Compact pressure boosting system according to DIN 1988 and DIN EN 806, for direct or indirect connection. Consisting of non self-priming, switched in parallel, vertically-mounted stainless steel high-pressure centrifugal pumps in glanded versions. Ready for connection with stainless steel pipework, mounted on a base frame, including control device with all necessary measurement and adjustment equipment.

For fully automatic water supply and pressure boosting in residential, commercial and public buildings, hotels, hospitals, department stores and for industrial systems.

For pumping drinking water, process water, cooling water, fire water (apart from fire-extinguishing systems in accordance with DIN 14462 and with the approval of the local fire safety authorities) or other types of industrial water that do not attack the materials either chemically or mechanically and do not contain abrasive or long-fibre constituents.

Special features/product benefits

• Heavy-duty system which satisfies all the requirements of DIN 1988 (EN 806)
• WRAS/ KTW/ ACS approval of the pumps for all parts that come in contact with the fluid (EPDM version)
• High-efficiency pump hydraulics of the Helix V series in conjunction with IE2 IEC standard motors, including 7.5 kW and larger IE3 standard motor (optional for smaller motor power)
• Bidirectional mechanical seals in the pumps for easy maintenance
• Flexible lantern design permits direct access to the mechanical seal
• The spacer coupling enables the mechanical seal to be replaced without dismantling the motor (from 7.5 kW)
• Hydraulics of entire system are pressure-loss optimised.
• Parts that come in contact with the fluid are corrosion-resistant
• Comfort CC-FC control device with extended functions, PLC microcomputer and graphics-capable touchscreen, including frequency converter for infinitely variable control of the base-load pump
• Factory inspection and default setting at optimum operating range (incl. acceptance test certificate based on EN10204 - 3.1)

Equipment/function

• Stainless steel high-pressure centrifugal pumps of the Helix V series
• Base frame made of electrolytically galvanised steel, with height-adjustable vibration absorbers for insulation against structure-borne noise
• Shut-off valve on the suction and pressure sides of each pump
• Non-return valve on the pressure side of each pump
• 8 litre diaphragm pressure vessel, PN16 including throughflow fitting to DIN 4807, pressure side
• Pressure sensor (4-20 mA), pressure side
• Pressure gauge, pressure side
• Automatic pump control by means of a fully electronic

Comfort Controller (CC-FC) in a sheet metal enclosure, RAL 7035 structure, protection class IP 54 consisting of an internal control voltage supply unit, CPU, frequency converter, analogue and digital input and output modules.

Operation/ display

• Fully graphics-capable touch screen with 3-colour backlight for indicating the operating status operation/ fault/ acknowledged fault, and supporting symbols and plain text for menu navigation in six languages (out of up to 27 languages, with European and Asiatic characters selectable)
• Menu navigation with plain text and symbol representation
• 3 user levels, display and selection of menu language, passwords, operating parameters, control parameters
• Factory-preset parameters for easy commissioning/start-up
• Three setpoints can be set as standard, setpoints 2 and 3 can be activated by contact or time, external setpoint specification by 0/4-20mA signal
• Display of pump status and actual pressure value
• Lockable main switch
• Operation selectable with / without standby pump
• Elapsed time indicator for each pump
• Elapsed time indicator for entire system
• Switching cycle counter for each pump
• Switching cycle counter for entire system
• Fault log for the last 35 faults with timestamp using a real-time clock

Control

• Fully automatic control for 1 to 6 uncontrolled pumps by means of setpoint/actual value comparison
• Frequency converter with sine filter for infinitely variable control of the base-load pump
• Day timer, e.g. for 2nd and 3rd setpoint
• Automatic, load-sensitive cut-in of 1 to n peak-load pump(s) depending on the pressure - constant, p-c control variable
• Operating mode of the pumps freely selectable (manual, off, automatic)
• Manual-0-Automatic switch Preselection of the operating mode of each pump and manual operation in the event of a controller fault "Manual" (emergency/test mode available at mains power, motor protection available), "O" (pump switched off – cannot be switched on using the controller) and "Auto" (pump enabled for automatic mode via the controller)
• Automatic, configurable pump cycling
• Pump cycling by means of service life optimisation over operating hours.
• Alternative: Pump cycling after a set time period, regardless of the operating hours
• Alternatively by impulse: The base-load pump is cycled at each new demand, regardless of operating hours
• Alternatively with pump preselection: one pump can be permanently defined as the base-load pump. All peak-load pumps are changed on a running time optimisation basis.
• Automatic, configurable pump test run (pump kick)
• Can be activated/deactivated
• Time between two test runs is freely programmable
• Disabling times can be programmed as desired
• Speed can be adjusted as desired

