Xylem ECOCIRC XL User Manual

ecocirc XL
ecocirc XLplus

ELECTRONIC DRIVE MANUAL

1 Introduction

1
2
3

The electronic drive described in this manual controls
both ecocirc XL and ecocirc XLplus circulators; the
drive’s main features are:

 sensorless motor control
 sine wave modulated PWM
 2 micro-controllers:

one dedicated to motor control
one implementing the following features:

- several operating and control modes

- night mode operation

- 0-10V analog input signal control

- PWM input signal control1

- 4-20mA pressure sensor control

- external temperature sensor control2

- external start/stop signal control

- fault signal control

- connection to Modbus control

systems2

- connection to Bacnet control systems3

 multiple alarms and errors detection and

control

 multiple pump status indication
 optional Wireless module control2
 optional RS485 module control2

In the next chapters, a detailed description of ecocirc
XL family drives’ features will follow.

Only on plug-connected models, see 1.1
Only on ecocirc XLplus
Only on ecocirc XLplus terminal-connected models, see 1.1

Circulator model

Options

Electrical connection

ecocirc XL/XLplus 25-40

(B)

Plug

ecocirc XL/XLplus 25-60

(B)

Plug

ecocirc XL/XLplus 25-80

-

Terminal

ecocirc XL/XLplus 25-100

-

Terminal

ecocirc XL/XLplus 32-40

(B)

Plug

ecocirc XL/XLplus 32-60

(B)

Plug

ecocirc XL/XLplus 32-80

(F) (B)

Terminal

ecocirc XL/XLplus 32-100

(F) (B)

Terminal

ecocirc XL/XLplus 32-120 F

(D) (B)

Terminal

ecocirc XL/XLplus 40-80 F

(D)

Terminal

ecocirc XL/XLplus 40-100 F

(D)

Terminal

ecocirc XL/XLplus 40-120 F

(D) (B)

Terminal

ecocirc XL/XLplus 50-80 F

(D) (B)

Terminal

ecocirc XL/XLplus 50-100 F

-

Terminal

ecocirc XL/XLplus 50-120 F

(D) (B)

Terminal

ecocirc XL/XLplus 65-80 F

(D) (B)

Terminal

ecocirc XL/XLplus 65-120 F

(D) (B)

Terminal

ecocirc XL/XLplus 80-120 F

(D)

Terminal

ecocirc XL/XLplus 100-120 F

-

Terminal

All the subsequent circulators must be considered XLplus models

ecocirc XL 20-35

(B)

Terminal

ecocirc XL 36-45

(B)

Terminal

ecocirc XL 15-75

(B)

Terminal

ecocirc XL 55-45

(B)

Terminal

ecocirc XL 20-140

(B)

Terminal

ecocirc XL 65-130

(B)

Terminal

ecocirc XL 40-200

(B)

Terminal

ecocirc XL 70-145

(B)

Terminal

ecocirc XL 40-275

(B)

Terminal

ecocirc XL 95-125

(B)

Terminal

ecocirc XL 27-375

(B)

Terminal

ecocirc XL 105-155

(B)

Terminal

ecocirc XL 45-340

(B)

Terminal

1.1 Product Range

B = Bronze
F = Flanged
D = Twin

ecocirc XL /

XLplus

Voltage

rating

Nominal

max input

current

Recommen

ded line

protection

[A]

[A]

25-80

25-100

32-80

32-100

40-80
40-100
50-100

36-45

15-75

1 230V
50/60Hz

<2

3

32-120
40-120

50-80

65-80

55-45

1 230V
50/60Hz

<3

4

50-120
65-120
65-130

1 230V
50/60Hz

<5

6

80-120

100-120

70-145

1 230V
50/60Hz

<9

10

Plug

connector

M12 (1)

Cable Ø

2÷5mm

M12 (2)

Cable Ø

2÷5mm

Power supply

3x

0.75÷1.5
mm2
(2P+T)

Fault signal

2x

0.75÷1.5
mm2

- Analog 0­10V

- External
pressure
sensor

- External
temperature
sensor

- External
start/stop

If NO fault
signal on
this cable
gland.

Multi-wire
control
cable,
number of
wires
according
to number
of control
circuits.
Shielded if
necessary

Multi-wire
control
cable,
number of
wires
according
to number
of control
circuits.
Shielded if
necessary
Communicati
on bus

Bus cable

M20 Cable

Ø 5÷13mm

M16 (1)

M16 (2)

Power supply

3x

0.75÷2.5

mm2
(2P+T)

- Power
supply

- Fault signal

5x

0.75÷1.5

mm2
(4P+T)

Fault signal

2x

0.75÷1.5

mm2

2 Electrical installation

Power Supply: 1 x 230V ±10%, 50/60Hz
Check that the power supply line is provided with:

 A mains isolator switch with a contact gap of at

least 3mm

 A high-sensitivity (HS) 30mA differential switch

(RCD – Residual Current Device), suitable for
earth fault currents with DC or pulsating DC
content (preferably Type B).

