Wilo Yonos GIGA-N 125-5,5 Installation And Operating Instructions Manual Download Page 1

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Pioneering for You

Wilo-Yonos GIGA-N

6088793 • Ed.01/2020-10

Installation and operating instructions

Summary of Contents for Yonos GIGA-N 125-5,5

Page 1: ...Pioneering for You Wilo Yonos GIGA N 6088793 Ed 01 2020 10 en Installation and operating instructions...

Page 2: ......

Page 3: ...of delivery 18 4 9 Accessories 18 4 10 Permissible forces and torques on the pump flanges 18 5 Transportation and storage 19 5 1 Delivery 19 5 2 Transport 19 5 3 Storage 20 6 Installation and electric...

Page 4: ...monitoring 54 10 3 Maintenance tasks 55 10 4 Draining and cleaning 55 10 5 Dismantling 55 10 6 Installation 59 11 Spare parts 63 11 1 Spare parts list 64 12 Faults causes and remedies 65 12 1 Mechanic...

Page 5: ...hapter contains basic information for the individual phases of the life cycle Fail ure to observe this information carries the following risks Injury to persons from electrical mechanical and bacterio...

Page 6: ...bout locally applicable regulations governing accident prevention Have read and understood the installation and operating instructions Personnel must have the following qualifications Electrical work...

Page 7: ...ckaging and covers may be removed from suction or outlet openings for inspec tion purposes They must be put back on afterwards to protect the pump and ensure safety 2 5 Installing dismantling Wear the...

Page 8: ...ring protection Demarcate the noisy areas Take measures to reduce noise e g insulation noise barriers Leakages Observe local standards and regulations Avoid pump leakages to protect persons and the en...

Page 9: ...h this manual Any other use is regarded as non compliant with intended use 3 2 Improper use WARNING Misuse of the pump can lead to dangerous situations and damage Never use with fluids that have not b...

Page 10: ...rements 1 2 3 4 5 7 6 8 2 5 3 1 8 6 4 7 11 22 kW 1 5 7 5 kW Fig 1 Electronic module overview 1 Cover attachment points 2 Operating button 3 Infrared window 4 Control terminals 5 Display 6 DIP switch 7...

Page 11: ...ntrol function Proportional Integral Differential control is available By selecting a good combination of individual control elements the operator can ensure fast reacting constant control without las...

Page 12: ...le For communication between pumps and the building management system one IF mod ule accessories is required which is plugged into the terminal room The master slave communication uses an internal int...

Page 13: ...ations in the delivery head However pump 1 adjusts itself to the changed conditions Pump cycling is dependent on the ramp time and generally lasts 4 sec Behaviour of the inputs and outputs 10 4 0 V 0...

Page 14: ...ault display the status display will be shown on both pump displays for as long as communication is interrupted This resets the ESM SSM contact at the same time The slave pump display flashes and show...

Page 15: ...enu 5 1 4 0 A disabled pump can not be operated until the disabling has been manually lifted The setting can be made directly at each pump or over the infrared interface If a pump master or slave is d...

Page 16: ...the event of an overload The electronic modules are equipped with a non fading memory for data storage pur poses The data is retained no matter how long the module is disconnected from the power supp...

Page 17: ...ally isolated Speed control Built in frequency converter Relative humidity At Tambient 30 C 90 non con densing At Tambient 40 C 60 non con densing 1 Average value of the sound pressure levels on a spa...

Page 18: ...flanges pump made of grey cast iron DN Forces F N Torques M Nm FX FY FZ Forces F MX MY MZ Torques M Pressure port 32 315 298 368 578 385 263 298 560 40 385 350 438 683 455 315 368 665 50 525 473 578 9...

Page 19: ...spended loads Danger of serious injuries caused by falling parts Loads may not be carried over work places where people are present The safety zone must be marked so that there is no danger when the l...

Page 20: ...transport lugs without protection Never feed the lifting gear over sharp edges without protection Use lifting equipment with sufficient bearing capacity The stability of the lifting equipment must be...

