Related Manuals for Wilo Yonos GIGA-N 80
Summary of Contents for Wilo Yonos GIGA-N 80
- Page 1 Pioneering for You Wilo-Yonos GIGA-N en Installation and operating instructions · 6088793 • Ed.01/2020-10...
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Page 3: Table Of Contents
Switching on the pump .................................... 37 Behaviour after being switched on................................ 38 Setting the control mode.................................... 38 8 Operation.................................... 39 Operating elements ...................................... 39 Display structure ...................................... 39 Explanation of standard symbols ................................. 40 Symbols in graphics/instructions.................................. 40 Installation and operating instructions Wilo-Yonos GIGA-N... - Page 4 12.3 Acknowledge fault...................................... 71 13 Factory settings .................................. 76 14 Disposal.................................... 77 14.1 Oils and lubricants...................................... 77 14.2 Water-glycol mixture ..................................... 77 14.3 Protective clothing ...................................... 77 14.4 Information on the collection of used electrical and electronic products.................... 77 WILO SE 2020-10...
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Page 5: General Information
Failure to follow the instructions can lead to (serious) injuries! ƒ CAUTION! Failure to follow the instructions can lead to property damage and a possible total loss. ƒ NOTICE! Useful information on handling the product Installation and operating instructions Wilo-Yonos GIGA-N... -
Page 6: Personnel Qualifications
ƒ Electrical work Have electrical work carried out by a qualified electrician. ƒ When connecting to the mains, comply with the locally applicable laws and regula- tions of the local energy supply company. WILO SE 2020-10... -
Page 7: Transport
ƒ Collect any leakage of fluids and operating fluids immediately and dispose of it ac- cording to the locally applicable guidelines. ƒ Tools and other objects should only be kept in their designated places. Installation and operating instructions Wilo-Yonos GIGA-N... -
Page 8: Maintenance Tasks
Eliminate any risk from electrical current. ƒ Equip hazardous components (extremely cold, extremely hot, rotating, etc.) with an on-site guard. ƒ Demarcate and cordon off the hazardous area. ƒ Define personnel responsibilities to ensure safe working practice. WILO SE 2020-10... -
Page 9: Application/Use
Persons under the age of 18 must be supervised by a technician. Application/use Intended use The glanded pumps in the Wilo-Yonos GIGA-N series are intended for use as circulators in building services. The Wilo-Yonos GIGA-N pumps may be used for: ƒ... - Page 10 Constant differential pressure ( > p-c) The control system keeps the delivery head constant at the adjusted differential pres- sure setpoint H . Control is independent of the volume flow and is applied until the maximum characteristic curve is reached. WILO SE 2020-10...
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Page 11: Twin-Head Pump Function/Y-Pipe Application
The maximum delivery head can even been reached at a sensor signal of < 100 %. Twin-head pump function/Y-pipe application NOTICE The properties described in this section are only available if the internal MP interface (MP = Multi Pump) is used. Installation and operating instructions Wilo-Yonos GIGA-N... - Page 12 4.3.1 Operating modes Main/standby operation Only one pump ever runs at a time. Each of the two pumps provides the configured flow rate. The other pump is available in case of malfunction or runs after pump cycling. WILO SE 2020-10...
- Page 13 The functions of EBMs/SBMs – “Readiness”, “Operation”, “Mains on” – can be set in menu <5.7.6.0> on the master. NOTICE “Readiness” means: The pump is able to run, there is no fault. “Operation” means: Motor running. “Mains on” means: Mains voltage is available. Installation and operating instructions Wilo-Yonos GIGA-N...
- Page 14 (former) slave will start up with the factory settings of a single pump. It will then run in Δp-c operating mode at about half the maximum delivery head. WILO SE 2020-10...
