OOPPEERRAATTIIOONNMMAANNUUAALLSS

FOR

MAKRO เสี ยมเรียบ

MASSTEC LINK CO., LTD.

59, 61, 63 Soi Chokechai 4 Soi 84, Chokechai 4 Rd. Ladprao, Ladprao, Bangkok 10230
Tel: 02-942-1433 (Auto 14 Line) Fax: 02-942-1320, 02-942-0904
CHILLED WATER PUMP

PUMP MODEL: ASP 100B

(CHP – 01, 02)

 INSTALLATION AND OPERATION
INSTRUCTIONS
FOR SPLIT CASE PUMPS – ASP SERIES
ENGLISH

WILO MATHER AND PLATT PUMPS PVT. LTD.

SHAILA TOWER, 3RD FLOOR
J1/16, EP BLOCK, SECTOR V, SLAT LAKE
KOLKATA – 700091, INDIA

N.B- Subject to change without prior notice

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CONTENTS
1. General Safety Instructions……………………………......................................................................... 04
2. General……………………………………………………………………………………………….. ........... 05
2.1 Uses…………………………………………………………………………………………………...... 05
2.2 Pump Description…………………………………………………………………………………….... 05
2.3 Nomenclature………………………………………………………………………………………. .... 05
2.4 Technical Data……………………………………………………………………………………………05
2.5 Noise and Vibration Level……………………………………………………………………………….05
3. Safety……………………………………………………………………………………………………...... 06
3.1 Danger Symbols used in these Operating Instructions………………………………………….... 06
3.2 Staff Training………………………………………………………………………………………....... 06
3.3 Risks Incurred by Failure to Comply with the Safety Precautions……………………………...... 06
3.4 Safety Precautions for the Operator……………………………………………………………….... 06
3.5 Safety Information for Inspection and Assembly…………………………………………………... 06
3.6 Unauthorized Modification and Manufacture of Spare Parts……………………………………... 06
3.7 Unauthorized Operating Methods………………………………………………………………….... 06
4. Transport and Storage…………………………………………………………………........................... 07
4.1 Transport………………………………………………………………………………………………... 07
4.1.1 General Recommendations.………………………………………………………………………... 07
4.1.2 Fitting Carrying Cables…….………………………………………………………………………... 07
4.2 Storage…..................................................................................................................................... 08
4.3 Preparation for Shipment……………………………………………………………………………….08
5. Installation………………………………………………………………………………………………….... 09
5.1 Preparations…………………………………………………………………………………………..... 09
5.1.1 Unpacking and Inspection…………………………………………………………………………... 09
5.1.2 General Rules for Pump Location………………………………………………………………….. 09
5.2 Foundations…………………………………………………………………………………………...... 09
5.3 Alignment……………………………………………………………………………………………...... 11
5.4 Piping…………………………………………………………………………………………………..... 13
5.4.1 Suction Piping……………………………………………………………………………………….... 13
5.4.2 Discharge Piping…………………………………………………………………………………….... 13
5.5 Electrical Connection………………………………………………………………………………….... 16
5.6 Instrumentation………………………………………………………………………………………….. 16
6. Operations and Maintenance…………………………………………………………………………….... 16
6.1 Priming…………………………………………………………………………………………………... 15
6.2 Final Check before Start-up…………………………………………………………………………….16
6.3 Starting Procedures…………………………………………………………………………………….. 16
6.4 Stopping Procedure…………………………………………………………………………………….. 16
6.5 Operation………………………………………………………………………………………………….17
6.6 General Rules on Pump Operation…………………………………………………………………… 17
6.6.1 Running a Pump Dry…………………………………………………………………………………. 17
6.6.2 Throttling at the Pump Suction……………………………………………………………………… 17
6.6.3 Restarting Motor-driven Pump Stopped by Power Failure………………………………………. 18
6.7 Checks to be made while Pump is Running…………………………………………………………. 19
7. Maintenance………………………………………………………………………………………………… 19
7.1 General Information……………………………………………………………………………………. 19
7.2 Daily Observation………………………………………………………………………………………. 19
7.3 Semi-annual Inspection……………….………………………………………………………………. 20
7.4 Annual Inspection…………………………………………………………………….......................... 20
7.5 Complete Overhaul……………………………………………………………………….................... 20
7.6 General Maintenance – Wear Rings…………………………………………………....................... 20
7.7 Shaft Seal………………………………………………………………………………........................ 21
8. Dismantling/Reassembly………………………………………………………………............................. 21
8.1 Dismantling………………………………………………………………………………...................... 21
8.2 Rotating Element Reassembly………………………………………………………...................... 22
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 8.3 Pump Reassembly………………………………………………………………………......................23
8.4 Recommended Lubricants……………………………………………………………….................... 28
9. Pump Sealing………………………………………………………………………………........................ 28
9.1 Stuffing Box Packing……………………………………………………………………….................. 28
9.2 Installing Soft Packing……………………………………………………………………................... 29
9.3 Dimension of Gland Packing....................................................................................................... 30
9.4 Mechanical Seals…………………………………………………………………………................... 30
9.5 Sealing Problems, Causes and Solutions.................................................................................... 31
10. Locating Troubles…………………………………………………………………………......................... 32
11. Spare Parts…………………………………………………………………………………....................... 33
12. Sectional Drawings…………………………………………………………………………....................... 34
Appendix A (Recommended Tightening Torques)……………………………………........................ 39
Appendix B (Useful Formulae)……………………………………………………………........................ 40
Appendix C (Material Equivalent Chart)……………….………………………………......................... 41
Appendix D (Product Range)...……………………...…………………………………………………….. 42

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1. General Safety Instructions
1. Inspect unit for shipping damage.
2. Read all instructions carefully.
3. Always disconnect all electrical power when handling pump.
4. Do NOT run the pump dry or against a closed discharge. This will damage the pump.
5. Do NOT operate this equipment at any flow, head, speed, temperature and maximum inlet pressure
other than those for which the pump was originally purchased.
6. Do NOT pump any other liquid than the one which the pump was originally purchased without the
consent of M&P.
7. Disregard of the warnings can result in pump failure and serious personal injury or death.
8. The area around the pump unit must be kept clear of debris to reduce the possibility of fire or
explosion due to debris coming into contact with hot surfaces of the unit.
9. Do NOT operate the unit with any of the supplied guarding removed or disabled.
10. Access to the equipment should be restricted to the personnel responsible for installation, operation
and maintenance. These personnel must be trained, adequately qualified, and supplied with the
appropriate tools for their respective tasks.
11. All personnel responsible for installation, operation, or maintenance of the equipment, have access to
and study the instruction manual before any work is done and that they will comply with all local and
industry based safety instructions and regulations.
12. Do NOT wear loose or frayed clothing or jewellery that could catch on the controls or become trapped
in the equipment.
13. The instructions included in this manual cover standard design of the equipment. This book does not
provide complete details and common deviations. Additional information may be obtained by
contacting M&P.
14. In case where there is any doubt as to the functioning or adjustment of any parts of the equipment
should be consulted immediately with M&P.