Page 21: ...low conditions are complete and correct 6 3 Preparing the installation WARNING Improper handling involves risk of personal injury and material damage Never set up the pump unit on unpaved surfaces or...

Page 22: ...e base must be well contoured before it hardens Remove the pipe sleeves after the concrete hardens When the baseplate is laid insert steel rods vertically into the base at regular intervals The requir...

Page 23: ...d 2s Fig 16 Connect the pump voltage free with settling section upstream and downstream of the pump CAUTION Incorrectly carried out pipework installation can lead to material dam age Welding beads cin...

Page 24: ...ation of the pump can affect the alignment The motor must be aligned to the pump not vice versa Check the alignment before the first start CAUTION Changes to the alignment during operation can result...

Page 25: ...n with speed n in rpm DA in mm radial displacement Krperm in mm Coupling size DA mm S mm S2 mm 68 68 2 4 5 80 80 2 4 5 95 95 2 4 5 110 110 2 4 5 125 125 2 4 5 140 140 2 4 5 160 160 2 6 6 180 180 2 6 6...

Page 26: ...status including operating temperature and inlet pressure Fig 21 Checking the axial alignment with a calliper gauge Fig 22 Checking the axial alignment with a calliper gauge circumferential check Usin...

Page 27: ...he motor Place shims under the motor feet until the height difference is compensated Pay attention to the axial alignment of the coupling Tighten the hexagon head screws again Finally check the functi...

Page 28: ...t also be fitted with a residual current circuit breaker Observe the manufacturer s installation and operating instructions for the ac cessories DANGER Risk of fatal injury due to contact voltage Even...

Page 29: ...of residual current operated protection circuits Exception residual current devices which have a selective type B universal current sensitive design are allowed Labelling Trigger current 11 kW 30 mA...

Page 30: ...used e g mains connection cables or communication cables use ferrules Always lead the mains cable through the designated threaded cable gland M25 or M40 1 5 4 kW 11 22 kW 5 5 7 5 kW M25 M25 M40 Fig 2...

Page 31: ...ross sections Secure cable glands tightly Ensure that no drips can run into the electronic module Bend the cables into a drain loop near the threaded cable gland Unused cable glands should be sealed w...

Page 32: ...1 22 kW 1 5 4 kW Fig 28 Power terminals Please also see the following table Terminal assignment Additional earthing DANGER Risk of fatal injury due to electrical current As motors from 11 kW generate...

Page 33: ...In1 1 GND 2 24 V 3 according to the sensor cable designations 1 2 3 In2 input Setpoint input In2 can be used as the input for remote adjustment of the setpoint in any operating mode Type of signal Vo...

Page 34: ...tage circuit This means that the internal supply meets the requirements for safe supply isola tion the GND is connected to PE 6 7 6 Differential pressure sensor con nection Cable Colour Terminal Funct...

Page 35: ...se of hot fluids The pump must not be operated outside of the specified operating range Do not operate the pump with the shut off devices closed Make sure that the NPSHA value is always higher than th...

Page 36: ...llation that has not been precon figured both pumps are set to their factory setting After connecting the twin head pump communication cable the error code E035 is displayed Both drives run at the eme...

Page 37: ...e closed The bearings are filled with the right amount of lubricant of the right type if applic able All protective devices coupling guard module cover etc are correctly attached and tightened Pressur...

Page 38: ...aracteristic curves e g on data sheet Table 15 p c control NOTICE Alternatively constant speed or PID operating mode can also be set Constant speed Constant speed mode deactivates all other control mo...

Page 39: ...itive and the process value drops below the setpoint the control will increase the pump speed Negative PID Control If the P term is negative and the process value drops below the setpoint the control...

Page 40: ...e Symbol Description Symbol Description Constant speed control min Min operation Constant p c control max Max operation PID Control Pump is running 2 Input In2 external setpoint activated Pump stopped...

