PUZeN e Booster System

Installation and Operating Instructions

MODEL
PZEU Series

PZEC Series

PZEM Series

PZEH Series

Please read your instruction manual carefully as it provides instructions on safe installation, use, and
maintenance. The appearance and specifications may be changed without notice to raise the unit’s
quality.

Homepage ☞ http://www.wilo.co.kr
Contents

Thank you for purchasing WILO Pumps products.

You can use more conveniently after reading

these operating instructions

Contents

Section Subject page

0 Contents -------------------------------------------------- 2

1 Introduction ---------------------------------------------- 3

2 Characteristics of products ----------------------------- 3

3 Application ------------------------------------------------ 3

4 Specification ---------------------------------------------- 3

5 Safety precautions --------------------------------------- 4

(Make sure to read & follow carefully!)

6 Transport and intermediate storage ------------------- 5

7 Components of product ---------------------------------- 5

8 Installation ------------------------------------------------ 6

9 Operating principle --------------------------------------- 10

10 Operation -------------------------------------------------- 12

11 Maintenance ----------------------------------------------- 13

12 Trouble – shooting ---------------------------------------- 15

13 Control unit ------------------------------------------------ 17

2
Introduction
▶These instructions for use contain information on PUZeN e booster system.
Before using your booster system, you should read and understand the entire instructions.
Make special note of all danger, warning and caution statements. Keep the instructions for using
as a reference.

▶ If not observing these operating instructions, a serious injury or a death could happen
by electric hazard. Also, install spare products at the special place where serious damages
could be happened by no water supply caused by product troubles.

▶ Move together these operating instructions and a product

when changing the location of the product. In this case,
the using purpose and installing condition should be appropriate.
Use after necessary treatments (example, Reset the operating data)

▶ Don’t use except the normal purpose and installing conditions. If not, It could cause
troubles or accidents. In that case, customers could have responsibility about that.

▶ If you have any question or error of these operating instructions,

please contact to our agents or the head office.

Characteristics of product
▶ Applying to new technology in booster system.
▶ Optimum structure through the Controller module.
▶ Minimize pressure fluctuations through multi FC
▶ Offering RS-485 Modbus communication port.
▶ Automatically distribute load to each pump.
▶ 7” full color touch screen as standard.
▶ Can control max. 6pumps

Application
▶ Pressurized water supply and pressure boosting in residential, commercial and
public buildings, hotels, hospitals, department stores and for industrial and process engineering.

※ Only use this product with clean water!

※ Excessively high or heavily fluctuating inlet pressure will require the provision and installation
of a pressure reducing valve to maintain a constant inlet pressure level.

Specification
Refer to the name plate about capacity, pressure head, voltage, power of a booster system.
Standard specification are as follows. (Some specifications could be changed by option)
▶ Product classification PUZeNe Series : Inverter control system

Liquid Clean water(0~70 ℃) Location Indoor

Surrounding temp. 0~40 ℃ Suction condition Pressurized

Under RH 85% Protector for a motor Over load relay

Humidity
(Over dew point)
3Phase, 380V, 50Hz
Pump type Centrifugal pump ※ Pump power source
(Standard)

※ Power source could be changed as each product. Therefore, must check the name plate surely. 3
Safety precautions (Make sure to read & follow carefully.)
These instructions contain basic references which must be strictly adhered to. It is imperative
for the installer and the operator to carefully read these instructions prior to installation and
commissioning. Please observe the safety directions under the main heading and following those.

1 Safety marks contained in these instructions.

The following safety marks explain the grades of human and property damage when users ignore
the instructions.

When not following indications marked by the warning signal

Death or serious Injury could happen.
Warning
When not following indications marked by the caution signal
Human damage or property damage could happen.
Caution
This signal warns the electric hazard.
Therefore, follow the indications of the warning signal or the
instructions carefully.

2. Personnel qualification

The personnel installing the pump must have the appropriate qualification for this work.

3. Dangers if the safety indication are not followed.

Failure to observe the safety indications can endanger persons and the installation.
Failure to abide by the safety indications will nullify your right to any claims for compensation.
In particular, failure to observe these indications can create the following dangers:

- Failure of important functions in the installation.

- Dangers to persons caused by electrical and mechanical effects.
- Environmental pollution by dangerous handling solution leakage.

4. Safety instructions for the operator.

Local regulations for the prevention of accidents must be observed. Dangers resulting from
electrical energy are to be prevented national/local energy supply company regulations must
be observed.

5. Safety indications for inspection and assembly work

The operator must ensure that all inspection and assembly is carried out by authorized and
qualified specialist staff who have studied the operating instructions in detail.
In principle, work may only be carried out on the installation when it is at rest.

6. Unauthorized modification and manufacture on spare parts

Changes to the pump/installation may only be made in agreement with the manufacturer. The
use of original spare parts and accessories authorized by the manufacturer will ensure safety.
The use of any other parts may invalidate claims invoking the liability of the manufacturer for
any consequence.

7. Improper operating modes

The operational safety of the appliance is only guaranteed if it is used as intended in

accordance with the operating instructions. The operational tolerance limitations stated in the
catalogue/data sheet must not be exceeded under any circumstance.
4
 Transport and intermediate storage
Make sure if there are the damages of products on transport or not. If you find any damage,
contact us. Deliver productions which have been properly packed.
Don’t give any impact on products

Transport of the unit requires proper preparation and handling. Always make sure that
the pumps and unit remain in horizontal position during transport and cannot slip out
Warning of the transport suspension arrangement. If the pump/unit slip out of the suspension
arrangement, It may cause personnel injury and damage to property!

Avoid a extreme variation of temperature and humidity when keeping at a warehouse.

Condensed water caused by severe humidity could cause the damage of metal components
Caution Admitted temperature = -10 ~ 50 ℃ / Admitted humidity = under RH 85 %

Be careful not to stress on cables of motor on delivery!

