Wilo Helix2.0-VE Installation And Operating Instructions Manual Download Page 1

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Pioneering for You

Drive for Wilo-Helix2.0-VE / Wilo-Medana CH3-LE

4254674 • Ed.01/2022-06

Installation and operating instructions

Summary of Contents for Helix2.0-VE

Page 1: ...Pioneering for You Drive for Wilo Helix2 0 VE Wilo Medana CH3 LE 4254674 Ed 01 2022 06 en Installation and operating instructions...

Page 2: ......

Page 3: ...3 English 4...

Page 4: ...pply during ini tial commissioning 28 9 2 Description of the operating elements 29 9 3 Pump operation 30 10 Control settings 36 10 1 Control functions 37 10 2 Selection of a control 38 10 3 Switch off...

Page 5: ...with others 1 3 Subject to change Wilo reserve the right to change the listed data without notice and not be liable for tech nical inaccuracies and or omissions The illustrations are differed from th...

Page 6: ...qualification Personnel must Be instructed about locally applicable regulations governing ac cident prevention Have read and understood the installation and operating in structions Personnel must have...

Page 7: ...e rating plate Earth the product Comply with the manufacturer s specifications when connect ing the product to electrical switching systems Have a defective connection cable replaced immediately by a...

Page 8: ...essure pipe Provide adequate aeration in enclosed spaces Make sure that there is no risk of explosion when carrying out any type of welding work or work with electrical devices 2 6 Maintenance work We...

Page 9: ...e g IEC VDE etc and instructions from local energy supply companies Follow all information that appears on the product and ensure that it remains permanently legible Warnings Rating plate Direction of...

Page 10: ...guaranteed for intended use in ac cordance with chapter Intended use of the installation and operating instructions The limit values must not fall below or exceed those values specified in the catalog...

Page 11: ...signation Explanation 1 Motor Drive unit Forms the drive together with the elec tronic module 2 Graphic display Provides information about settings and pump status Self explanatory user interface for...

Page 12: ...IT1 performance range 3 0 55kW 4 0 kW depending on drive type Speed range 1000 rpm 3600 rpm depending on drive type Ambient conditions2 Protection class IP55 EN 60529 Ambient temperature during opera...

Page 13: ...ions and declaration of conformity 5 4 Accessories Accessories have to be ordered separately CIF module PLR for connecting to PLR interface converter CIF module LON for connection to the LONWORKS main...

Page 14: ...atal Always use suitable lifting equipment and secure parts against falling Never stand underneath a suspended load During storage and transport as well as before all installation and as sembly work e...

Page 15: ...bear loads Flush the pipeline system if required Dirt can cause the pump to fail Install only after completion of all welding and soldering work and after the pipeline system has been flushed if requi...

Page 16: ...stall a swing check valve on the discharge side of each pump 6 6 Double pump installation A double pump can be two single pumps operated in one common collector pipe NOTICE For double pumps in a commo...

Page 17: ...ssure sensors Other sensors Pressure sensors In p c control mode the measuring points of the relative pressure sensor should be in stalled on discharge pump side The cable connection should be connect...

Page 18: ...th the drive the earthed connection must also be fitted with a residual current circuit breaker Observe the installation and operating instructions for the accessories DANGER Risk of fatal injury Touc...

Page 19: ...pond to the specifications on the pump rating plate Threaded cable glands and threaded cable connections There are six cable bushings to the terminal room on the electronic module In case of drive is...

Page 20: ...al input EXT OFF 24VDC Metal with shielding 4 5 6 11 12 Fig 10 DI1 Digital input LACK OF WATER 24VDC Metal with shielding 4 5 6 11 12 Fig 10 DI1 Bus Wilo Net Bus communication Metal with shielding 4 5...

Page 21: ...ements Cable length 2m Use shielded cables When using ferrules the maximum cross section of the terminal for communication in terfaces is reduced to 0 25 1mm2 In order to comply with electromagnetic c...

Page 22: ...7 8 9 10 11121314 15 16 17 Fig 10 Terminals for analogue inputs digital inputs and Wilo Net Wilo Net AI3 AI4 and DI2 are not assigned Terminal assignment Designation Assignment NOTICE Analogue IN AI1...

Page 23: ...use a calibrated torque wrench 1 Observe the current type and voltage on the rating plate 2 Establish the electrical connection via a fixed connection cable equipped with a con nector device or an al...