 If an automatic circuit breaker (CB) is required,

use an automatic circuit breaker with C-type
characteristic curve.

a. Connect the ground (earth) lead; be sure

that the ground (earth) lead is longer than
the phase leads

b. Connect the phase leads

For cable requirements and organization of wiring
harness inside the cable glands, refer to par. 2.3

Wiring harness.

2.2 I/O connection

1. Open the terminal block removing the screws

2. Connect the appropriate cable according to the
terminal block diagram. See Figure 8, Figure 9 and
the requirements of par. 2.3 and 2.4.

2.3 Wiring harness

For plug-connected models

2.1 Power Supply connection

For plug-connected models, see Figure 6 and follow
the subsequent steps:

1. Open the connector cover and insert the cable
inside the cable gland

2. Pull down the contact retention spring

3. Connect the cable according to the wiring diagram

4. Align the two parts of the connector

5. Push the two parts one inside the other

6. Close the connector and tight carefully the cable
gland

For terminal-connected models, see Figure 5 and
follow the subsequent steps:

1. Open the terminal block cover removing the
screws

2. Insert the cable inside the M20 cable gland

3. Connect the cable according to the wiring diagram
(see Figure 7 and Figure 9)

Table 1

Table 2

For terminal-connected models

- Analog 0­10V

- External
pressure
sensor

- External
temperature
sensor

- External
start/stop

If NO fault
signal on
this cable
gland.

Multi-wire
control
cable,
number of
wires
according
to number
of control
circuits.
Shielded if
necessary

Multi-wire
control
cable,
number of
wires
according
to number
of control
circuits.
Shielded if
necessary
Communicati
on bus

Bus cable

Function

Terminal

pair

Contact rating

See

par.

External
start/stop



The drive
provides 5VDC
through these
terminals: no

external voltage
must be
provided!

2.5.1

0-10V external
analog input



2.5.2

Fault signal



Max 250V at 2A
(inductive load)

2.5.3

4-20mA
pressure sensor
input



2.5.4

External
temperature
sensor4



The drive works
with a KTY83
temperature
sensor (1KΩ at
25°C)

2.5.5

Communication
bus (standard)4



TIA/EIA RS485

2.5.6

Communication
bus (optional)4



TIA/EIA RS485

2.5.7

Optional
Wireless /
RS485 module



2.5.8

4

Vin

thres

holds

[V]

Speed

setpoint

[rpm]
when

Vin

Pump

status

when Vin

Po
int

Speed

setpoint

[rpm]
when

Vin

Pump

status

when Vin

Po
int

0

-

Input

disabled

-

-

Input

disabled

-

0.8

-

Input

disabled

- 0 OFF



1.19

-

Input

disabled

- 0 OFF



1.20 0 OFF



MIN

RUN



1.49 0 OFF



MIN

RUN

1.50

MIN

RUN



MIN

RUN



10.0

MAX

RUN



MAX

RUN



Table 3

2.4 Connection diagram

With reference to Figure 8 and Figure 9:

 and , which is the factory setting, should be

maintained.

NOTICE

The drive provides 5VDC through these terminals: no
external voltage must be provided to these terminals!

2.5.2 External analog input 0-10V []

An external analog signal 0-10V, applied to terminals

 and , controls the circulator speed in a range from

0 to 100%, following a linear function as depicted in

Figure 1.

2.5 I/O description

2.5.1 External start/stop []

The circulator can be started or stopped via an
external potential-free contact or a relay connected to
terminals  and . If no external start/stop switch is
connected, the connection jumper between terminals

Only on ecocirc XLplus

Table 4

Figure 1

In the below table a description of the milestones
shown in Figure 1.

Table 5

2.5.3 Fault signal []

The drive controls a relay for a potential-free fault
signal: in case of blocking error, the relay is activated
so that the terminals  and  are short circuited.