MECHANICAL HAZARDS

Crushing Hazards
a) Use only qualified personnel to lift or move unit at any time.
b) Never lift unit using hooks or slings on shafts.
c) Never place eyebolts in tapped holes except for removal of upper case half only.
d) Use proper lifting techniques when manually lifting components.
e) Do not place hands under component in such a way that the component would fall on the hands if
dropped.

Shearing Hazards
a) Do not place fingers, hands, arms, etc. into the suction or discharge openings or into any other
opening (such as the air relief valve hole). To prevent ingress of any objects, retain the protective
covers or packaging in place until the removal is necessary for installation. If the packaging or
suction or discharge covers are removed for inspection purposes, replace afterwards to protect
the pump and maintain safety.

Entanglement Hazards
a) The area between the stuffing box and bearing bracket is covered with shaft guards. Do not
remove the guard. Do NOT wear loose or frayed clothing or jewellery that could catch on the
controls or become trapped in the equipment.

Impact Hazards
a) Do not use excessive force when adjusting packing glands or any other bolts as wrench slippage
can result in impact of the hand against the casing.

Electrical Hazards
a) Use only qualified electricians for electrical installation and maintenance.

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 b) Refer to manuals provided with electrical components and disconnect power supply as
recommended for servicing.
c) Ground the unit according to local codes.

Thermal Hazards
a) Most surfaces on the driver can become hot during operation. The stuffing box and bearing
bracket areas on the pump can become hot in the event of a malfunction or maladjustment. These
surfaces may retain hot for some time after the unit has been shut down. Use care when touching
these surfaces and wear protective gloves if necessary to touch these surfaces when hot.
b) If the packing is too tight, the drain water from the stuffing box can become hot enough to scald.
Ensure that drain water is not excessively hot before extensive contact.

Noise Hazard
a) Noise levels, especially for diesel engine driven units, can exceed safe levels. Refer to the noise
level published in the accompanying documentation, and, if this noise level exceeds local code or
safe levels, place the unit in a controlled access area and provide ear protection to personnel
authorised to be in this area.

Personal Protective Equipment

a) Wear helmet and eye protection at all time in the vicinity of the unit. Wear ear protection when
loud units are running.

2. General
Assembly and installation should only be carried out by qualified personnel
2.1 Uses
Pumps of M&P series are used to transport clean or slightly polluted, non-aggressive liquids containing no
solid components in:
– Warm water heating systems
– Chilled and cooling water systems
– Water systems for industrial use
– Industrial circulating systems, Water supply, process fluids
– Heat transfer media circulation
– Irrigation
– Fire protection
2.2 Pump Description
Single stage centrifugal pump, pump casing split axially for easy maintenance, sealed by mechanical seal or
packed gland.
2.3 Nomenclature
150 D

Discharge Diameter
Impeller Code
150 D F /FM

Discharge Diameter
Impeller Code
Fire Version

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3. Safety
These instructions contain important information which must be followed when installing and operating the
pump. 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.
3.1 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 voltage with:

The following symbol is used to indicate that by ignoring the relevant safety instructions, damage could be
caused to the pump/machinery and its functions:

3.2 Staff training

The personnel installing the pump must have the appropriate qualifications for this work.
3.3 Risks incurred by failure to comply with the safety precautions
Failure to comply with the safety precautions may endanger persons and pump/system. Failure to comply with
the safety precautions could also invalidate any claim for damages.
In particular, lack of care may lead to problems such as:
– Injury resulting from electrical or mechanical factors.
– Failure of important pump or machinery functions,
– Failure of prescribed maintenance and repair procedures.
– Danger to the environment through emission of hazardous substances.
3.4 Safety precautions for the operator
Existing regulations for the prevention of accidents must be followed.
Dangers caused by electrical energy are to be excluded. Electric motor /diesel engine suppliers are to be
observed for this.
3.5 Safety information for inspection and assembly
The operator is responsible for ensuring that inspection and assembly are carried out by authorised and
qualified personnel who have studied the operating instructions closely.
Work on the pump/machinery should only be carried out when the machine has been brought to a standstill.
3.6 Unauthorized modification and manufacture of spare parts
Alterations to the pump or installation may only be carried out with the manufacturer's consent. The use of
original spare parts and accessories authorised by the manufacturer will ensure safety. The use of any other
parts may invalidate claims invoking the liability of the manufacturer for any consequences.
3.7 Unauthorized operating methods
The operating safety of the pump or installation supplied can only be guaranteed if it is used in accordance
with IOM. The limiting values given in the catalogue or data sheet must neither be exceeded nor allowed to fall
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below those specified.

4. Transport and Storage

4.1 Transport
4.1.1 General recommendations

Existing regulations for the prevention of accidents must be followed.

– The wearing of gloves, hard-toed boots and hard hats is compulsory for all transport work.
– Wooden cases, crates, pallets or boxes may be unloaded with fork-lift trucks or using hoisting
slings, depending on their size and construction.

– A hoist complying with local regulations must be used to lift heavy parts weighing more
than 30 kg. The load-bearing capacity must be adapted to the weight.
– Only lifting hooks or shackles which comply with local safety regulations may be used to lift machines or
parts using lugs. The carrying chains or cables must never be passed over or through the lugs or over sharp
edges without protection.
– Lifting hooks, lugs or shackles may not be exposed to cantilever loads. Their load axis must lie in the
direction of the tractive forces.
When lifting, ensure that the load limit of a cable is reduced for angled pulling.
– The safety and efficiency of a cable are best guaranteed if, wherever possible, all load-bearing elements are
stressed vertically.
If necessary a lifting arm should be used to which the carrying cable can be attached vertically.
– It is absolutely forbidden to stand beneath a raised load. In this connection the safety zone must be marked
out such that there is no danger if the load or part there of slips or the hoist breaks or tears. A load should
never remain in a raised position for longer than necessary. Accelerating and braking during the lifting process
must be performed such that there is no danger to persons.
– If a block and tackle or a similar hoist is used, it must be ensured that the load is lifted vertically. The raised
load must be prevented from swinging. This can be achieved, for example, by using a second block and
tackle, whereby the angle of pull of both should be less than 30° to the vertical.