Page 24: ...ency converter must not be protected by a residual current deviced Frequency converters can impair the function of residual current operated protection cir cuits NOTICE This product can cause a direct...

Page 25: ...ation must be shielded via the metal threaded cable gland of the cable bushing 4 5 and 6 Fig 8 When used for ex tra low voltage cables up to three cables can be passed through for each threaded cable...

Page 26: ...inals H L GND must be wired with a communication line from pump to pump Incoming and outgoing cables are clamped in a terminal A possible cable for the Wilo Net communication Y St Y 2x2x0 6 telecommun...

Page 27: ...ectronic module upper part Fig 16 pos 1 Fig 1 pos 2 M5 4 5 Threaded cable gland union nut Fig 8 pos 1 M25 11 Threaded cable gland Fig 8 pos 1 M25x1 5 8 Threaded cable gland union nut Fig 8 pos 6 M20x1...

Page 28: ...ury due to lack of protective devices Due to missing protective devices of the electronic module or in the range of the coupling motor electric shock or contact with rotating parts can lead to life th...

Page 29: ...17 9 2 Description of the operating ele ments Fig 18 Operating elements Item Designation Explanation 1 Graphic display Provides information about settings and pump status User interface for setting th...

Page 30: ...rgency operation Fig 19 Green focus Navigation in menu Green focus Navigation in menu Yellow focus Change settings Turn Menu selection and parameter setting Press Activation of menus or confirming set...

Page 31: ...h PT Portuguese NO Norwegian NL Dutch DA Danish PL Polish HU Hungarian CS Czech RO Romanian SL Slovenian HR Croatian SK Slovak SR Serbian LT Latvian LV Lithuanian ET Estonian RU Russian UK Ukrainian B...

Page 32: ...ecomes yellow The setpoint is changed by turning the operating button right or left The changed setpoint is confirmed by pressing the operating button again The pump accepts the value and the display...

Page 33: ...ive but configured for Motor stop No Active Override OK No special inluence The following table lists Active Influences Double Pump Status indicated in the Home Screen Symbol fromhighest tolowest prio...

Page 34: ...ttings External interfaces Dual pump management 1 2 NOTICE If there are more than three sub menu items an arrow above or below the visible menu items shows that Turn the operating button in the corre...

Page 35: ...vious menu Status area and status displays The status area is located on the left side above the main menu area 1 1 If a status is active it is possible to display and select status menu items in the...

Page 36: ...in the display for selecting the control settings in the available lan guages Universal Display text 1 0 Settings 1 1 Control settings 1 1 1 Control mode p v p v p c p c n c n c PID control PID contr...

Page 37: ...ge of 30 to 100 Constant differential pressure p v Q H H set H 2 set p v p v The control keeps the differential pressure created by the pump constant above the permit ted flow rate at the selected dif...

Page 38: ...u select 1 Set control mode 2 Select Control mode Settings Control settings External interfaces Dual pump management Universal Display text 1 0 Settings 1 1 Control settings 1 2 Monitoring setting 1 3...

Page 39: ...1 Control mode 1 1 2 p v Setpoint p v 1 1 7 Emergency operation mode 1 1 8 Emergency operation speed 1 1 9 Setpoint source 1 1 10 Substitute setpoint 1 1 11 No flow stop ON OFF 1 1 12 No flow stop lim...

Page 40: ...annot be selected greyed out If the setpoint is selected via the Analogue input AI 2 the analogue input can be set via the Settings menu If an external setpoint source is selected analogue input or CI...

Page 41: ...en selecting the menu item the desired delivery head can be set as the setpoint NOTICE The setpoint can only be set if the setpoint source is set to Internal set point see Setting the setpoint source...

Page 42: ...point source 1 1 9 1 Internal setpoint 1 1 9 2 Analog input AI2 1 1 9 3 CIF module 1 1 10 Substitute setpoint 1 1 15 Pump ON OFF Setting the setpoint n c When the menu item is selected the desired spe...

Page 43: ...ol mode with inversion OFF or inversion ON Setting the emergency operating mode In the event of a fault the failure of the required sensor an emergency mode can be defined When the emergency operation...

Page 44: ...Setting the parameter Kp When selecting the menu item the desired Kp can be set NOTICE This parameter is set by default to fit most of the water supply applica tions This parameter can be adjusted by...