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Page 15: Other Functions
For double pump function (“Main/standby operation” mode), this also applies to the standby pump. If the time interval before pump cycling set in menu <5.8.1.2> expires, a pump kick takes place at the standby pump. Installation and operating instructions Wilo-Yonos GIGA-N... -
Page 16: Variants
Type key Example: Yonos GIGA-N 40/200-15/2-R1-P5 Product family Yonos Series GIGA Construction Nominal diameter DN of pressure port Nominal diameter of the impeller in mm Rated power P in kW Number of poles Version without differential pressure measurement WILO SE 2020-10... -
Page 17: Technical Data
Observe relevant manufacturer specifications! ƒ The fluid must be sediment-free. ƒ The use of other fluids requires approval from Wilo. ƒ Mixtures with a proportion of glycol of > 10 % influence the flow calculation. ƒ In systems built according to the state of the technology, under normal system con- ditions it can be assumed that the standard seal/standard mechanical seal is com- patible with the fluid. -
Page 18: Scope Of Delivery
A flow value is not output by every pump type. Always read and follow the material safety data sheet for the fluid being pumped! ƒ Scope of delivery Wilo-Yonos GIGA-N pump ƒ Installation and operating instructions Accessories Accessories have to be ordered separately. -
Page 19: Transportation And Storage
CAUTION Property damage due to incorrect transport To ensure proper alignment, all equipment is pre-assembled. If dropped or if im- properly handled, there is a risk of misalignment or deficient performance due to de- Installation and operating instructions Wilo-Yonos GIGA-N... -
Page 20: Storage
ƒ Manually rotate the drive shaft several times once a week. Storage for more than three months Additional precautionary measures: ƒ All rotating parts must be coated with a suitable protective medium to protect them from rust. WILO SE 2020-10... -
Page 21: Installation And Electrical Connection
Rotate pump shaft once a week to prevent scoring at the bearings and sticking. ƒ If the pump is to be stored for more than a year, consult Wilo and ask what action should be taken to conserve the pump. - Page 22 The base must be able to permanently support the unit installed on the baseplate. The base must be level to ensure there is no tension on the baseplate or unit. Wilo recom- mends constructing it using premium, non-shrink concrete of an adequate thickness.
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Page 23: Pipework
• Avoid air pockets in piping by means of appropriate installations. NOTICE Make subsequent work on the unit lighter! • To ensure the entire unit does not have to be emptied, install a non-return valve and shut-off valves before and after the pump. Installation and operating instructions Wilo-Yonos GIGA-N... -
Page 24: Aligning The Unit
ƒ vibrations ƒ premature wear ƒ excessive coupling wear 6.6.1 Coupling alignment max. max. ∆Ka min. min. Fig. 17: Coupling alignment without spacer max. max. ∆Ka min. min. Fig. 18: Coupling alignment with spacer WILO SE 2020-10... - Page 25 Turn the coupling and write down the measuring result after every quarter turn. ƒ Alternatively, the radial coupling alignment can also be checked with a ruler. Fig. 19: Checking the radial alignment with a comparator Installation and operating instructions Wilo-Yonos GIGA-N...
- Page 26 A [Nm] justing screw B [Nm] 80, 88, 95, 103 110, 118 17.5 125, 135 140, 152 Fig. 23: Adjusting screw A for axial safeguard 160, 172 180, 194 67.5 200, 218 225, 245 250, 272 WILO SE 2020-10...
- Page 27 Risk of damage due to vibrations! Incorrect alignment can lead to vibra- tions. Vibrations can damage or destroy individual components. • Carefully align the pump unit until all measurement results are within the permiss- ible range. Installation and operating instructions Wilo-Yonos GIGA-N...
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Page 28: Electrical Connection
Risk of material damage if the electronic module is not installed! Normal operation of the pump is only permitted with the electronic module in- stalled! The pump must not be connected or operated without the electronic module being installed! WILO SE 2020-10... - Page 29 S must be greater than or equal to the val- ues listed in the following table! Motor power [kW] Short-circuit power S [kVA] ≥ 1800 ≥ 2400 ≥ 3000 18.5 ≥ 3500 Table 9: Required short-circuit power S Installation and operating instructions Wilo-Yonos GIGA-N...
- Page 30 ƒ ƒ Communication cable IF module The shield must be applied to the EMC cable clips in the electronic module and to the other end. The cables for SBM and SSM do not have to be shielded. WILO SE 2020-10...
- Page 31 [Nm] ± 10 % 1x threaded cable gland M12 reserved for connect- M12x1.5 ing cable for an optional differential pressure sensor M16x1.5 M20x1.5 11.0 M25x1.5 16.0 M40x1.5 Table 11: Tightening torques for threaded cable glands Installation and operating instructions Wilo-Yonos GIGA-N...
- Page 32 • Motors from 11 kW must be additionally connected to a reinforced earth con- nection. Fig. 29: Additional earthing, from 11 kW motor power Tightening torque [Nm] ± 10 % Control terminals Power terminals 1.5 – 7.5 kW 11 – 22 kW WILO SE 2020-10...