Page 41: ...until the displayed menu num ber is reached Wait time The remaining time in seconds is displayed until the next state is reached automatically or a manual input can be made ON X Set DIP switch to OFF...

Page 42: ...itches to the next level down After the change the number of the new menu level increases by one digit e g from menu 4 1 0 0 to menu 4 1 1 0 Information menu element When this symbol appears current s...

Page 43: ...ed personnel Error acknowledgement menu 6 0 0 0 Error acknowledgement If an error occurs the display shows the error page Pressing the operating button takes you from the error page to the error ackno...

Page 44: ...to the status page 8 6 2 Changing to menu mode To change to the menu mode 2 s While the display is showing the status page press the operating button for 2 seconds except in event of a fault Standard...

Page 45: ...ating button The number of the new menu level is displayed e g when changing from 4 4 1 0 to 4 4 0 0 NOTICE If the operating button is pressed for 2 seconds while a Level up menu element is selected t...

Page 46: ...onal settings can be made in service mode The mode is activated or deactivated as follows CAUTION Risk of material damage caused by changing the settings incorrectly Incorrect changes to settings can...

Page 47: ...N position Termination is activated NOTICE Both DIP switches must always be in the same position ON X To deactivate return the DIP switch to the starting position 8 7 Menu elements reference This chap...

Page 48: ...0 Consumption Energy consumption in kWh MWh 4 2 3 0 Pump cycling countdown Time to pump cycling in hours at a resolu tion of 0 1 h Shown only for twin head pump master and internal pump cycling Can be...

Page 49: ...peration or mains on signal is present SBM Run signal SBM Readiness signal SBM mains on signal 4 3 4 0 Ext off Signal present at the External off input OPEN Pump is switched off SHUT Pump is enabled f...

Page 50: ...ntdown Only displayed for twin head pump master 5 1 3 2 Internal external Internal pump cycling Only displayed for twin head pump master External pump cycling Shown only for twin head pump master see...

Page 51: ...ll sub menus 5 3 1 0 In1 sensor value range Display of sensor value range 1 Not displayed with PID Control 5 3 2 0 In1 value range Setting of value range possible values 0 10 V 2 10 V 0 20 mA 4 20 mA...

Page 52: ...setting OFF default setting settings are not changed by confirming Not displayed when access disable is active Not displayed when BMS is active ON confirming will reset the settings to factory settin...

Page 53: ...f frost make sure the fluid level is sufficient Operate the pump every month for 5 minutes Doing this prevents deposits from oc curring in the pump compartment 9 2 Shutdown and storage WARNING Risk of...

Page 54: ...roper operation can damage the pump or motor Operating with the shut off device closed is not recommended and generally dangerous in the case of hot fluids The pump must not be allowed to operate dry...

Page 55: ...ower supply and secure it against accidental switch on Any damage to the pump connection cable should only ever be rectified by a qualified electrician Observe the installation and operating instructi...

Page 56: ...oid dam age to interior parts 4 Put the slide in unit down at a safe workplace To continue dismantling the slide in unit fix it vertically in position with the drive shaft facing downward The kit must...

Page 57: ...Pull off the thrower 4 5 and V gaskets 4 3 3 Remove the bearing cover 4 2 and retaining ring 4 4 4 Loosen the hexagon head screw 8 2 remove the lock washer 8 3 and remove the pump support foot 8 1 5 C...

Page 58: ...electronic module due to non discharged capacitors Touching live parts will result in serious injuries or death Before working on the pump disconnect the power supply and wait for 5 minutes Check whe...

Page 59: ...d check the single components for wear before installation Damaged or worn parts must be replaced with original spare parts Coat location points with graphite or something similar before installation...

Page 60: ...e shaft nut 6 Fasten the pump support foot 8 1 with the hexagon head screw 8 2 and lock washer 8 3 Neck rings The pump is optionally equipped with exchangeable neck rings During operation the gap back...