4.1.2 Fitting the carrying cables

The equipment is all assembled for proper alignment and if dropped or mistreated in any
ATTENTION ! way misalignment and poor performance will result. The hoist used must have a load-
bearing capacity which corresponds to the weight of the pump. The weight of the pump
can be taken from the catalogue or data sheet of the pump. To avoid any distortion, please lift the pump as
shown.

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4.2 Storage
Short Term: (less than three months)- when it is necessary to store a pump for a short time before it can be
installed, place it in a dry, clean, well-ventilated place, free from vibration, moisture and rapid or wide
variations in temperature. Protect the bearings and couplings against sand, grit, or other foreign matter. To
prevent rusting or seizing, lubricate the unit and turn the rotor several revolutions by hand at least once a
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week.

Long Term: (more than three months). Additional precautions are required if the pump is scheduled for storage
for an extended period of time. All the rotating parts are to be coated with a suitable protective fluid in order to
keep the parts from rusting. For storage in excess of one year contact M&P.
Note: Improper storage could result in non-warranty covered restoration of the
equipment.

5. Installation
5.1 Preparations

5.1.1 Unpacking and Inspection

The pump must be checked for compliance with the information on the delivery note. M&P must be
notified immediately of any damage or missing parts. Check crates, boxes and wrappings for spare
parts or accessories which could be enclosed with the pump.

5.1.2 Site
The pump must be installed protected from the elements in a frost and dust. All flanges and exposed finished
metal parts are cleaned of foreign matter and treated with an anticorrosion compound, such as grease,
vaseline, or heavy oil. For protection during shipment and erection, all pipe flanges,
ATTENTION ! pipe openings and nozzles are protected by wooden service flanges or by screwed-in
metal plugs, which prevent the entrance of dirt, dust, moisture or foreign matter. All
small piping is cleaned, and protective guards are installed, if necessary.

5.1.3 General Rules for Pump Location

Pumps installed indoors, in poorly lighted and cramped locations, or where dirt and moisture accumulate, are
improperly placed for dismantling and repair; they will be neglected and both pump and
ATTENTION ! driver may become damaged. Pumps should be placed in light, dry and clean locations
whenever possible.

If a motor driven unit will be operated in a damp, moist, or dusty location, the proper motor must be selected.
Pumps and drivers designed for outdoor installation are specially constructed to withstand exposure to
weather and usually are readily available for overhaul.

Sufficient room must always be provided for dismantling the pump; that is, enough headroom must be allowed
so that the upper half of the casing may be lifted free of the rotor. For large pumps with heavy casings and
rotors, a travelling crane or facilities for attaching a hoist should be provided over the pump location.

Pumps should be located as close as possible to the source of liquid supply. When possible, it is advisable to
locate the unit below pumping level of the water, to facilitate priming. The manufacturer’s recommendations for
suction conditions should always be followed.

For most pumping units, more satisfactory service is obtained when rigid foundations are provided.

The suction supply system must provide the pump with Net Positive Suction Head (NPSH) equal to or greater
than that required by the pump at any capacity on its operating curve.

5.2 Foundations
The correct planning and execution of stable concrete foundations is a deciding factor for the low-noise
operation of pumps.
To increase the stabilizing mass and to compensate for unbalanced forces, direct and rigid connection
between the pump unit and the foundation block is recommended. The foundation should be sufficiently
substantial to absorb any vibration and to form a permanent, rigid support for the base plate. This is important
in maintaining the alignment of a direct connected unit. In building the foundation, the top of the foundation
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should be left approximately one inch low to allow for grouting. Foundation bolts of the proper size should be
embedded in the concrete, located by template. A pipe sleeve about 2 ½ diameters larger than the bolt should
be used to allow movement for the final positioning of the bolts.

Installation for Motor Drive:

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5.3 Alignment

Reliable, trouble-free, and efficient operation of a pumping unit requires correct alignment of pump and driver
shaft. Misalignment may be the cause of:
 Noisy pump operation
 Vibration
 Premature bearing failure
 Excessive coupling wear

When the unit is received with the pump and driver mounted on a common base plate, it should be placed on
the foundation and the coupling halves disconnected. The coupling should not be reconnected until all
alignment operations have been completed.
A gap of about 20 to 40mm should be allowed between the base-plate and the foundation to allow for
grouting. Adjust the metal supports or wedges until the shafts of pump and driver are level. Check the
coupling faces as well as the suction and discharge flanges of the pump for horizontal or vertical position by
means of a sprit level. Correct the positions, if necessary, by adjusting the supports or wedges under the
base-plate as required. The faces of the coupling halves should be spaced far enough apart such that they
cannot strike each other. Due allowance should be made for wear of the thrust bearings. A minimum
dimension for the separation of the coupling halves is usually specified by the coupling manufacturer and
reference should be made to their instruction Sheet to ensure gap is correct.

Check for angular alignment by inserting a taper gauge or feelers between the coupling faces and comparing
the distance between the faces at four points spaced at 90 0 intervals around the coupling. The unit will be in
angular alignment when measurements show that coupling faces are the same distance apart at all points.

Check for parallel alignment by placing a straight edge across both coupling rims at the top, bottom and at
both sides. The unit will be in parallel alignment when the straight edge rests evenly on the rim at all positions.
Allowance may be necessary for temperature changes and for coupling halves that are not of the same
outside diameter. Care must be taken to have the straight edge parallel to the axes of the shafts.

Angular and parallel misalignment is corrected by adjusting the shims under the pump or driver, or relocating
positioned units on the base-plate. After each change, it is necessary to check the alignment of the coupling
halves. Adjustment in one direction may disturb adjustment already made in another direction. When
alignment is correct, the foundation bolts should be tightened evenly but not too firmly. The unit can then be
grouted to the foundation. Foundation bolts should not be fully tightened until the grout has hardened - usually
about 48 hours after pouring. After the grout has set and foundation bolts have been properly tightened, the
unit should be checked for parallel and angular alignment and, if necessary, corrective measures taken.
Alignment should be checked again after unit has been connected to the pipe work.

Direction of rotation of the driver should be checked to make certain that it matches that of the pump. Pump
direction of rotation is indicated by a direction arrow on the pump casing. The coupling halves can then be
reconnected. Once the pump has been running for about ten hours, the coupling halves should be given a
final check for misalignment due to pipe strains or changes in temperature. If the alignment is correct, both
pump and driver should be doweled to the base plate.