- Page 33 Systems with a high switching frequency (> 20 on/off operations per day) Ext. Off should be switched on/off via “External off”. Can be configured in the service menu <5.1.7.0> Contact load: 24 V DC/10 mA Installation and operating instructions Wilo-Yonos GIGA-N...
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Page 34: Protective Devices
It may cause burns. • Depending on the application, insulate the spiral housing. • Provide corresponding guards. • Allow the pump to cool down at ambient temperature after switching it off! • Observe local regulations. WILO SE 2020-10... -
Page 35: Commissioning
Filling and venting NOTICE The standard version of the Wilo-Yonos GIGA-N pump has no air vent valve. The suction line and pump are vented via a suitable venting device on the pressure flange of the pump. An optional air vent valve is available. -
Page 36: Twin-Head Pump Installation/Y-Pipe Installation
The factory setting does not correspond to the output required for the system. The re- quired pump output is determined with the help of the pump curve diagram for the se- lected pump type (e.g. from the data sheet). WILO SE 2020-10... -
Page 37: Switching On The Pump
ƒ After reaching the speed, slowly open the shut-off device in the pressure pipe and adjust the pump to the duty point. ƒ While the pump is starting, vent completely via the venting device. Installation and operating instructions Wilo-Yonos GIGA-N... -
Page 38: Behaviour After Being Switched On
The sign before the P term determines the controller’s dir- ection of action. The I term (I term) of the controller provides integral control based on the system devi- ation. A constant deviation results in a linear increase of the output signal until the set- WILO SE 2020-10... -
Page 39: Operation
Activating or deactivating the access disable feature. For additional in- formation, see “Activating/deactivating access disable” chapter Terminating the “Multi Pump” communication. For additional informa- 3 & 4 tion, see “Activate/Deactivate termination” chapter Table 17: DIP switch Installation and operating instructions Wilo-Yonos GIGA-N... -
Page 40: Display Structure
(icon flashes) DP/MP operating DP/MP operating mode: mode: Parallel operation Main/reserve Table 18: Standard symbols of status display Symbols in graphics/instructions In the “Operating instructions” chapter, graphics are used to illustrate the operating concept and setting instructions. WILO SE 2020-10... -
Page 41: Display Modes
• Before working on the pump, disconnect the supply voltage and wait for 5 minutes. • Check whether all connections (including potential-free contacts) are voltage- free. • Never poke around in the openings on the electronic module and never insert anything into it! Installation and operating instructions Wilo-Yonos GIGA-N... - Page 42 8.5.3 Display error page If an error occurs, the display changes from the status page to the error page. The dis- E000 play shows the letter “E” and the three-digit error code, separated by a decimal point. WILO SE 2020-10...
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Page 43: Operating Instructions
Pressing the operating button activates or deactivates the access disable feature. The selection is confirmed by pressing the operating button. Operating instructions 8.6.1 Adjusting the setpoint The setpoint can be adjusted on the status page. Installation and operating instructions Wilo-Yonos GIGA-N... - Page 44 When service mode is activated (using DIP switch 1), menu <5.0.0.0> is displayed first. ± 5.0.0.0 12.3 Fig. 40: Service mode menu Fault event In the event of a fault, menu number <6.0.0.0> is displayed ± 6.0.0.0 E000 Fig. 41: Fault event mode menu WILO SE 2020-10...
- Page 45 The selected setpoint or setting is confirmed, and the value or symbol stops flashing. The display is back in menu mode with the menu number unchanged. The menu num- ber flashes. ± 2.0.0.0 2.0.0.0 12.3 2.0.0.0 2.0.0.0 Fig. 44: Changing settings and returning to the status page Installation and operating instructions Wilo-Yonos GIGA-N...
- Page 46 When access is disabled, this is shown on the status page by the default “access disable” symbol. To activate or deactivate: ƒ Set DIP switch 2 to the “ON” position. Menu <7.0.0.0> is displayed. ƒ Turn the operating button to activate or deactivate the disable function. WILO SE 2020-10...
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Page 47: Menu Elements Reference
Setting/display of setpoint ± 1.0.0.0 (for additional information, see “Adjusting the setpoint” chapter) Control mode Setting/display of control mode (for addi- ± 2.0.0.0 tional information see “Control modes” and “Setting the control mode” chapters) Installation and operating instructions Wilo-Yonos GIGA-N... - Page 48 The value display shows the identity of the Only displayed for twin-head pump regular base-load pump statically. The master 4.3.1.0 units display shows the identity of the temporary base-load pump statically. Status of SSM relay if a fault message is present 4.3.2.0 WILO SE 2020-10...