RATINGS

V

< 250VAC

max

I

< 5A (if resistive load)

max

I

< 2A (if inductive load)

max

Interface

RS485 (TIA/EIA) optically isolated

Baud rate

4800 / 9600 (factory setting) / 14400 /
19200 / 38400 / 56000 / 57600 baud

Data
format

8 data bits, no parity, 1 stop bit

Protocol

Modbus RTU (factory setting)
Bacnet MSTP5

Address

1247 Modbus RTU
0  127 Bacnet MSTP5
ID #1 factory setting

Interface

RS485 (TIA/EIA) not isolated

Baud rate

4800 / 9600 (factory setting) / 14400 /
19200 / 38400 / 56000 / 57600 baud

Data
format

8 data bits, no parity, 1 stop bit

Protocol

Modbus RTU (factory setting)
Bacnet MSTP

5

Address

1247 Modbus RTU
0  127 Bacnet MSTP5
ID #1 factory setting

Priority

Possible settings

User

Interface

External

Start/Stop

External

0-10V

Bus signal

1 Stop 2

Regulation

3 Stop

4

Regulation

5 Stop

6

Regulation

7 Stop

2.5.4 External analog input 4-20mA []

The circulator can be equipped with a 4-20mA external
differential pressure sensor, connected to terminals 
and , with the purpose of increasing the precision in
operating modes involved with pressure regulation.
For setting, in the drive, the correct pressure sensor
model used, see par. 4.3.5.3.

2.5.5 External temperature sensor []

The circulator can be equipped with an external KTY83
temperature probe (1KΩ at 25C), connected to
terminals  and , with the purpose of measuring an
absolute or a differential water temperature, in
temperature dependent / influenced operating modes.
For setting, in the drive, the desired temperature­dependent control mode, see par. 6.1.2

2.5.6 Communication bus (standard)
[]

The circulator (model ecocirc XLplus only) can
communicate remotely through a built-in RS485 port,
whose characteristics are:

The aim of this additional communication bus is to
offer a connection to an external BMS, or to a generic
external device, even when the standard
communication bus (described in 2.5.6) is used for
dual pump operations (in case of a twin-head pump or
2x single-head pumps)

NOTICE

Don’t use this communication bus, implemented on
terminals , and , for connecting 2 pumps in dual
pump operations

2.5.8 Optional wireless / RS485 module
[]

The drive can be equipped with

 an optional Wireless module;
 an optional RS485 module

Both the modules shall be plugged inside the drive
(see Figure 12), fixed by the provided clips and with
the cable connected to the connector  (see par. 6.2
and 6.3).

For setting, in the drive, the correct communication
parameters, see par. 4.3.5.2.

NOTICE

This communication bus, implemented on terminals ,





and , is the only one which can be used for

connecting 2 pumps in dual pump operations (see par.

4.3.5.1)

2.5.7 Communication bus (optional)
[]

The circulator (model ecocirc XLplus only) can
communicate remotely through an optional RS485
port, available exclusively in case the optional Wireless
module or the optional RS485 module is installed;
main characteristics of this port are:

2.6 Settings priority

All the I/O signals, described in 2.5, can interact
together changing the behavior of the circulators they
are connected to: in particular, in case two or more
signals are enabled and active at the same time, the
circulator will operate according to the setting with the
highest priority.
Refer to the table below for the settings priority:

EXAMPLE 1

In case the external start/stop switch is open or
unconnected (External Start/Stop = Stop), the drive
shall not accept any regulation.

EXAMPLE 2

The circulator can be driven through the User Interface
only if no external signals are applied (to the provided
terminals) and no communication bus is connected

Only on ecocirc XLplus terminal-connected models

6
7
8
9

3 First Start-up

Before operate the circulator, verify the correct
connection of the wirings.

1. Switch on the power supply to the pump

The drive light all the LEDs of the User Interface,
to allow a quick detection of any display
malfunction

2. (6) After few seconds, the drive will display the

message SIN (7) or SING (8)
While this message (“SIN” or “SING”) is displayed,
the drive gives the possibility to set the dual pump

operations’ parameters: if the user does not

change this setting, the device will default to the
factory setting (single-head pump) and proceed to
the next step.
For setting, in the drive, the correct dual pump
operations’ parameters see par. 4.3.5.1.

3. (6) After few seconds, the drive will display the

message CON (7) or CONN (8)
While this message (“COM” or “COMM”) is
displayed, the drive gives the possibility to set the
communication parameters: if the user does not
change this setting, the device will default to the
factory settings (9600baud, address = 1, no
optional module, Modbus RTU protocol) and
proceed to the next step.
For setting, in the drive, the correct communication
parameters see par. 4.3.5.2.

4. (9) After few seconds, the drive will display the

message PrE (7) or PrES (8)
While this message (“PRE” or “PRES”) is
displayed, the drive gives the possibility to set the
differential pressure sensor’s parameter: if the user
does not change this setting, the device will default
to the factory setting (differential pressure sensor

1.0bar) and proceed to the next step.
For setting, in the drive, the correct differential
pressure sensor’s parameter, see par. 4.3.5.3.