Both suction and discharge pipes should be supported independently near the pump to ensure that when
flange bolts are tightened no strain will be transmitted to the pump casing. A check valve and a gate valve
should be installed in the discharge line. The check valve, placed between the pump and the gate valve, is to
protect the pump from excessive pressure and to prevent water running back through the pump in case of
failure of the driver. The gate valve is used in priming, starting and when shutting down the pump. Except on
axial flow and mixed flow pumps, it is advisable to close the gate valve before stopping the pump. This is
especially important when the pump is operated against a high static head. If taper pipes are used to increase
the size of discharge piping, they should be placed between the check valve and pump.
From existing manual

11
Coupling Alignment:

Incorrect alignment of the set can result in damage to coupling and set!

In accordance with the statutory provisions the coupling is to be protected by the safety device
such that accidents caused by accidentally touching rotating parts are avoided.

Incorrect Alignment:

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5.4 Piping

Under no circumstances may the pump be used as a fixed support for the pipe! Satisfactory operation cannot
be maintained when piping imposes forces and torques on the pump. Piping should be independently
supported near the pump so that no strain will be placed on the pump casing. A
ATTENTION ! pump can be easily sprung and pulled out of position by drawing up on the bolts in the
piping flanges. The alignment can be seriously affected in this way and it is important, therefore, that the
alignment should be checked again after the pipes are finally fitted. Piping flanges must be brought squarely
together before the bolts are tightened. The suction and discharge piping and all associated valves and similar
equipment should be supported and anchored near the pump, but independent of it, so that no strain is
transmitted to the pump casing. Where any noise is objectionable, pump should be insulated from the piping
with rubber connections. Always keep pipe size as large as possible and use a minimum of fittings to reduce
friction losses.

5.4.1 Suction Piping

The major source of trouble in centrifugal pump installations, other than misalignment, is a faulty suction line.
The suction piping should be as short and as direct as possible. It should be at least one size larger than
suction inlet tapping and should have a minimum of elbows and fittings. If a long suction line is required, the
pipe size should be increased to reduce friction losses. The suction piping should be laid out with a continual
rise towards the pump, without any high spots, to prevent the formation of air pockets, which invariably cause
troubles. Only eccentric reducers, installed straight side up should be between the suction piping and the
pump suction flange.

Elbows and other fittings next to the pump suction should be selected and arranged carefully, or the flow into
the impeller will be unfavourably disturbed. Long radius elbows are generally preferred for suction lines, as
they create less friction and provide a more uniform flow distribution than standard elbows.

The suction pipe must be tight and free of air leaks or pump will not operate properly.
ATTENTION ! After installation, the suction piping should be blanked off and hydrostatically tested for
air leaks before the initial start-up.

5.4.2 Discharge Piping

Discharge piping should never be smaller than pump tapping and should preferably be one size larger.
Generally, both a check valve and a gate valve are installed in the discharge line. The check valve is placed
between the pump and the gate valve and protects the pump against reverse flow and water hammer in the
event of unexpected driver failure. The gate valve is used when priming the pump or when shutting it down for
inspection and repairs. Except on axial flow and mixed flow pumps, it is advisable to close the gate valve
before stopping the pump. This is especially important when the pump is operated against a high static head.

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14
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 

 
 



 




   




15
5.5 Electrical connection

Electrical connection should be made by a qualified electrician. Please follow the electrical
equipments instructions carefully. General guidelines are as follows:

– The supply cable must be laid in such a way that it never touches the pipe work and/or the pump and motor
casing.
– Check the mains current and voltage.
– Please observe data on the motor rating plate.
– Mains fuse: depends on nominal motor current.
– Observe earthing regulations.
– Never install a pump without proper overload protection

5.6 Instrumentation
A number of instruments are essential to maintain a close check on the performance and condition of the
installed centrifugal pumps. A compound pressure gauge should be connected to the suction of the pump and
a pressure gauge connected to the discharge. Pressure taps are provided in the suction and discharge
branches for this purpose.

It is also advisable to provide a flow-metering device, as it is impractical to determine the capacity delivered by
the pump with any degree of accuracy without one.

6 Operations and Maintenance

6.1 Priming
The pump must be primed before starting. Centrifugal pumps should almost never be started until they are
fully primed, that is, until they have been filled with the liquid pumped and all the air has
ATTENTION ! escaped. The pump casing and suction piping must be filled with liquid before starting
since this damage some of the parts of the pump, which depend upon liquid for their
lubrication. A hand pump or ejector can be used for priming when desired.
These pumps are not self-priming and if a pump fails to generate its rated pressure in starting, it must be
stopped at once and re-primed.

All that is required to prime pumps with a positive inlet head is to open air cocks at the top of the pump casing
and the inlet isolating valve. The liquid will then drive the air through the air cocks, which must be closed when
priming is complete, and before the pump is started. It may be advisable to turn the rotating element of smaller
by hand, so clearing air, which may be trapped in the pockets formed by curved impeller vanes.

There are two methods of priming pumps drawing from an elevation lower than the suction branch:

 By exhausting the air from the casing. To allow this method, the stuffing boxes must be sufficiently air
tight, or they should be liquid sealed from some external supply. Some form of sight gauge is usually
fitted to indicate when the casing is properly primed.
 If the suction pipe is fitted with a foot valve, the pump can be primed from some external supply under
pressure; the pressure imposed on the pump must not be greater than that for which it is designed.

If the pump is to handle hot fluid, fill slowly to ensure the temperature is raised gradually.
Depending on the fluid temperature and the system pressure, if the air cock is completely
loosened hot liquid can escape or even shoot out at high pressure. Beware of scalding.

16
 6.2 Final Check before Start-up
After a centrifugal pump has been properly installed and all necessary precautions have been taken in aligning
with its driver, it is ready for service on its initial start. The following basic checks should be completed before
the pump is started.

 Pump is fully primed

 Bearings filled with the correct amount and type of grease.
 Pump driver alignment is within tolerance.
 Motor direction of rotation is correct.
 Coupling guard is in place and bolted down.
 Pressure gauges mounted on both pump suction and discharge with correctly ranged pressure
gauges fitted. Pressure gauges should not be installed at the bends in the piping, where their readings
may be affected by the kinetic energy of the fluid.
 All blanks removed and the pump suction valve fully open.
 Pump discharge valve is fully closed.