If cables are damaged, it could cause a electric shock, a leakage and a fire.

Components of product

Fig. 1

No. Components Amounts

1 Control unit 1
2 Pump 2~6
3 Bed 1
4 Manifold for suction 1
5 Manifold for discharge 1
6 Isolating valve 2/pump
7 Check valve 1/pump

•Shape of components could be changed according to models.

5
Installation
Check whether products are complete or not!
■ Ascertain the same product as you’ve ordered by a name plate and perhaps,
if any, damage on delivery.
■ Ascertain all components of pumps are complete. (refer to “components of products”)

A booster system is used with a pressure tank which has proper capacity and is
connected to the discharge manifold. Especially, the step control type must use
Warning a pressure tank, unless, it could cause failures by severe pressure fluctuation
and frequently repetition of the start and stop.
1. Install location
- A booster system is for the indoor, nevertheless, if installed outdoor, make devices to avoid
rain, wind and damage by freezing.
- The suction of a pump should be pressurized. (recommended suction pressure : 0.2㎏f/㎠)
- Don’t put the hands or foreign matter such as stick. Serious personal injury and property
damage may result.
Water level of a reservoir always keep higher than the top of a pump’s suction for
avoiding dry operation. Keep over recommended suction pressure at the suction
Caution of a pump. Especially, must vent air after cleaning a reservoir entirely! And
fluctuation of the suction pressure should be below 1.0㎏f/㎠
- Install where to be without direct sun light, dirty & humidity and corrosive and inflammable gas
whereas, to have good ventilation. (Admitted surrounding temperature is 0 ~ 40℃.)
- Install where easily to repair and check. Make booster system handled by a qualified personnel.
- Install where is close to water source and the length of a suction pipe should be short.
- If there is a possibility to be frozen to burst, Use complementary goods for avoiding freezing.

Obviously, make facilities for drain to avoid submergence damage by

Warning water leakage on installation, replacement, repair, and pump’s failure!
2. Plumbing

- Make suction/discharge pipes not weigh a booster system

- Make a suction pipe short and not bent as much as possible.
- Attach the strainer for prevent pumps from a foreign matter interrupting normal pump operation.
- Recommend to attach flexible joints or valves at a suction/discharge pipe conveniently
to disassemble.
- Recommend to install by-pass pipe at a discharge pipe for conveniently checking.
- Equip device to avoid water hammer at discharge pipe.
- If you operate it when damaged pressure tank, it is possible that discharge pressure is irregular
or has leak.
- In near the confluent pipe, don’t bend the discharge and suction pipe. It may be cause of noise
and vibration.
Enlarge a suction pipe over one level more than standard in case suction is over 10m or
bent over two times. If not so, the fluctuation of discharge pressure could be severe or
Caution the protector of dry operation could work at suction side. Also, do as the above in case
that electric valves attach to discharge or water demand severely!
3. Electric wiring

Electric Wiring should be performed by electrician having a license. In order to prevent electric shock,
the breaker against electric leakage and the grounding should be installed.
- Electric wiring about the main parts should be completed on installation site for avoiding damage
during the transport.
- The main (R.S.T) and earth (E) should be wired in accordance with the wiring diagram inside of
the control unit.
- When moving and installing the panel, bring each sensor with it to prevent extension electrical
wire. And don’t wire together power and sensor wiring(More than 10cm)
- Don’t connect the earth wire with gas pipes, or it could be the cause of an explosion. 6
 Installation
- Please check the following items
① Is a breaker for the electric leakage proper?
② Is the electric wiring proper? (about the connecting state and the diameter of lines)
③ Notice that three terminals of a motor should be firmly assembled.
- Please check the rotating direction of a pump! The direction is marked on a motor fan cover
or a pump. Don’t run the pump reversely.
- Don’t allow the power wires to come into contact with piping, pumps and motors.
- The power source should be in accordance with the name plate.
4. Dry running protector
Booster system may occur fatal damage in driving without water.
Dry running protector is equipped to avoid pump’s dry running.
On the improper suction condition, a electrode bar could work abnormally.
Before installing, please check whether the suction condition is proper or not!

1) Protecting dry running with electrode bar

Through electrode bar, you can use it without any additional setting.

At the Suction, a electrode bar is assembled for avoiding dry operation

Electrode bar

Air purging plug

Fig. 2 Dry running protector

(The place impossible to use a electrode bar)

If a suction pipe is too long or bent too many times, the function against
dry operation could work, because air is suctioned together with water on operating.

Caution If abnormal noise happen at the suction, stop the system, and after improving
the suction condition, operate a system again.
Don’t use the system at the place where air is apt to be suctioned with water.
If not, the components for rotating are apt to be broken.

7
Installation

2) Preventing low suction pressure by pressure transmitter

Preventing dry running by receiving the signal from the transmitter and sensing the suction
pipe pressure with pressure transmitter method.

Fig 3. Pressure transmitter in the discharge pipe

5. Pressure transmitter on discharge side

pressure transmitter on discharge side to drive booster system.
Two of sensors are installed on discharge pipe for main sensor and spare sensor function.

Fig 4. Main and spare sensor by using two pressure transmitter

8
Installation

Don’t ramify pump’s terminal for power supply to use another purpose for it.
That is the reason for system fault.
Don’t come metallic foreign substance into internal control panel during the
electric wiring.
Don’t exceed ±10% of working voltage.