Monitoring

• Actual value of the system and actual frequency of the frequency converter are output via 0-10 Volt analogue signal for external measurement / display applications, 10 Volt depending on the sensor range value
• Conductivity test of the sensor cable
• Motor protection switch / contactor combination (from 5.5 kW thermal overload relay)
• Automatic changeover to the standby pump in the event of a operating pump fault
• Monitoring of maximum and minimum system values with adjustable time delays and limits
• Monitoring of maximum and minimum system values with adjustable prominent time display
• Zero-flow test for switching off the system when no water is being drawn off (adjustable parameters)
• Pipe filling function for filling empty pipes (initial filling of the consumer network)
• Protection against low water level via contact e.g. for float switch or pressure switch

Interfaces

• Potential-free contacts for SBM/SSM collective operation and collective fault signals
• Logical reversal can be applied to SBM and SSM
• Contacts for switching external systems ON /OFF and protection against low water level
• External on/off via contact for deactivation of the system's automatic mode
• Inputs for thermal winding contact (WSK) connection

Optional accessories (factory installation or retrofitting after technical checks)

• Signal converter for 0/ 2-10V to 0/ 4-20mA
• Evaluation relay for PTC motor protection
• Individual run/fault signal
• DDC control module (external pump cycling, external pump test run, external acknowledgement, external switching the peak-load pump on / off)
• Battery-backed power supply unit
• Redundant sensor
• Soft starter for peak-load pumps
• Connection to BMS systems in accordance with VDI 3814

Recommended accessories (to be ordered separately)

• Optional WMS low-water cut-out switchgear kit;
• Flexible connection lines or expansion joints
• Break tank for system separation
• Diaphragm pressure vessel
• Threaded caps for systems with threaded joint tubing

Bus systems (optional)

• BACnet, Profibus, LON bus, CAN bus, Modbus RTU, Web server (Ethernet), GSM modem
• Remote data transmission possible via GPRS modem

Further details on request

Standards followed

• Specifications for drinking water installations (TRWI) DIN 1988 (EN806)
• Diaphragm pressure vessel/ diaphragm expansion tank DIN 4807
• Electronic Equipment for Use in Power Installations (EN 50178)
• Electrical Equipment of Machines (EN 60204-1)
• Household and Similar Electrical Appliances - Safety (EN 60335-1)
• Low-voltage switchgear combinations EN 60439-1/ 61439-1
• EMC - Immunity for Industrial Environments (EN 61000-6-2)
• EMC emitted interference for domestic, trade and commercial applications and small companies EN 61000-6-3 (up to 22.0 kW, above this EN 61000-6-4 emitted interference for industrial applications)

Operating data

• Fluid media
  Water
• Number of pumps
  5
• Maximum operating pressure PN
  16 bar
• Maximum inlet pressure p inl
  10 bar

Motor data

• Mains connection
  3~400 V, 50 Hz
• Rated power P₂
  7.50 kW
• Rated current I_N
  13.70 A
• Rated speed n
  2900 rpm
• Insulation class
  F
• Protection class motor
  IP55
• Protection class switchgear
  IP54

Materials

• Pump housing
  1.4301
• Impeller
  1.4307
• Shaft
  1.4301
• Shaft seal
  Q1BE3GG
• Gasket material
  EPDM
• Pipework material
  1.4571

Installation dimensions

• Pipe connection on the suction side DNs
  DN 100
• Pipe connection on the pressure side DNd
  DN 100

Information for order placements

• Brand
  Wilo
• Product description
  Comfort COR-5 Helix V 1609/K/CC
• Net weight, approx. m
  842 kg
• Article number
  2532292