6.3 Starting Procedures

Start the pump with the discharge valve closed. When the motor reaches its nominal running speed, check
that the discharge pressure is normal and steady, without large fluctuations. Otherwise, stop the pump and
repeat the priming procedure. If the problem persists, look for air leaks on the suction pipe and check the foot
valve the fluid level. If the motor runs slow, check the connections. The starting procedure is as follows:

 Prime the pump, opening the suction valve and closing the drains to prepare the pump for operation.
 Start the motor.
 Open the discharge valve slowly.
 Observe the leakage from the stuffing boxes. If the packing is new, do not tighten up on the gland
immediately, but let the packing run in before reducing the leakage through the stuffing boxes.
 Check the general mechanical operation of the pump.

Do not allow the pump to run for long periods with discharge valve tightly closed.
ATTENTION !

The pump should be shut down at once and the trouble should be corrected if the pump is running at its rated
speed and found any of the following faults:
 Pump does not deliver any water
 Pump does not deliver enough water
 Flow is getting down
 Discharge pressure is not enough
 Driver overloaded
 Vibration on pump
 High noise level
 Bearing overheating

6.4 Stopping Procedure

The stopping procedure is as follows:
 Close the discharge valve.
 If a non-return device is built into the discharge pipe, the valve can remain open provided there is a
back pressure.

When switching off the pump the valve on the inlet pipe must not be closed.

 Stop the driver.

 If the pump is out of operation for long periods the valve on the inlet pipe is to be closed
17
  If the pump is out of operation for long periods and/or there is a risk of freezing, the pump is to be
drained or protected against freezing.
6.5 Operation
ATTENTION ! The pump should always run quietly and free from vibrations and not be operated at
temperatures higher than those given in the catalogue/data specification sheet.
The pump can be switched on and off in different ways, depending on the operating conditions and the degree
of automation in system. The following is to be observed:

Start Procedure
 Ensure that the pump is completely full
 Ensure a continuous flow to the pump with a sufficiently large NPSH value.
 Avoid an overly weak back-pressure causing overload.
 To avoid an excessive temperature rise in motor and excessive strain on pump, coupling, motor and
bearings, the set should not be turned on more than 10 times/hour.
Stop Procedure
 Avoid reverse operation of the pump
 Do not work for too long with overly small transport (volume of flow) capacities.

6.6 General Rules on Pump Operation

6.6.1 Running a pump dry:

Only a centrifugal pump with excessive clearances between stationary and rotating parts could run dry for an
indefinite period of time. Most centrifugal pumps have close clearance leakage joints and cannot run dry at all,
or in some cases for longer than a few seconds, without being seriously damaged.

6.6.2 Throttling at the pump suction:

Throttling the suction of a centrifugal pump causes a reduction of the absolute pressure at the inlet to the
impeller. This can be made to result in a reduction of capacity by forcing the pump to operate “in the break”,
and reducing the delivered capacity by altering the shape of the head-capacity curve. Such operation is
harmful to the pump. Pump efficiency is reduced when operated “in the break”, but most important, erosion
and premature destruction is caused by cavitation induced when the suction is throttled.

Pump capacity can be reduced simply and safely by throttling the discharge. In this manner, artificial friction
losses are induced by throttling, and a new system-head curve is obtained, which intersects the head-capacity
curve at the desired flow.

Throttling at the suction is permissible only when the suction pressure exceeds the minimum requirements by
a large margin, such as the case of the second pump in series unit. The effect, however, is not to reduce
capacity by operation in the break, but rather by the reduction of the total net head generated by the series
unit. This causes the head-capacity characteristics and the system-head curve to intersect at a lower rate of
flow.

6.6.3 Restarting motor-driven pumps stopped by power failure:

If a check valve protects a pump against reverse flow after a power failure, there is generally no reason why
the pump should not be restarted once current has been re-established. The type of motor control used will
determine whether or not the pump will start again automatically once the power is restored. Starters are
made with low-voltage protection, with low-voltage release, or without either. Starters with low-voltage
protection will de-energise under low-voltage conditions, or following power failure, and the units they control
must be restarted manually. Starters with low-voltage protection can only be used with momentary contact
pilot devices and cannot be used with maintained-contact pilot devices, such as float switches, unless auxiliary
relays are incorporated in the controls.

If the starter does not incorporate low-voltage protection, resumption of power will always cause the unit to
start again automatically. Because pumps operating on a suction lift may lose their prime during the period
when power is off, starters should be provided with low-load protection for such installations. This does not

18
apply, of course, if the pumps are automatically primed, or if some protection device is incorporated so that the
pump cannot run unless it is primed.

6.7 Checks to be made while pump is running

 The pump must run smoothly, quietly and free from vibration at all times.
 The pump must never run dry.
 Never run the pump for a long period against a closed discharge valve.
 The bearing temperature may exceed the ambient temperature by up to 50 0C. But must never rise
above 80 0C.
 The valves in the auxiliary lines must remain open while the pump is running.
 If the pump has soft packing type stuffing boxes, these should drip during operation. The gland nuts
should only be slightly tightened. In case of excessive leakage from the stuffing box, tighten the gland
nuts slowly and evenly until the leakage is reduced to the dripping state. Check the stuffing box for
overheating by hand. If the gland nuts can not be tightened any further, remove the old packing rings
and clean the packing chamber, insert the new packing rings. Make sure that each packing ring is cut
at correct size. The joint in successive rings should offset to each other by 900.
 If the pump has a mechanical seal, it will experience only minor or no visible leakage during operation.
If there is considerable leakage from the seal, that means the seal surfaces are worn out and it needs
to be replaced. The life of the mechanical seal highly depends on the purity of the water.
 The flexible coupling elements should be regularly checked and replaced as soon as they show signs
of wear.
 Stand-By pumps should be run for a short time at least once a week to ensure they are in constant
readiness for operation. Check the integrity of auxiliary connections.

7 Maintenance
7.1 General information
– The operator is responsible for ensuring that inspection and assembly are carried out by authorised and
qualified personnel who have studied the operating instructions closely.
– By drawing up a maintenance plan, costly repairs can be avoided with a minimum of maintenance expense
and a fault-free pump operation obtained.

Before carrying out any maintenance work, switch off the pump and ensure that it cannot be
switched on again by unauthorised people. Never carry out work on a running pump.

Depending on the operating condition of the pump and/or installation (fluid temperature) the entire
pump can become very hot.
Avoid touching the pump owing to the risk of burning.

7.2 Daily Observation

Pump installations that are constantly attended should be inspected hourly and daily. A card record system is
unnecessary for these inspections, but the operator should immediately report any irregularity in pump
operation. A change in the sound of a running pump should be investigated immediately. Bearing
temperatures should be observed hourly. An abrupt change in bearing temperature is much more indication of
trouble than a constant high temperature.
Stuffing box operation should also be observed hourly. The stuffing box leakage should be checked to see
whether it is sufficient to provide cooling and lubrication of the packing but not excessive and wasteful.