Page 45: ...ro flow test delay appears The delay time before to stop the pump can be set here NOTICE In water supply systems there are times with all taps are closed and no flow demand The control function zero f...

Page 46: ...the terms in the display for selecting the monitoring settings in the available languages Universal Display text 1 2 Monitoring settings 1 2 1 Min pressure detection 1 2 1 1 Min pressure detection ON...

Page 47: ...ing Settings 2 Min Pressure detection The function can be switched ON and OFF If the function is switched ON the following additional settings appear in the Menu Min pressure detection Min pressure de...

Page 48: ...of lack of water detection Via the analog input usually by suction pressure sensor and or via a digital input usually level switch The selection and configur ation of the method is done in Lack of wat...

Page 49: ...cted on pumps suction side The pressure sensor has to be connected to the terminals AI 2 The AI 2 analog input must be configured accordingly 11 3 2 Lack of water detection by binary input The functio...

Page 50: ...by switch See also Chapter 13 3 Application and function of the digital control input DI 1 NOTICE The binary input usage will be automatically configured to unused when the function Lack of water det...

Page 51: ...d SBM EBM collective run signal individual run signal The SBM contact can be assigned to any of the two pumps The following configuration is possible The contact is activated when the motor is in oper...

Page 52: ...management 1 4 1 Connect double pump 1 4 1 1 Double pump partner address 1 4 1 2 Establish double pump pairing 1 4 2 Disconnect double pump 1 4 3 Double pump function 1 4 3 1 Duty Standby 1 4 4 Pump c...

Page 53: ...pump from which the double pump pairing is started is the main pump The main pump is to be the pump to which the pressure sensor is connected Connect double pump Double pump partner address Establish...

Page 54: ...4 1 Time based pump cycling ON OFF 1 4 4 2 Time based pump cycling interval 1 4 4 3 Manual pump cycling Pump cycling Time based pump cycling ON OFF Time based pump cycling Interval Manual pump cyclin...

Page 55: ...faces Setting and function Overview of the terms in the display for selecting the external interfaces in the available languages Universal Display text 1 3 External interfaces 1 3 1 Relay output SSM S...

Page 56: ...elay output SSM SBM Function control input DI1 Function analogue input AI1 Function analogue input AI2 Setting Wilo Net Table 13 Selection External interfaces NOTICE The menu items for setting the ana...

Page 57: ...ed control in sequence SSM relay forced control Normal Forced energized Forced NOT energized Selection options SSM SBM relay Forced control Help text Normal SSM Depending on the SSM configuration faul...

Page 58: ...ck of water detection by switch NOTE This selection is only available if Lack of water detection by switch is enabled see chapter 11 3 2 Lack of water detection by binary input NOTE The configuration...

Page 59: ...p fails or the double pump connection is interrupted the partner pump is also stopped Main pump Partner pump States Ext OFF Pump motor behaviour Display Text at Active influences Ext OFF Pump motor be...

Page 60: ...Active Off OFF Override OFF DI1 2 Not active On OK Normal op eration Active Off OFF Override OFF DI1 3 Active Off OFF Override OFF DI1 Not active Off OFF Override OFF DI1 4 Not active On OK Normal op...

Page 61: ...c it can be used as sensor input for pressure sensor at suction port to support optional function Lack of water detection via pressure sensor In this case the pressure sensor must be configured as AI...

Page 62: ...signal types 0 10V voltage range of 0 10V for the transfer of measurement values 2 10V voltage range of 2 10V for the transfer of measurement values Cable break is detected for a voltage below 1V 0 2...

Page 63: ...rrent range of 0 20mA for transfer of setpoints 4 20mA Electric current range of 2 20mA for transfer of setpoints If the current is be low 2 mA the motor is switched off and cable break is detected se...

Page 64: ...break is detected see Overview of transfer func tions 0 20mA Electric current range of 0 20mA for transfer of setpoints 4 20mA Electric current range of 2 20mA for transfer of setpoints If the current...

Page 65: ...0 of maximum speed up to maximum speed For all other control functions dp c dp v PID and pc setpoint can be set from 0 to 100 of the sensor range 10 5 V 20 mA 10 mA 1 V 2 mA 3 2 V 6 4 mA 2 8 V 5 6 mA...