Input terminal for pump’s power supply

Output terminal for fault signal
Input terminal for remoting auto operation
Input terminal for signal of dry-running protector

Input terminal for signal of pressure transmitter

Output terminal for pump operation status

Based on 2pumps

Fig 5. Wiring diagram(It could be changed depending on specification of power supply)

Name of terminal Function

R, S, T, E Input terminal for pump’s power supply(Standard: 3Φ 380V 50Hz)
Output terminal for fault signal
In case that booster system occurs some fault, output fault signal
EC, EA
as electric contact. If the fault is cleared, automatic reset.
Normal condition: EC-EA(OFF) Fault condition: EC-EA(ON)
RC, RA Input terminal for signal of remoting auto driving
Input terminal for water level(electrode bar) signal of dry-running
DP
protector
24V, PT1, PT2, PT3 Input terminal for signal of pressure transmitter
CM, 1R, 2R Output terminal for pump operation status
* Composition for terminal is changed depending on specification of power supply, option for
control panel.
* Refer to wiring diagram attached on each control panel.

9
 Operating principle
1. Single Inverter operating mode, PZEU Series

- Operating the pumps stand in a row from 2 to 6.

- Depending on the sequential operation, all pump(among the selected by pump setting status
with no abnormalities) evenly operate.(To prevent over-load of the one pump)

Stop 1 Variable speed pump

1 Constant speed pump
1 Variable speed pump
…………….. 5 Constant speed pumps
1 Variable speed pump

Increase in water demand

Decrease in water demand

Pressure
Adjustable stop pressure(p- Stop)

Adjustable starting pressure(p- Start)

On/off pressure for peak load pump

Capacity

<Operation condition>

① When current pressure goes down below set-pressure in discharge parts,

FC pump is operating initially.

② If the capacity is continuously increasing, FC pump will be operating to max. speed. When the
FC pump reach max. speed, constant speed pump is operating in a row.

③ If the capacity is decreasing, FC pump will go down to speed by starting frequency.

Constant speed operating pumps will be stopped and FC pump keep set-pressure constantly.

④ If there is no capacity, FC pump will raise current-pressure by stop-pressure and then

stop operating.

10
 Operating principle
2. Combi Inverter operating mode, PZEC Series

- Operating the pumps stand in a row from 2 to 6.

- FC pumps are set according to attached FC numbers.
- The operation of the FC pumps is given priority depending on setting.
- Constant speed driving pumps are operated by sequential.(To prevent over-load of the one pump)

1 Variable 2 Variable 1 Constant speed pump 4 Constant speed pumps

Stop speed pump 2 Variable speed pump 2 Variable speed pump
speed pump

Increase in water demand

Decrease in water demand
In 2 Frequency Converter

4-Pumps, 2-FC

Adjustable stop pressure(p- Stop)

Pressure

Adjustable starting pressure(p- Start)

On/off pressure for peak load pump

Capacity

<Operation condition>

① When current pressure goes down below set-pressure in discharge parts,

FC pump is operating initially.

② If the capacity is continuously increasing, FC pump will be operating to max. speed, and second
FC pump will drive. It becomes main pump.

③ If the capacity is increasing, constant operation pumps drive in turn.

④ If the capacity is decreasing, FC pump will go down to speed by starting frequency.

Constant speed operating pumps will be stopped and FC pump keep set-pressure constantly.

⑤ If the capacity is decreasing continuously, main FC pump stops driving and the next FC pump is
set as the main pump and then operate.

⑥ If there is no capacity, FC pump will raise current-pressure by stop-pressure and then

stop operating.

11
 Operating principle
3. Multi Inverter operating mode, PZEM Series

- Operating the pumps stand in a row from 2 to 6.

- All of the pumps are operating through FC. Operation is set by step control.

Stop 1 Variable speed pump 2 Variable speed pumps …………….. 6 Variable speed pumps

Increase in water demand

Decrease in water demand

4 FC pumps

Adjustable set pressure

Pressure

On/off pressure for FC pump

Capacity

<Operation condition>

① When current pressure goes down below set-pressure in discharge parts,

FC pump is operating initially.

② If the capacity is continuously increasing, Initial FC pump will be operating to max. speed.
When the FC pump reach max. speed, second FC pump will operate. It will be main FC pump.

③ If the capacity is continuously increasing, Second FC pump will be operating to max. speed.
When the FC pump reach max. speed, third FC pump will operate. It will be main FC pump.

④ If the capacity is decreasing, third FC pump is stopped and second FC pump will shift to main
pump.

⑤ If the capacity is decreasing, the main FC pump is stopped. The other FC pumps will shift to
main pump. Main FC pump is maintaining the set pressure.

⑥ If there is no capacity, FC pump will raise current-pressure by stop-pressure and then

stop operating.
12
 Operating principle
4. Step operating mode

- Operating the pumps stand in a row from 2 to 6.

- All of the pumps are operating by step control if there are no problems in the pumps.
(To prevent over-load of the one pump)

Stop 1 Constant speed pump 2 Constant speed pumps …………….. 6 Constant speed pumps

Increase in water demand

Decrease in water demand

3 pumps

Main pump
Pressure Stop pressure
Stop pressure for
step control

On
pressure

Capacity
-q0~q1: one pump is operation/stop repeatedly.
-q1~q2: one pump is operation continuously.
-q2~q3: one or two pumps are operation among the whole pumps.
-q3~q4: two pumps are continuously operating.
-q4~q5: two or three pumps are operation among the whole pumps.
-q5~q6: three pumps are continuously operating.

<Operation condition>

① When current pressure goes down below set-pressure in discharge parts,

one pump is operating initially.
② If the capacity is continuously increasing, the other pumps are operating by turn.

③ If the capacity is decreasing, initial operating pump will be stopped.

④ Pump will be stopped, when it reach following conditions.

▶If the pump is operating, pump will not stop over the stop pressure; It should be past
“Min. run time”.
▶Currently several pumps are operating. If you want to stop it, “Seq. delay time” should be past.
▶Merely, pump’s auto operation switch turns off or has a trouble which is stopped. In this case,
“Min. run time” does not use, it will follow “Seq. delay time”.