The pressure gauges and flow indicator, if these are installed, should also be checked hourly for proper
operation. Recording instruments, if available, should be checked daily to ensure that the capacity output,
pressure, or power consumption do not indicate that something needs attention.

19
7.3 Semi-annual Inspection
The stuffing box gland should be checked semi-annually for free movement. The gland bolts and nuts should
be cleaned and oiled and inspected to see if the packing needs replacement.

The pump and driver alignment should be checked and corrected if necessary. Bearings should be checked to
see if the correct amount of grease is provided and it is still of suitable consistency.

7.4 Annual Inspection

Centrifugal pumps should be very thoroughly inspected once a year. In addition to the semi-annual
maintenance procedure, the bearings should be removed, cleaned and examined for flaws. The bearing
housings should be carefully cleaned. Bearings should be examined for scratches and wear after cleaning.
Immediately after inspection, bearings should be coated with oil or grease to prevent dirt or moisture from
getting into them.

The packing should be removed and the shaft sleeves should be examined for wear. The coupling halves
should be disconnected and alignment checked. Drains, sealing water piping, and other piping should be
checked and flushed.

The pump stuffing boxes should be repacked and the coupling reconnected.

If instrument and metering devices are available, these should be recalibrated and a test made to determine
whether proper performance is obtained. If internal repairs are made, the pump should again be tested after
completion of the repairs.

7.5 Complete Overhaul

General rules cannot easily be made to determine the proper frequency and regularity of complete overhauls
of centrifugal pumps. The type of service for which the pump is intended, the general construction of the
pump, the liquid handled, the materials used, the average operating of the pump, and the evaluation of
overhaul costs against possible power savings from renewed clearances, all enter into the decision on the
frequency of complete overhauls. Some pumps on severe service may need a complete overhaul monthly,
where as other applications only require overhaul every two to four years or even less frequently.

7.6 General Maintenance - Wear Rings

Wearing rings are fitted in the casing (casing wearing rings) and frequently on the impeller wearing rings).
These wearing rings provide a close running clearance, to reduce the quantity of liquid leaking from the high-
pressure side to the suction side. These rings depend on the liquid in the pump for lubrication. They will
eventually wear so that the clearance becomes greater and more liquid passes into the suction. This rate of
wear depends on the character of the liquid pumped. Figure below gives the nominal clearances between the
wear rings. These clearances are good for dissimilar metals, which have a low tendency to gall. However wear
rings, which are of the same material, must have more clearance than is recommended in figure below.
 Nominal Wear Ring Nominal Diametrical
Internal Diameter (mm) Clearance (mm)

50 0.26
100 0.42
150 0.46
200 0.52
250 0.56
300 0.60
350 0.66
400 0.70
450 0.75
500 0.85

20
Note: Above clearances are for wear ring/impeller combinations of dissimilar metals.

7.7 Shaft Seals

Pump with mechanical seal:

 The mechanical seal is mounted directly on the shaft. No adjustment is required after its assembly.
 The life of the mechanical seal is strictly dependent on the particles in the liquid, operating
temperatures and dry running. Under standard operating conditions, the life of mechanical seal is
about 10,000 operating hours.
 When operating properly the mechanical seal has no visible leaks.
 The mechanical seal is maintenance free; its tightness is to be checked regularly.
 The slightest leak is a sign of the start of tightness problem caused by damage to the sliding surfaces,
sealing rings, bellows, diaphragm or other components of the mechanical seal.

Pump with gland:

 A properly run-in and well-adjusted gland requires very little maintenance. If over time the leak
becomes too big, the gland must be re-tightened.
 If the gland is tightened too far and can not be re-tightened, it must be re-packed. It is recommended
that the gland packing be replaced after two years’ operation.
 Before packing the glands, the packing space and the shaft sleeve must be thoroughly cleaned.
 Place the first ring around the shaft and insert into the packing space. Offset each subsequent packing
ring joint by 900 compared to the previous packing ring joint and insert into packing space individually.
 Bring gland forward and tighten nut by hand. After assembly the shaft must be able to easily turned by
hand.
 The gland packing must drip slightly during operation.

8 Dismantling / Reassembly
Most pump designers and specialists consider that a centrifugal pump need not be opened for inspection
unless either factual or circumstantial evidence indicates that overhaul is necessary.
The following rules must be followed when dismantling the pump:
 Disassembly and re-assembly must be done by skilled personnel.
 List the order of the dismantling of the parts.
 Parts with pressure-tight faces must be handled with the greatest care.
 If it is difficult to remove parts from the shaft, employ the usual penetrating oils or releasing fluids. If
this is not enough, heat the jammed parts, beginning at the outside to prevent overheating the shaft
more than necessary.
 Repeat the operation several times if necessary, but never use enough force to risk distorting the shaft
and never use a hammer or other impact tools.
 The gasket between the pump casing and cover must be replaced paying strict attention to the
thickness of the original one.
 The reassembly of the pump is carried out in the reverse order of the disassembly.
 Pay attention when fixing the screws for casing/cover and cover/bearing housing.

8.1 Dismantling
Before starting work on the pump set, make sure it is disconnected from the
ATTENTION ! mains and can not be switched on accidentally.

Centrifugal pumps should be dismantled with great care. These pumps can be dismantled without disturbing
the suction and discharge piping. The following procedure should be followed for dismantling of the pumps:

21
  Close all valves in the suction and discharge lines and drain the pump by opening the drain plug and
the air vent screw.
 Disconnect the stuffing boxes flushing pipes.
 Remove coupling guard and other safety guard.
 Remove the coupling bolts and nuts.
 Unscrew and remove glands. These are split across the centreline and the relationship of each half to
the other is maintained with pegs or set screws. After splitting the glands the two halves can be taken
away completely.
 Remove the top clamp of the bearing bracket assembly.
 Unscrew and remove all the splitting flange bolts and remove the two parallel dowel pins. The upper
half casing then can be lifted away straight up to prevent damage to internal parts.
 Pull out the rotating assembly fitted with impeller, bearing housing and to be carried to a safe working
place. This assembly should be removed vertically to prevent damage to the impellers, wear rings
and other parts.
 Release coupling pins and bushes from half coupling.
 Unscrew and remove the bearing housing covers from both ends.
 Remove the bearing housing from the rotating assembly.
 Remove the shaft lock nut and washer and pull out bearings.
 Remove the water throwers.
 Remove the casing wear rings.
 Gland packing can be removed from the sleeve together with the logging rings.
 Unscrew the shaft sleeves from the shaft and care should be taken that the sleeves are threaded in
different hands – one is of R.H. and the other of L.H. marked on it.
 Now impeller is free to be removed. The impeller is press fit on the shaft and drawing tackle is
recommended.
 Clean all parts, replace damaged or worn out ones.

