
T [phone]
F [phone]

Vertriebsbüro
Oberösterreich:
Trattnachtalstraße 7
4710 Grieskirchen
T [phone]
F [phone]

Schweiz

EMB Pumpen AG
Gerstenweg 7
4310 Rheinfelden
T [phone]
F [phone]

Standorte weiterer
Tochtergesellschaften

Argentinien, Aserbaidschan,
Belarus, Belgien, Bulgarien,
China, Dänemark, Estland,
Finnland, Frankreich,
Griechenland, Großbritannien,
Irland, Italien, Kanada,
Kasachstan, Korea, Kroatien,
Lettland, Libanon, Litauen,
Niederlande, Norwegen,
Polen, Portugal, Rumänien,
Russland, Saudi-Arabien,
Schweden, Serbien und
Montenegro, Slowakei,
Slowenien, Spanien,
Südafrika, Taiwan,
Tschechien, Türkei, Ukraine,
Ungarn, Vereinigte Arabische
Emirate, Vietnam, USA

Die Adressen finden Sie
unter www.wilo.de oder
www.wilo.com.

Stand Januar 2008

Wilo-Vertriebsbüros in Deutschland

Erreichbar Mo–Fr von 7–18 Uhr.

– Antworten auf

– Produkt- und Anwendungsfragen

– Liefertermine und Lieferzeiten
– Informationen über Ansprechpartner vor Ort
– Versand von Informationsunterlagen

* 14 Cent pro Minute aus dem deutschen Festnetz

der T-Com. Bei Anrufen aus Mobilfunknetzen

sind Preisabweichungen möglich.