⑤ If there is no capacity, last operating pump will raise set pressure and stop.
13
 Operation
Close the door of a control unit on operating for avoiding electric accidents
by high voltage and hazards caused by the leakage of pumps and pipes.
Besides, electric appliances around a system should be treated in the same
Warning
way.
Care not to block the motor ventilator with unexpected materials before
operating. It could cause a fire, damages of a product.
Caution Please Re-drive after turning off all lamps when stopping booster
system.
1. Initial operating order
Air vent
valve
Ready to ① Check a main power breaker and a protector capacity.
operate ② Check the cable square of main power.
③ Check a main power voltage.
④ Check connecting state of pipes and wires.
⑤ Check water level in a suction reservoir. Fig 6. Air vent valve
At each pump, close a isolating valve in the suction and release a air vent valve(Fig
6.) and slowly open a isolating valve in the suction. Water and air come out together.
Air vent
If air vents sufficiently, fasten the plug again and open the isolating valve
completely.(The operation with a isolating valve close could cause dry operation and
troubles.)

① Supply power (Pump power / Control power)

Supply power
② Turn on all breakers (MCCB & ELCB) in a control unit.
At that time, pump operating switch(page19,6) must be placed “Stop” .

Check the rotating direction of a pump as operating each pump in a short term
Check the
rotating by pump operating switch(page19,6) placed “Manual”. the rotating direction of a
direction pump is marked on the motor fan cover or the pump. If the direction is reverse,
change two of pump power lines (R.S.T).

If you separate panel and motor’s wiring, CONNET it in same order as before
separation. Otherwise, it will be cause of fault about different direction of
Caution rotation FC and direct operation.

Set operating data for the automatic operation.

Install
operating
(The setup of operating data for each items refers to 『Set』
data ☞ Essential operating data :
Setting Pressure, Final Stop Pressure, Inverter Minimum frequency, Shut-Off Pressure

If pump operating switch(page19,6) is placed “Auto” and touching “Auto” icon on the
Automatic
7” touch screen display, the system is operated in accordance with operating data.
operating
Please, check operating state and whether it work normally or not.

At initial operation, Must vent the air which stayed inside pipes or pumps as
opening an air vent plug.
If air does not vent sufficiently, even if opening a tap, water could not come out.
On operating, check whether pressure, vibration, and noise are normal or not.

14
Maintenance
When repairing or checking the system, must cut off all powers and make
pumps stop for the safety. On automatically operating, there is the hazard
Warning that the system could be operated unexpectedly.
When flooded the product, there is concern about electric shock. You must drive after
repairing and safety checking trough WILO service center.
1. General check

- In case that on-pressure, off-pressure, electric current and noise are higher than normal value,
refer to 『trouble - shooting』.
- If a mechanical seal is normal, there is almost not leakage.
If the leakage is too much, replace it with new one.
- Check up the leakage and the damage of pipes.

2. Adjustment of the on-pressure

Adjusting of the on-pressure only in case that the discharge pressure is too high or low

3. Maintenance in the winter

In the winter, when not using for long time to avoid being frozen to burst, use thermal insulations
for pipes and manifolds or drain water from pumps and manifolds through plugs.

4. Charging the pressure tank.

On checking up the pressure tank, if the pre-loading pressure of a tank is too low, charge air
as the following way. After completely draining the water in the tank, open the cap on the top of
a tank and charge air with a air compressor. Be careful not to charge the oil, which is mixed with air,
to the pressure tank. If the pre-loading pressure is too low, the pressure tank does not normally
work. Oppositely, if the pre-loading pressure is higher than the on-pressure, the on/off of the pump
is too much repeated. in that case, vent air as pressing a part popped out in the center of a air valve.

※ The pre-loading pressure is set as the 90% of on-pressure or

“ on-pressure - 0.5㎏f/㎠ ” (deviation ±10 %)

Cap

Valve stopper

Air valve

Fig 7. Membrane tank

15
Maintenance

5. Checking the control unit

Don’t arbitrarily change the structure and installation except the operating data.
The personnel checking the control unit must have the appropriate qualifications.
Must turn off the main power before the inspection or the maintenance of a control unit.
- Carefully check up the following items periodically.
① The cooling state of a inverter.
② The overheat, the abnormal smell, the color deformation of a part in a control box.
③ The state of wiring.
④ The vibration and the noise.
- Never do a insulation test nor a withstand voltage test. It could breakdown the semiconductors
in the control unit.

- The static electricity that is occurred by touching, damages the electric circuit. Therefore, must
handle the circuit board with care.

- In a inverter type, even after the main power has already been off, it takes 3~4 minutes to
completely discharge a inverter. Therefore, wait until the inverter is completely discharged.

- After turning off the power, check the rust of bolts and nuts. Tighten loosened screws and nuts.

- In case of a inverter type, when there is a foreign matter by the cooling fan of a inverter, cooling
capacity becomes down. Therefore, removes it, after turning off the main power and completely
discharging the inverter.