During dismantling, the various parts removed must be marked to ensure proper reassembly.

8.2 Rotating Element Reassembly

The dismantling procedure should be carried out in reversed sequence for reassembly of the pump. The
following care should be taken before reassembly:

 Clean the bearing housings and pump casing properly.

 Replace stuffing box packing.
 Clean the bearings and fill them with the correct amount and type of grease. In case of large axial and
radial clearance, replace the bearings.
 Inspect the casing wear ring and impeller neck diameter. If the diametric clearance exceeds 1 mm,
replace the wear rings or both.
 All gaskets should be replaced.
 Inspect the shaft sleeves. If there is any major wear, replace them.
 Impellers must be remounted on the pump shaft so that they will rotate in the proper direction, always
away from the curvature of their vanes.
 The assembled rotating element should be placed in the lower half of the casing and the total lateral
clearance checked. When the thrust bearing is assembled and the shaft is in its proper position, this
total clearance should be suitably divided and the impellers centrally located in the casing.
 To avoid shaft distortion, all abutting joints must be square with the shaft axis and with each other, and
the impeller and sleeves must not be tightened with excessive force. This will cause crushing of metal
at these joints, exerting severe moments on the shaft. The shaft may become bowed under the
influence of these moments and develop a marked vibration, in addition to the possibility of rubbing
and binding at the internal running joints.
 If possible after assembly, the rotating assembly should be supported in its bearings or on centres to
check for concentricity and any eccentricity corrected.

ATTENTION ! Never use the old gaskets, make sure the new gaskets and O-rings are the same size as
22
 the old ones.

8.3 Pump Reassembly

Great care must be exercised in replacing the upper half of the casing and tightening up the casing bolts. The
casing bolts must be tightened precisely according to the order of tightening as indicated in numbers as shown
in figure. After all the bolts have been tightened once, they should be tightened again to ensure the tightness
of the casing joint. They must be tightened once more when the pump has been brought up to operating
temperature. Tightening torques for bolts and screws are given in appendix:

As soon as all work is finished, all scheduled safety and protective devices must be properly
fitted and put into operation.

23
Exploded view with mechanical seal execution (Single Stage)

24
Exploded view with packed gland execution (Single Stage)

25
Exploded view with mechanical seal execution (Double Stage)

26
Exploded view with mechanical seal execution (Through Bore)

27
8.4 Recommended Lubricants

Greases

Manufacturer Grease Type

1. Atlantic Refining Co. Atlantic Lubricant 54
2. Cities Service Oil Co. Trojan Grease H-2
3. Continental Oil Co. Conoco Super Lube
4. Gulf Oil Corp. Gulf Supreme Grease No.2
5. Mobile Oil Co. Mobilux Grease No.2
6. Pennzoil Co. Pennzoil 705 HDW
7. Phillips Petroleum Co. Philube Multi-Purpose L-2
8. Quaker State Oil Refining Corp. Quaker State Multi-Purpose Lubricant
9. Shell Oil Co. Inc. Shell Alvania Grease 2
10. Sinclair Refining Co. Litholine MP Grease
11. Standard Oil Co. Of California. Chevron Industrial Grease Med.
12. Sun Oil Co. Sun72 XMP Grease or Prestige 42
13. Texaco, Inc. Texaco Novatex Grease No.2

NOTE: Do not mix greases while the pump is in operation. Should it be necessary to change make of grease
used, bearings and housings should be cleaned with kerosene and completely re-packed with new grease.

Oils
Manufacturer Oil Type
1. American Oil Co. American Industrial Oil No.15
2. Atlantic Refining Co. Atlantic Hytherm Oil – C
3. Cities Service Oil Co. Pacemaker Oil No.1
4. Continental Oil Co. Conoco Dectol 15 R & O
5. Gulf Oil Corporation Gulf Harmony 44
6. Mobile Oil Co. Mobil DTE Oil Light
7. Pennzoil Co. Pennbell SFI 8
8. Phillips Petroleum Co. Magnus Oil, Grade Light
9. Quaker State Oil Refining Corp. Quaker State Motor Oil SAE 10W
10.Richfield Oil Corporation Eagle Oil R & O, No.10
11.Shell Oil Co., Inc. Shell Tellus Oil Grade 27
12.Texaco , Inc. Texaco Regal Oil A (R&O)

9 Pump Sealing
9.1 Stuffing Box Packing:
Stuffing box packing troubles are one of the commonest causes of centrifugal pump failure. The conditions
that contribute to stuffing box difficulties are:

a) Shaft running off centre because of excessive wear in the bearings, a bent shaft, or misalignment.
This condition can be readily checked – first by disconnecting the coupling and rechecking the
alignment, and secondly by mounting an indicator on the pump casing in the vicinity of the stuffing
box to determine whether the shaft revolves concentrically.

28
 b) Shaft or shaft sleeves worn and scored at the packing. A routine examination of these parts will
reveal whether they must be renewed or repaired.

c) Shaft vibration due to unbalance in the rotor, cavitation, operation at extremely light flows or
beyond the recommended maximum capacity, or instability in parallel operation.

d) Plugging of the water seal connection or improper location of the seal so that no sealing liquid can
enter the stuffing box. The presence of dirt or grit in the sealing liquid will similarly cause stuffing
box difficulties by scoring the shaft or shaft sleeves.

e) Excessive tightening of the gland with resulting absence of the leakage that lubricates the
packing. Hourly and daily observation of the pump operation, together with the knowledge that
some leakage is necessary for proper stuffing box operation, will prevent troubles from this cause.

f) Failure to provide suitable cooling through water-cooled stuffing boxes if the pump is so fitted.

g) Excessive clearance between the bottom of the stuffing box and the shaft or shaft sleeve, which
causes the packing to be gradually pushed into the pump interior. This condition can arise when
the shaft or shaft sleeves are repaired by grinding them down excessively instead of replacing
them or building them up to original dimensions.

h) Packing not properly selected for pressure, temperature, or rubbing speed conditions.

i) Packing not properly inserted into the stuffing box because the individual rings are too short and
the gap between ring ends is excessive, or because the ring joints are not staggered.
9.2 Installing Soft Packing:

j) Loosen and remove the gland from the stuffing box.