5. After few seconds, the drive will display the

message 4dG (7) or 4DEG (8)
While this message (“4DG” or “4DEG”) is
displayed, the drive is performing the first (out of 4)
cycle of the Air Purge procedure: if the user does
not stop this procedure, the device will finalize the
4 cycles (decrementing in each sub-phase the
countdown “4DG”-“3DG”-“2DG”-“1DG” or “4DEG”­“3DEG”-“2DEG”-“1DEG”) and then proceed to the
next step.
To stop or start the Air Purge procedure, see
par.4.3.4.2

6. At the end of the Air Purge procedure, the pump

starts pumping in Constant Head control mode
(factory default)
For more information about Control Modes and
relative default value, see par. 4.3.3

NOTICE

All the steps from 1 to 5 are always the same at every
start-up, regardless it’s the first or not.
In step 6, the starting control mode of a generic (not
the first) start-up procedure is the last used before the
power-off.

Only on ecocirc XLplus
On plug-connected models
On terminal-connected models
Only if an external differential pressure sensor is connected to the

provided terminals (see 2.5.4)



Control Mode button

See par. 4.3.3



Control Mode indicators (LEDs)

See par. 4.3.3



Parameter button

See par. 4.2



Parameter indicators (LEDs)

See par. 4.2



Setting buttons

See par. 4.3.1



Numeric display



Power indicator (LED)

See par. 4.1.1



Status indicator (LED)

See par. 4.1.2



Remote control indicator (LED)

See par. 4.1.3

4 Control Panel

For a description of buttons, indicators and display
present on the user interface, follow the table below
referring to Figure 10 (in case of plug-connected
models) and to Figure 11 (in case of terminal­connected models).

 If the Remote (green) LED is permanently lit, then

the drive both

o detected a communication bus on the

provided terminals

o acknowledged the correct addressing

 If the Remote (green) LED is blinking with 50%

duty every second, then the drive

o detected a communication bus on the

provided terminals

o has not been correctly addressed

Particular behaviors (in this condition) for this indicator
are the following

 If the Remote (green) LED switches from being

permanently lit to being not lit, then the drive

didn’t detect any valid Modbus RTU message (at

least) for the last 5 seconds

 If the Remote (green) LED switches from being

permanently lit to blinking with 50% duty every
second, then the drive has not been correctly
addressed (at least) for the last 5 seconds

4.1 LEDs description

4.1.1 Power indicator []

When the Power (green) LED is lit, the circulator is
supplied with power and the electronic devices are
operative

4.1.2 Status indicator []

 If the LED is not lit, then the pump is

stopped or disabled and the pump motor is not
running.

 If the Status (orange) LED is lit, then the pump is

still enabled and the pump motor is running,
because in presence of a non-blocking alarm

 If the Status (red) LED is lit, then the pump is

stopped or disabled and the pump motor is not
running due to a blocking error

 If the Status (green) LED is lit, then the pump is

running

4.1.3 Remote control indicator []

This indicator is used only on ecocirc XLplus
circulators, because it is related to the presence of any
kind of communication.
The way the Remote LED is lit (permanently) or blinks,
depends on several settings and conditions as below

4.1.3.1 Condition 1

If no optional wireless / RS485 module is used
(referring to par. 4.3.5.2, parameter “Module” is set to
value “None”) and the protocol for the communication
bus is Modbus RTU (parameter “Protocol” is set to
value “Modbus”)
 If the LED is not lit, then the drive cannot

detect any valid Modbus message on the terminals
provided for the communication bus

4.1.3.2 Condition 2

If no optional wireless / RS485 module is used
(referring to par. 4.3.5.2, parameter “Module” is set to
value “None”) and the protocol for the communication
bus is Bacnet MSTP (parameter “Protocol” is set to
value “Bacnet”)
 If the LED is not lit, then the drive didn’t

receive any valid request, coming from any other
Bacnet MSTP device, (at least) for the last 5
seconds

 If the Remote (green) LED is permanently lit, then

the drive is exchanging information with any other
Bacnet MSTP device

4.1.3.3 Condition 3

If the optional wireless module is used (referring to par.

4.3.5.2, parameter “Module” is set to value “Wireless”)
 If the LED is not lit, then the connection

with the wireless module is damaged or absent

 If the Remote (green) LED is blinking with 10%

duty every second, then the drive is exchanging
information with the wireless module

4.1.3.4 Condition 4

If the optional RS485 module is used (referring to par.

4.3.5.2, parameter “Module” is set to value “RS485”)
 If the LED is not lit, then either

o the connection with the RS485 module is

damaged or absent

o the drive didn’t receive any valid request,

coming from any other external device, (at
least) for the last 5 seconds

 If the Remote (green) LED is blinking with 90%

duty every second, then both

o the RS485 module is correctly connected
o the drive is exchanging information with any

other external device