- Check up the rotating troubles of cooling fans, the troubles of magnetic contactors, the abnormal
noise, and if there is any trouble, replace it with new one.
6. The replacement time of major components

The expected life of each component is calculated on the normal operating condition. Replace
the component by the following criteria.
Classification Component Life time Criterion of replacement
Mechanical seal 1year Excessive leakage
Pump &
O-ring and gasket Each time Whenever disassembling
motor
Motor bearing 3years Abnormal noise or severs noise

Mechanical Pressure transmitter 3years When output signal is not correct

parts Pressure tank 3years Abnormal operation(Pressure fluctuation)
Severe contact’s damage or abnormal
Magnetic contactor 3years
operation
Severe contact’s damage or abnormal
Relay 3years
operation
Control unit
Inverter electrolytic
3years When capacity is reduced
condenser
Inverter cooling fan 2years Abnormal noise
Circuit board 3years Uncertain performance

• When disposing a printed circuit board or electric components, observe the relevant law!
• Our product include a printed circuit board. Don’t dispose it at a common garbage can!
16
Trouble-shooting
1. General faults

Fault Cause Remedy

Even if a tap is open, • A discharge valve is closed. • Open a valve.

water does not flow. • It is not enough to vent air. • Vent air through a plug.
• Trouble in a pump/ a motor. • Repair or replace.
• A motor rotates reversely. • Exchange two of three main power
terminals in a control unit.
• Water level of a reservoir is low. • Compensate water to a reservoir.
• Trouble in a pressure transmitter. • Repair or replace.
• Operation mode is in the “STOP”. • Change a operation mode to the
“AUTO”.
• Trouble in wiring(Disconnection) • Repair or replace.
• On-pressure is low. • Reset the on-pressure.

Even if all tape are closed, • Off-pressure is high. • Reset the off-pressure.
pump don’t stop. • Trouble in a pressure transmitter. • Replace.
• The operation mode is “Manual” • Change the operation mode to
“AUTO”.
• Trouble in a control unit. • Repair or replace.
• Leakage in pipes. • Repair or replace.
• The performance of pump is low. • Repair or replace.

Pump is running without • Leakage in pipes. • Repair or replace.

water flow. • Leakage in a check valve. • Repair or replace.

Vibration of pump is • The gap of on & off-pressure is • Reset a on & off-pressure.

abnormal. small.
• Trouble in a pressure tank. • Recharge air to the required
pressure.
• Pressure fluctuation in pipes. • Repair pipes(remove air).

Water doesn’t reach to • On-pressure is low. • Reset a on & off-pressure.

the highest tap. • The selection of a system is fault. • Recheck water capacity & head.
• Pump’s performance is down. • Repair or replace.

Pump don’t work by turns • Trouble in a control unit. • Repair or replace.

or in parallel. • Trouble in a pressure transmitter. • Repair or replace.
• Trouble in a pump or a motor. • Repair or replace.

The MCCB in a control unit • Short of wiring between pump • Repair or replace.
is tripped. and power.
• A circuit wiring short or a • Repair or replace.
damaged breaker
• Short of power line. • Repair or replace.

Pressure fluctuation • Inflow air because a suction pipe • Reduce the pipe’s length & enlarge
is severe. is too long or the diameter is too the diameter of pipes.
small.
• Operating without a pressure • Check pre-loading pressure of a tank
tank or the pre-loading pressure and adjust it.
is incorrect.
• Electric valve works or shifts on • Install a pressure reducing valve and
water demand is severely large. enlarge capacity of a pressure tank.

17
Operating Instructions of Control Panel
Construction of control panel

No. Part Name Q’ty(pcs) Purpose

1 Main Circuit Breaker 1 For cut-off main power

2 Molded Case Circuit Breaker 1~6 For protecting pump

3 Transformer 1 For supplying power to control

4 Frequency converter 1~6 For operating pump

5 PCU+G22 1 Controller

6 Pump operating switch 2~6 For changing pump’s operating mode

7 Magnetic contactor 4~12 For operating pump

• Construction of control panel could be changed according to models.

19
Safety rules
1. General
Installation and commissioning by trained and qualified personal only!

1.1 About this document

These Installation and operating instructions are an integral part of the product.
They must be kept readily available at the place where the product is installed. Strict
adherence to these instructions is a precondition for the proper use and correct
operation of the product. These Installation and operating instructions correspond to
the relevant version of the product and the underlying safety standards valid at the
time of going to print.

2. Safety
These instructions contain important information which must be followed when installing
and operating. These operating instructions must therefore be read before assembly and
commissioning by the installer and the responsible operator. Both the general safety
instructions in the "safety precautions" section and those in subsequent sections
indicated by danger symbols should be carefully observed.

2.1 Danger symbols used in these operating instructions

Safety precautions in these operating instructions which, if not followed, could cause
personal injury are indicated by the symbol.

When warning of electrical danger with.

Warning
2.2 Qualification
Installer must have a qualification for the work.

2.3 Warning when not following safety instruction

If you don’t follow safety instruction, people can be in danger and you can’t get any
warranty. You may meet following danger.
- Failure of critical function.
- A person’s risk by electrical or mechanical impact

2.4 Safety instruction for product manager

- Obey the existing regulation for accident prevention.
- Remove the risk factor by electrical energy

2.5 Safety instruction for checking and installing work

Only technical expert that know well about instruction checks and installs the
product. Please do basic work in stop status.

2.6 Unauthorized modification and spare parts manufacturing

- If you want to change the components, get permission manufacturer in advance.
- Using genuine spare components and authorized in manufacturer part is safe.
- If you use other components and what happens, you can’t get warranty.

2.7 Not allowed operating method

- Only in accordance with the correct use instruction in the manual, work normally.

3. Transport and intermediate storage

The control panel is to be protected against moisture and mechanical damage caused
jolts/impacts.
It should not be exposed to temperatures outside the range -10 C to + 50 C.

4. Scope of application
The PUZeNe is used to automatically control of pressure boosting systems.
It is used in water supplies of residential high rise buildings, hotels, hospitals,
administrative and industrial buildings. 20
Product and Accessories
1. Functional description
PUZeN e system is controlled and managed by the PCU+G22 in conjunction with the
respective pressure and transmitters. The unit pumps are started and stopped in cascade
mode in response to demand variations by pressure-actuation within the range between the
set pressure levels. Splitting the unit capacity onto a number of small pumps ensures
constant adaption to the actual demand situation within the limits of the set pressure level.