Page 66: ...mergency operation If the emergency operation is set to Pump OFF the motor of the pump is switched off when a cable break is detected The applied analog signal of 1 2 V or 2 4 mA represents the ac tua...

Page 67: ...d at the end of electrical bus line Switched off must be selected After termination is done an individual Wilo Net address is assigned to the pumps In the Settings menu select Universal Display text 1...

Page 68: ...ngs 2 Language The language can be set See Chapter 9 3 3 Initial settings menu NOTICE After selecting a language other than the one currently set the display may switch off and restart During this pro...

Page 69: ...y text 1 5 Display settings 1 5 1 Display brightness 1 5 2 Language 1 5 3 Unit 1 5 4 Key lock 1 5 4 1 Key lock ON Setpoint bar bar 1 Display settings 2 Key lock You can activate or deactivate the key...

Page 70: ...rol input OFF or 0 10 V signal of pumps that are switched off will start briefly This prevents blockage after long downtimes Pump kick Pump kick ON OFF Pump kick Interval Pump kick Speed Fig 29 Pump k...

Page 71: ...the pump automatically switches to a lower PWM frequency when a critical defined temperature in the drive is reached By doing so the required pump output is achieved NOTICE Due to the automatic PWM fr...

Page 72: ...nostics help 2 1 1 Device information 1 Diagnostics help 2 Device information you can read information about product names the product and serial number as well as software and hardware version 16 1 2...

Page 73: ...e double pump connection can be read NOTICE The overview of the double pump connection is only available if a double pump connection has been previously configured see chapter 12 Dual Double pump oper...

Page 74: ...t for a suction pressure sensor if in use The H act value is given if a differential pressure sensor dp c dp v is in use In the submenu Statistics Data the following information can be read Statistica...

Page 75: ...Switched OFF External interfaces SSM SBM relay Relay function SSM Collective fault signal SSM relay function Fault present Double pump SSM relay function System mode SSM SSM relay forced control Norma...

Page 76: ...place faulty fuses Pump makes noises Motor has bearing damage Have the pump checked by Wilo customer service or a specialised service centre and repaired if necessary Table 17 Mechanical faults 18 2 D...

Page 77: ...as occurred If the pump identifies as part of per manent monitoring that the cause of the error no longer applies the error message is re voked and operation resumes NOTICE The pump also performs an e...

Page 78: ...contacts between module and motor 408 There is flow through the pump in the opposite direction of flow External influences cause flow against the direction of the pump s flow Check power control of th...

Page 79: ...ce motor and or control module Additional information about causes and remedy The pump cannot determine which of the two component is defective Contact service 421 Electronic module defective Electron...

Page 80: ...substitute operation modes which ensure functioning of the pump without the required external value 557 No plausible sensor value at analogue input AI2 The configuration and the present signal lead t...

Page 81: ...ormation about causes and remedy The pump function is slightly impaired The motor meets the pump function up to the perform ance limit 573 Communication to display and operating unit interrupted Inter...

Page 82: ...fied by a qualified electrician Never use an object to poke around the openings on the electronic mod ule or motor and never insert anything into the module or motor Follow the installation and operat...

Page 83: ...ng parts pose a risk of cuts crush injuries bruises or impacts which can be fatal Always use suitable lifting equipment and secure parts against falling Never stand underneath a suspended load Make su...

Page 84: ...t removed The electronic module can be replaced without any risk DANGER Risk of fatal injury If the rotor is driven by the impeller when the pump is at a standstil dangerous contact voltage can arise...

Page 85: ...ces Following removal of the electronic module a po tentially fatal shock voltage may be present at the motor contacts Ensure system is voltage free cover or screen off adjacent live parts Close the s...

Page 86: ...en 86 Installation and operating instructions Drive for Wilo Helix2 0 VE Wilo Medana CH3 LE Ed 01 2022 06 Fig 31 Open the cover of the electronic module Fig 32 Detach the module fan connection cable...

Page 87: ...g 34 Remove module fan including cable and rubber seal Mounting the fan Install the new module fan in the reverse order 20 Spare parts Obtain genuine spare parts only from a qualified specialist or Wi...

Page 88: ...re parts 21 Disposal Information on the collection of used electrical and electronic products Proper disposal and appropriate recycling of this product avoids damage to the environ ment and risks to p...

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Page 92: ...Pioneering for You 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 www wilo com...

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