Page 61: ...2 1 3 2 7 2 7 1 7 1 Fig 57 Fitting the slide in unit 1 1 1 2 14 Fig 58 Inserting the slide in unit 1 Mark positions of the parts that belong together with a coloured pen or scriber 2 Mount the impelle...

Page 62: ...move the cable for the differential pressure sensor 2 Fit the new O ring between the electronic module and the motor on the contact ing chamber 3 Press the electronic module vertically downwards into...

Page 63: ...5 kW 0 8 11 22 kW 4 3 Threaded cable gland union nut M12x1 5 M16x1 5 M20x1 5 M25x1 5 M40x1 5 3 0 6 0 8 0 11 0 16 1x threaded cable gland M12 reserved for connecting cable for an op tional differentia...

Page 64: ...data from the pump and rating plate This helps prevent return queries and incorrect orders 11 1 Spare parts list 1 3 1 4 17 18 1 2 1 1 2 2 2 3 1 2 2 1 2 2 2 3 1 2 4 5 4 2 4 3 4 4 4 1A 4 1B 4 2 4 4 4 3...

Page 65: ...g out electrical work can lead to death due to electric shock Electrical work must be carried out by a qualified electrician in accordance with the locally applicable regulations WARNING No persons ar...

Page 66: ...ror becomes a final fault The fault must be acknowledged at the pump 5 C A fault is present the pump stops immediately If the fault persists for more than 5 minutes the counter is increased After the...

Page 67: ...is higher than the design specification Check the pump dimension ing consult with the manufac turer X X X X The pump is strained Correct the pump installation X X X Pump unit poorly aligned Correct a...

Page 68: ...ly blocked If the blocking has not been remedied after 10 seconds the pump switches off Check shaft for ease of move ment contact customer ser vice A A Motor errors E020 Excess temper ature in wind in...

Page 69: ...ck elec trical installa tion F D E033 Intermediate circuit over voltage Voltage fluctu ations in the mains Check elec trical installa tion F D E035 DP MP mul tiple instances of same iden tity Multiple...

Page 70: ...s tomer service A A E121 Motor PTC short circuit Internal elec tronics error Contact cus tomer service A A E122 Interruption to NTC power element Internal elec tronics error Contact cus tomer service...

Page 71: ...ual Press the operating button Menu number 6 0 0 0 is displayed without flashing On the units display the current incidence x as well as the maximum in cidence of the error y are displayed in the form...

Page 72: ...6 0 0 0 6 0 0 0 6 0 0 0 S 1 1 1 1 S 0 60 12 3 E000 Fig 65 Acknowledging error type A or D Acknowledging error types A or D To change to menu mode press the operating button Menu number 6 0 0 0 flashes...

Page 73: ...ror y in the format x y Incidence X Y 6 0 0 0 6 0 0 0 S 3 6 75 12 3 E000 Fig 67 Acknowledging error type B X Y If the current incidence of the error is less than the maximum incidence Wait for auto re...

Page 74: ...ype B X Y 12 3 3 Error type C 1 4 8 7 3 6 5 2 Fig 69 Error type C flowchart Program step query Contents 1 Error code is displayed Motor Off Red LED On 2 Error criterion fulfilled 3 5 min 4 Error count...

Page 75: ...0 0 0 is displayed without flashing The graphics show The units display shows the current incidence x as well as the maximum incidence of the error y in the format x y After 300 seconds the figure for...

Page 76: ...ol single pump resumes Yes No Table 31 Error type E 5 1 2 4 3 Fig 72 Error type F flowchart Program step query Contents 1 Error code is displayed 2 Error counter is increased 3 Error criterion fulfill...

Page 77: ...time 300 sec 5 7 1 0 Display orientation Display on original orienta tion 5 7 2 0 Pressure value correction active 5 7 6 0 SBM function SBM Run signal 5 8 1 1 Pump kick active inactive ON 5 8 1 2 Pump...

Page 78: ...mestic waste Please note the following points to ensure proper handling recycling and disposal of the used products in question Hand over these products at designated certified collection points only...

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Page 80: ...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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