2. Structure of Control System

. PUZeN e system can control up to 6 pumps.
. The design of control system configured by pump and frequency converter configuration as
PZEU series(1 frequency converter), PZEM series(each frequency converter to pumps) and
PZEC Series(2~3 frequency converter)

3. Operation Mode
3.1 FC operation
An electronic pressure sensor provides the actual system pressure value as a 4-20 mA
current signal. The controller(PCU+G22) then keeps the system pressure constant by
comparing the desired and actual values. The speed controlled base load pump will start
up if required. Here the speed of the pump depends on consumption. If the power
requirements of this pump can't be met, a second pump is switched on. With increasing
requirement further pumps will be switched on. If the requirement drops such that the
controlling pump is operating in its lower power range and is not needed to meet
requirements, one pump after the other switches off. At last the base load pump
switches off by the zero flow detection. With decreasing system pressure under the set-
point, the system switches on again.

3.2 Non-FC Pump operation

Operating method is almost same with FC operation but non-FC pumps are only
operating with the constant speed.

4. Operating and stop of pumps

When just one pump is operating, it will be stopped after increases set pressure. If pressure
doesn't decrease after the increased set pressure is returning to the original set pressure,
basic load pump will turn off after the specified time.
When FC failure in PZEU and PZEC series, it automatically switches on step control.
(It is option in PZEM series)

Function

Optimal operation control for peak-load pump

The PCU+G22 optimize the peak-load pump on/off control.
Decrease unnecessary pump running and increase pump life cycle and save the energy.

Optimal speed control for variable speed pump

Reflect the law of similarity in program, when peak-load pump is on/off, minimize the
pressure hunting.

Pressure Trigger
Display the set point pressure and actual pressure by real time graph.

21
Function
Indication of pump load rate
Display each pump load rate as circle graph.

Real time indication of pump operating rate

Display real time indication of pump operating rate.

Help
Display each function’s description for user.

Change of pressure unit and power unit

Supply various pressure and power unit for user.

List of pump failure hisrtoy

Maximum 37 alarms occur history can save and the alarm list used for booster system
maintenance and prevent trouble.

Schedule operation
Automatically change the pressure set value according to hourly, monthly, weekly, seasonal
schedule mode which can be set by users.

Standby pumps
The standby pump, which is defined by user, does not run during the normal operation. If the
normal operating pump is stopped due to fault, the standby pump is cut-in.

Pump changeover
The pump with the lowest running hours is initially started and lastly stopped for the running
time optimization.

Sequence delay time or Delay time for cut-in and out

For reducing pressure overshoot and the number of start/stop time of pumps, user can set the
delay time(s) for pump cut-in and cut-out.

Stop at the small outlet water capacity(Stop pressure of main pump)

Main pump stops in small water capacity or stopping water capacity which can be detected by
pressure sensor in a periodic time.

Max. pressure setting

Protect pipe system and pump system with auto-stopping for the unexpected pressure rising in
outlet. System is automatically started when the actual pressure is increased up to the
pressure set value after stop.

Min. pressure setting

For the preventing continuous running of system due to the leakage in the outlet piping
system or pump system, the pump system stops when detecting the minimum pressure which
can be set by user.

22
Function
Warning at abnormal low pressure
For the detecting of the leakage in the outlet pipe or dry running when the actual pressure is
lower than pressure set value.

Ramp-up and -down time of frequency converter

For stabilizing of the output pressure and protecting motor, user can set the ramp-up and
ramp-down time of frequency converter.

Min. frequency setting

To meet the required pressure quickly, setting the FC starting frequency.

Preventing of the pump blocking

The pump starts automatically and runs for a short time to prevent the pump blocking after
the prolonged shutdown or the damage due to the operation with air in water.

Auto and manual operation

User can choose the operation mode either automatic or manual operation.
(PZEU Series standard)

Kick-off
The pump kicks off in case of fault.

Auto re-start
User can choose auto re-start or manual re-start when the electrical power is re-supplied after
power failure.

Dry running protection

For ensuring from the damage of pump and shaft seal due to dry running, all pumps are
stopped when the detecting of dry running through sensing device. After removing causes,
system can automatically re-start or manually start. These starting methods can be selected in
the menu. After over 5 times auto re-starting, system does not automatically re-start.

Locking password
Password can be set for the preventing from the unauthorized changing of the important
setting values and operation parameters of system except the basic setting values.

PID control
Change the number of operating pump or speed as frequency with PID control in case of there
is a difference between feedback value and set value.

Wired external controller

Externally control the pressure set value, start and stop of the system via serial
communication(RS-485)

23
Function
Compensation for friction loss
Change the pressure set value to compensate the friction loss according to user s definition.

Differential pressure control

Through additional sensor and function, it can circulate hot water by differential pressure
control(Optional).

Number of starting time

User can define the minimum running hours or operating counter per hour.

Diminishing(Reduction) operation
Pump system does not operate as maximum capacity in case of the electrical power shortages
or water shortages.

Starting up

When you are starting up the pump, you should have service from the WILO service center.
Before the first putting into power, performing moderate connecting wire. In particular,
checking the connection. Starting up pump, you will check the whole of procedure. And refer to
installation and operating instructions.

Re-tighten all supply terminals before putting the unit into operation !

1. Factory setting
The controller is preset factory side. This factory presetting can be restored again by
WILO-Service.

2. Overcurrent protection
OCR(Over Current Relay)in MCCB or Frequency converter protect motor from overcurrent
damage.

24
Fault message
When occur system fault, the cause of the fault must be removed.

Fault text Causes System Remedy

conditions

Pump # Fault Overcurrent of motor. Pump stop Check the pump

Detecting dry running by

Dry running System stop Check suction condition
dry running protection.

Dry running occurred more than

Repeated dry System stop Check suction condition
5 time in the 24 hours.