- Page 49 Only displayed when BMS is active Field bus system Only displayed when BMS is active Field bus system Gateway Protocol Only displayed when BMS is active Status of “AUX” terminal 4.3.6.0 Device data Displays device data 4.4.0.0 Installation and operating instructions Wilo-Yonos GIGA-N...
- Page 50 Only displayed for twin-head pump ± 5.1.7.0 master Collective External off Only displayed for twin-head pump master Settings for Building Management System Including all sub-menus, only dis- 5.2.0.0 (BMS) – building automation played when BMS is active WILO SE 2020-10...
- Page 51 HV/AC HV (“heating”) mode ± 5.6.1.0 AC (“cooling/air-conditioning”) mode Emergency op- Displays emergency operation speed 5.6.2.0 eration speed Auto reset time Time until automatic acknowledgement of ± 5.6.3.0 an error Other settings 1 5.7.0.0 Installation and operating instructions Wilo-Yonos GIGA-N...
- Page 52 Error acknow- For additional information, see “Acknow- Only displayed if an error is ± 6.0.0.0 ledgement ledging errors” chapter. present. Access disable Access disable feature inactive (changes ± possible) (for additional information, see 7.0.0.0 “Activating/deactivating access disable” chapter). WILO SE 2020-10...
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Page 53: Shutdown
Grease or oil the blank components. For this, use silicone-free grease or oil. Observe the manufacturer’s instructions for preservatives. Maintenance/repair It is recommended to have the pump serviced and checked by the Wilo customer ser- vice. Maintenance and repair work require the pump to be partially or completely dismantled. -
Page 54: Personnel Qualifications
Wilo recommends checking the flexible coupling elements regularly and replacing them at the first sign of wear. ƒ Wilo recommends briefly operating the standby pumps at least once a week to en- sure they are always ready for operation. WILO SE 2020-10... -
Page 55: Maintenance Tasks
8. Remove coupling guard. 9. If present: Remove the intermediate sleeve of the coupling. 10.Remove the fastening screws of the motor from the baseplate. NOTICE Observe the section drawing in the section “Spare parts”. Installation and operating instructions Wilo-Yonos GIGA-N... - Page 56 6. Remove the hexagon head screws (7.2) and remove the protective grid (7.1). 7. Loosen the impeller nut (2.2) and remove along with the lock washer and impeller disc. Version with mechanical seal (optional: mechanical seal on the sleeve) Fig. 48: Version with mechanical seal WILO SE 2020-10...
- Page 57 If the volume flow decreases and the motor shows signs of in- creased current consumption, this could be caused by an impermissibly high gap back- lash. In this case, replace the neck rings. Installation and operating instructions Wilo-Yonos GIGA-N...
- Page 58 Risk of material damage if the electronic module is not installed! Normal operation of the pump is only permitted with the electronic module in- stalled! The pump must not be connected or operated without the electronic module being installed! Dismantling, module 11 ... 22 kW WILO SE 2020-10...
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Page 59: Installation
• Reinstall any uninstalled safety devices, such as module or coupling covers, once the work is complete. NOTICE Observe the drawings in the section “Spare parts”. 10.6.1 Installing the shaft/bearing 4.1A 4.1B bracket Fig. 53: Shaft Installation and operating instructions Wilo-Yonos GIGA-N... - Page 60 In this case, replace the neck rings. 10.6.2 Assembling the slide-in unit Version with mechanical seal (optional: mechanical seal on the sleeve) Fig. 55: Housing cover, mechanical seal WILO SE 2020-10...
- Page 61 5. Insert a new housing seal (1.2). 6. Carefully insert the slide-in unit into the spiral housing (1.1) and tighten with the hexagon head screws (14). Installation and operating instructions Wilo-Yonos GIGA-N...
- Page 62 The pump must not be connected or operated without the electronic module being installed! Installation, module 11 ... 22 kW NOTICE The electronic module must be dismantled and installed according to the instructions enclosed with the spare part! WILO SE 2020-10...