System stop or
FC # Fault Fault of FC. Check # FC
run peak pump

Continuously
Low discharge Low discharge pressure even Check discharge
operating
Pressure if all pumps running. condition
but still alarm

Wrong parameters in set

Setting values System stop Check setting values
values.

Signal error from transmitter.

And value of sub-pressure Check pressure
PT Fault System stop
transmitter is different with main transmitter
transmitter value over 20%.

Over pressure than Max. Check discharge

Max. pressure System stop
pressure value. condition

Repeated Max. Pressure error

Repeated Max. Check discharge
occurs more than 5 times within System stop
Pressure condition
5 minutes.

Low pressure than Min. pressure Check discharge

Min. pressure Alarm or Stop
value. condition

S-PT Fault Fault of sub transmitter. Only alarm Check S-PT

Fault of the main transmitter.

M-PT Fault Only alarm Check M-PT
(automatically shift sub transmitter)

Value of sub. pressure transmitter

10% PTs Error is different with Alarm Check S-PT & M-PT
main transmitter value over 10%.
Low suction Detecting dry running by
System stop Check suction condition
pressure transmitter.

Over the number of pump Check the operation

# starting No. Alarm
start/stop than set valve. condition

Abbreviation

PR : Pressure
PRE : Previous
DIS : Discharge
PT : Pressure transmitter
SUC : Suction
MIN : Minimum
MAX : Maximum
FC : Frequency converter
FREQ : Frequency
DTC : Detecting
25
Icon

Icon Action

Move to Home

Move to Info

Move to Set

Move to Alarm

Move to upper page

Delete recovered alarm

Delete all recovered alarm

Auto run ON, OFF

Display Auto run

Alarm occurred

Move to right page

Move to left page

Move to upper page

Move to below page

26
Handling method
1. How to use pop-up screen

② ①

1) If you want to change “B-01. Set PR”, touch “①”. Pop-up screen “②” turn up.
2) Enter the value by “②” keypad.
3) On the keypad ‘Esc’ means cancel, ‘←’ means delete 1 digit, ‘Clear’ means delete all,
‘↵’ means save.
4) If save the value or cancel the value, pup-up screen will turn off.
5) Can’t input the outside of setting range. When you enter the value, refer to help.

27
Handling method
2. How to use touch screen

1) If you want to change “B-09. Power cut restart”, touch “①”.

The value change “Yes” or “No”.
2) Back to original value, touch “①” 1 more.
3) The value will save automatically without save action.

28
Menu tree

Home Home Page. 31

Installation help Page. 33

Info System Page. 34

Pressure Trigger Page. 35

Pump 1 Page. 35

Pump 2

Pump 3

…
Pump 6

Set Basic B-01. Set PR Page. 37

B-02. Shut PR Page. 37

B-03. Starting PR Page. 38

B-04. Final stop PR Page. 38

B-05. MIN run time Page. 38

B-06. FC MIN FREQ Page. 39

B-07. Sequence delay time Page. 39

B-08. Dry-run restart set Page. 39

B-09. Power cut restart set Page. 40

B-10. Step control stop PR Page. 40

Extra E-01. MAX PR Page. 42

E-02. MIN PR Page. 42

E-03. MIN PR DTC delay Page. 42

E-04. MIN PR set Page. 43

E-05. MIN SUC PR limit Page. 43

E-06. SUC PR DTC delay Page. 43

E-07. Sensor Offset Page. 44

E-08. Sensor Span Page. 44

E-09. Shut PR deviation Page. 45

E-10. Shut PR DTC time Page. 45

E-11. Shut PR judging time Page. 45

E-12. Sampling cycle Page. 46

E-13. PID Value Page. 46

E-14. Starting number Page. 46

29
Menu tree

Extra E-15. Dry-run DTC delay Page. 47

E-16. Loss compensate Page. 47

E-17. Reduction set Page. 47

E-18. Pump block DTC time Page. 48

E-19. Pump block run time Page. 48

E-20. Step changeover Page. 48

E-21. Pipefill PR Page. 49

E-22. Pipefill end DTC time Page. 49

E-23. Low-water LV DTC Page. 49

E-24. Low-water LV DTC delay Page. 50

E-25. Low-water LV RSTR set Page. 50

E-26. Backlight time Page. 50

Factory F-01. Sub DIS PT

F-02. SUC PT

F-03. Register Sub pump

F-04. Remote control ADD

F-05. Cut-in FREQ

F-06. Unit change

F-07. FC change cycle

F-08. Auto operating mode

F-09. Date

F-10. Pump initialization

F-11. System initialization

F-12. Password

F-13. DIS PT capacity

F-14. Half FREQ conversion rate

Schedule S-01. Monthly Schedule Page. 52

S-02. Daily Schedule Page. 53

S-03. Hourly Schedule Page. 53

S-04. Seasonal Schedule Page. 54

Alarm Alarm list and Initialization Page. 55

30
Home
Home

① ② ③ ④ ⑤
⑥

⑦ ⑧

⑩ ⑪
⑫
PUZeN e home screen.

① Home Icon : Move to “Home” screen

② Info Icon : Move to “Info” screen
③ Set Icon : Move to “Set” screen
④ Alarm Icon : Move to “Alarm” screen
⑤ Back Icon : Move to previous menu

⑥
: Touch  Auto run start(Water drop animation rotate)

: Retouch  Auto run stop(Water drop animation rotation stop)

: Alarm occurred  (Water drop animation rotate)

: Touch  Auto run Stop(Water drop animation rotation stop)

⑦ Panel Graphic : Move to “Info>>System” screen directly(refer to page 33)

⑧ Set PR & DIS PR : Move to “Set>>Basic>B-01. Set PR” screen directly by touching “Set PR”
Move to “Info>>Pressure Trigger” screen directly by touching “DIS PR”

31
Home
Home

⑨ : Green – Pump run by common power

Red – Pump fault
White – Pump stand by
Blue – Pump set by manual mode
Gray – Pump set by reserved mode(Back up)

100%
: Green and pump load rate display, Indicates pump run by frequency converter
(40% ~ 100%, Display by 1% unit )
Move to “Info>>Pump #” screen directly(refer to page 34)

⑩ Manifold Graphic : Move to “Installation help” directly(refer to page 31)

⑪ Date, day, time display : Move to “Set>>Factory>>F-11.Date” screen directly
⑫ Alarm message

Installation help

Move to installation help page, when touch the manifold at “Home” display.