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Page 63: Spare Parts
“Installing the electronic module” chapter Spare parts Spare parts may be ordered via a local installer and/or Wilo customer service. List of ori- ginal spare parts: Refer to the Wilo spare parts documentation and the following in- formation in these installation and operating instructions. -
Page 64: Spare Parts List
Trouble-free pump operation can only be guaranteed when original spare parts are used. Use only original Wilo spare parts! Information to be provided when ordering spare parts: spare part numbers, spare part names/descriptions, all data from the pump and rating plate. This helps prevent return queries and incorrect orders. -
Page 65: Faults, Causes And Remedies
Further steps for troubleshooting If the points listed here do not rectify the fault, contact customer service. Customer service can assist in the following ways: Installation and operating instructions Wilo-Yonos GIGA-N... -
Page 66: Mechanical Faults
Inlet pressure too low or – Correct the fluid level negative suction head too – Minimise resistances in the high suction line – Clean filter – Reduce negative suction head by installing the pump lower WILO SE 2020-10... -
Page 67: Error Codes, Display
Pump is pumping against – Open shut-off valve in pres- a closed shut-off valve sure pipe Table 25: Causes of error and remedies 12.2 Error codes, display Classification Fault Cause Remedy Error type No error – Installation and operating instructions Wilo-Yonos GIGA-N... - Page 68 Faulty contact Electronic Contact cus- module has no tomer service contact to mo- E025 Winding inter- Motor faulty Contact cus- rupted tomer service WSK or PTC in- Motor faulty Contact cus- E026 terrupted tomer service WILO SE 2020-10...
- Page 69 Communica- Impermissible Different Contact cus- tion errors E051 DP/MP com- pumps tomer service bination DP/MP com- MP communic- Check cable E052 munication ation cable de- and cable con- time-out fective nections Installation and operating instructions Wilo-Yonos GIGA-N...
- Page 70 EMC (immission/interference resistance) may interrupt communication. This results in error code “E070” being displayed. You can check this by disconnecting all communication cables installed by the cus- tomer in the electronic module. If the fault no longer occurs, there may be an external WILO SE 2020-10...
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Page 71: Acknowledge Fault
Error code is displayed ƒ Motor Off ƒ Red LED On ƒ SSM is activated ƒ Error counter is increased > 1 min? Error acknowledged? End; auto control resumes Table 27: Error type A Fig. 63: Error type A, diagram Installation and operating instructions Wilo-Yonos GIGA-N... - Page 72 Wait until the remaining time is up. The waiting time before manual acknowledge- ment is always 60 seconds for error types A and D. 12.3 ƒ Fig. 65: Acknowledging error type A or D Press the operating button again. The error is acknowledged, and the status page is displayed. WILO SE 2020-10...
- Page 73 The time until manual acknowledgement is always 300 seconds. On the value display, the remaining time until manual acknowledgement of the error is displayed in seconds. ƒ Press the operating button again. The error is acknowledged, and the status page is displayed. Installation and operating instructions Wilo-Yonos GIGA-N...
- Page 74 ƒ Red LED On Error criterion fulfilled? > 5 min? ƒ Error counter is increased Error counter > 5? ƒ SSM is activated Error acknowledged? End; auto control resumes Table 30: Error type C Fig. 69: Error type C, flowchart WILO SE 2020-10...
- Page 75 If the current incidence (x) is the same as the maximum incidence of the error (y), the error can be acknowledged manually. ƒ Press the operating button again. The error is acknowledged, and the status page is displayed. Installation and operating instructions Wilo-Yonos GIGA-N...
- Page 76 Fig. 73: Acknowledging error type E or F ƒ Press the operating button again. The error is acknowledged, and the status page is displayed. NOTICE The error will be acknowledged automatically if the cause of the error is eliminated. WILO SE 2020-10...
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Page 77: Factory Settings
(e.g. 2008/98/EC). 14.4 Information on the collection of Proper disposal and appropriate recycling of this product prevents damage to the envi- used electrical and electronic ronment and putting your personal health at risk. products Installation and operating instructions Wilo-Yonos GIGA-N... - Page 78 Please consult your local municipality, the nearest waste disposal site, or the dealer who sold the product to you for information on proper disposal. See www.wilo‑recycling.com for more information about recycling. Subject to change without prior notice! WILO SE 2020-10...
- Page 80 Local contact at www.wilo.com/contact WILO SE Wilopark 1 44263 Dortmund Germany T +49 (0)231 4102-0 T +49 (0)231 4102-7363 wilo@wilo.com Pioneering for You www.wilo.com...