32
Home
Home >> Installation help

33
Info
Info >> System

① PUZeN e ⑤
② ⑥
③ ⑦
④ ⑧

This is the system information screen(“Info” icon touch), display the information of
PUZeN e booster system

① Booster system model name

② Quantity of booster system’s pumps
③ Quantity of booster system’s frequency converter
④ TCU G22 program version
⑤ Display Main Pressure transmitter(Discharge)
⑥ Display Sub(spare) pressure transmitter(Discharge)
⑦ Display Suction pressure transmitter
⑧ Display Pressure transmitter range

34
Info
Info >> Pressure trigger

Pressure trigger : Show the set pressure and discharge pressure by graph.
Time cycle is 60 sec.

⑤
①
②
③
④

Display information of Pump 4

① Display Pump 4 operation rate
② Display Pump 4 operating time
③ Display Pump 4 rated current
④ Display Pump 4 power
⑤ Display Pump 4 load rate

※ This is example of 6 pumps booster system.

35
Set
Set

①
②
③
④

Set screen(Touch “Set” icon)

① Move to Basic function set

② Move to Extra function set
③ Move to Factory function set
④ Move to Schedule function set

36
Set
Basic

37
Set
Basic

38
Set
Basic

39
Set
Basic

40
Set
Extra

41
Set
Extra

42
Set
Extra

43
Set
Extra

44
Set
Extra

45
Set
Extra

- This value can effect performance of control panel

- Before make a change, check the installation site environments.

- This value can effect performance of control panel

- Before make a change, check the installation site environments.

46
Set
Extra

- This value can effect control panel’s performance.

- Before the change default, check the installation site environments.

47
Set
Extra

- This value can effect control panel’s performance.

- Before the change default, check the installation site environments.

48
Set
Extra

- This value can effect control panel’s performance.

- Before the change default, check the installation site environments.

49
Set
Extra

50
Set
Factory

- Password is needed when entering the factory menu.

- Factory menu is already set by WILO, changing factory menu can cause wrong
behavior and fault. Before changing factory menu, ask to WILO service.

- F-16, F-17, F-18 are enabled in PZEH

51
Set
Schedule

- Touch “①”, menu will change “No”/”Monthly”/”Daily”/”Hourly”/”Seasonal”.

- Activate menu’s color will change and touch the menu for detail schedule set.

- Touch the menu to set the schedule, after “No”  “Yes” set the setting pressure.

52
Set
Schedule

53
Set
Schedule

54
Alarm
Alarm

① ② ③
④

Maximum 37 alarm message can save.

① Show the occurred time of alarm

② Show the message of alarm
③ Show the recovery time of alarm, if the alarm is not recovered display continuous
④ Move to upper page, when
⑤ Move to downer
⑥ Delete each recovered alarm
⑦ Delete all recovered alarm

※ Alarm message list

- Pump # Fault
- Dry-running
- Repeated dry
- FC# Fault
- Low discharge pressure
- Setting values
- PT Fault
- Max. Pressure
- Repeated Max. pressure
- Sub PT Fault
- Main PT Fault
- 10% PTs Error
- Low suction pressure
- # starting No.

55
 Designation of PUZeN e booster system

PZe -

① System ③ No. of ④ Pump ⑤ Capacity ⑦No. of FC ⑨ Option

class pumps class for control part

② Power ⑥ No. of ⑧ Option ⑩ Option

supply impeller for motor for mechanical
part

① System class ② Power supply ③ No. of pumps

Code System class Code Power Code Power Code No. of pumps

PZEU PUZeN e Uni(Single Inverter) 2 220V,60Hz B 220V,50Hz 2 2 pcs

PZEC PUZeN e Combi System 3 380V,60Hz C 380V,50Hz 3 3 pcs

PZEH PUZeN e Half System 4 440V,60Hz D 440V,50Hz 4 4 pcs

PZEM PUZeN e Multi(Multiple Inverter) 5 460V,60Hz E 460V,60Hz 5 5 pcs

6 480V,60Hz F 480V,50Hz 6 6 pcs

④ Pump class ⑤ Capacity ⑥ No. of impeller

- Pump series No. of No. of No. of
Code Pump class Code Code Code
impeller impeller impeller
H Helix V Series 01 1 stg 06 6 stg 10 11 stg

M MVI Series 02 2 stg 07 7 stg 11 12 stg

03 3 stg 08 8 stg 12 13 stg

04 4 stg 09 9 stg 13 14 stg

05 5 stg A 10 stg 14 15 stg

⑦No. of FC ⑧ Option for motor ⑨ Option for control part

Code No. of pumps Code Option Code Option

1 1 pcs E2 IE2 Motor S Stainless steel Panel

2 2 pcs E3 IE3 Motor L Individual Earth Leakage Breaker

3 3 pcs G3 Explosion proof Motor E EOCR(Electronic Over Current Relay)

4 4 pcs

5 5 pcs

6 6 pcs

⑩ Option for mechanical part

Code Option Code Option

1 Bigger bore size for suction pipe K Forging Counter Flange

2 Bigger bore size for discharge pipe O Remove 1 impeller stage

3 STS304 bed T Applying SS bed

I Insulation bolt and nut

56