k) Using a packing puller, begin to remove the old packing rings.

l) Remove the split lantern ring and then continue removing packing with the puller.

m) After the packing has been removed, check the sleeve for scoring and nicks. If the shaft sleeve or
shaft cannot be cleaned up, it must be replaced. For the size of packing please refer to the pump
data sheets.

n) Wrap the packing tightly around a mandrel, which should be the same size as the pump shaft or
sleeve. The number of coils should be sufficient to fill the stuffing box. Cut the packing along one
side to form individual rings.

o) Assemble the split packing rings on the pump. Each ring should be seated individually, with the
split ends staggered 900 and the gland tightened to seat and fully compressed the ring. Be sure
the lantern ring is reinstalled correctly at the flush connection. Then back off the gland and
retighten only finger-tight.

p) Allow excess leakage during break-in to avoid the possibility of rapid expansion of the packing,
which could score the shaft sleeve or shaft so that leakage could not be controlled.

q) Leakage should be generous upon start-up. If the packing begins to overheat at start-up, stop the
pump and loosen the packing until leakage is obtained. Restart only if the packing is leaking.

Leakage to Prevent Burning and Sleeve Scoring:

Pressure, lb/in2 (kPa) Leakage, drops/min (cc/min)
0-60 (0-400) 60 4
61-100 (401-700) 190
101-250 (701-1700) 470

29
9.3 Dimensions for Gland Packing

SHAFT GROUP A B
1 10 10
2 10 10
3 16 16
4 16 16
5 20 20
6 20 20
7 20 20

9.4 Mechanical Seals

Pumps handling hazardous or expensive liquids, or liquids where the necessary leakage from a packed gland
is unacceptable, are often furnished with mechanical seals.
Mechanical seals are made in a wide variety of designs to suit particular applications, The manufacturer's
instructions for fitting or replacing the specific seal type used must, therefore, be followed exactly. A
mechanical seal is a precision device and must be treated accordingly.

When the pump is equipped with mechanical seal, no attention or adjustment to the seal is normally required.
Except for possible slight initial leakage, the seal should operate with negligible attention.

30
9.5 Sealing Problems, Causes and Solutions:
Problems Causes Solutions
No liquid delivered by Lack of prime (packing loose or Tighten or replace packing and prime pump.
pump defective, allowing air to leak into
suction)
Not enough liquid Air leaking into the stuffing box Check for leakage through stuffing box while operating
delivered by pump – if no leakage after reasonable gland adjustment,
new packing may be needed.
Lantern ring may be clogged or displaced and may
need centering in line with sealing liquid connection.
Sealing liquid line may be clogged.
Shaft or shaft sleeve below packing may be badly
scored, allowing air to be sucked into pump.
Replace packing and check smoothness of shaft or
Defective packing shaft sleeve.
Not enough pump Defective packing As for preceding.
pressure
Pump works for while Air leaks into stuffing box As for preceding.
and quits
Pump takes too much Packing too tight Release gland pressure and retighten reasonably.
power Keep leakage flowing – if none, check packing,
sleeve, or shaft.
Pump leaks Defective packing Replace worn packing. Replace packing damaged by
excessively at stuffing lack of lubrication.

Trouble Cause Cure

Wrong type of packing Replace packing not properly installed or run in.
Replace improper packing with correct grade for liquid
being handled.

Shaft or shaft sleeve scored
Stuffing box Packing too tight
overheats Packing not lubricated
Wrong grade of packing
Insufficient cooling water to jackets
Stuffing box improperly packed
Packing wears too Shaft or shaft sleeve worn or scored
fast Insufficient or no lubrication
Packing packed improperly
Wrong grade of packing
Pulsating pressure on external seal
liquid line
Put in lathe and machine-true and smooth or replace.
Release gland pressure.
Release gland pressure and replace all packing if any
burnt or damaged.
Check with pump or packing manufacturer for correct
grade.
Check for open supply line valves or clogged line.
Repack.
Remachine or replace.
Repack, making sure packing loose enough to allow
some leakage.
Repack properly, making sure all old packing removed
and box clean.
Check with pump or packing manufacturer.
Remove cause of pulsation.

31
9 Locating Troubles:
Symptom/Troubles Possible Causes Key

Pump does not 1,2,3,4,6,11,14,16, 1. Pump not primed

deliver water 17,22,23 2. Pump or suction pipe not completely filled with liquid
3. Suction lift too high
Insufficient capacity 2,3,4,5,6,7,8,9,10, 4. Insufficient margin between suction pressure and vapour pressure
delivered 11,14,17,20,22,23, 5. Excessive amount of air or gas in liquid
29,30,31 6. Air pocket in suction line
Insufficient pressure 5,14,16,17,20,22,2 7. Air leakage in suction line
developed 9,30,31 8. Air leakage into pump through stuffing boxes
9. Foot valve too small
10. Foot valve partially clogged
Pump loses prime 11. Inlet of suction pipe insufficiently submerged
after starting 12. Water seal pipe plugged
13. Seal cage improperly located in stuffing box, preventing sealing fluid entering
Pump requires space to form the seal
excessive power 14. Speed too low
15. Speed too high
Stuffing box leaks 16. Wrong direction of rotation
excessively 17. Total head of system higher than pump design head
18. Total head of system lower than pump design head
Packing has short 19. Specific gravity of liquid different than design
life 20. Viscosity of liquid differs from that for which designed
21. Operation at very low capacity
Pump vibrates or is 22. Parallel operation of pumps unsuitable for such operation
23. Foreign matter in impeller
noisy
24. Misalignment
25. Foundations not rigid
Bearings have short 26. Shaft bent
life 27. Rotating part rubbing on stationary part
28. Bearings worn
Pump overheats and 29. Wearing rings worn
sizes 30. Impeller damaged
31. Casing gasket defective, permitting internal leakage
32. Shaft or shaft sleeves worn or scored at the packing
33. Packing improperly installed
34. Incorrect type of packing for operating conditions
35. Shaft running off-centre due to worn bearing or misalignment
36. Rotor out of balance resulting in vibration
37. Gland too tight, resulting in no flow of liquid to lubricate packing
38. Failure to provide cooling liquid to water cooled stuffing box
N.B: 1-13- Suction
39. Excessive clearance at bottom of stuffing box between shaft and casing,
troubles
causing packing to be forced into pump interior
40. Dirt or grit in sealing liquid, leading to scoring of shaft or shaft sleeves
14-22- System 41. Excessive thrust caused by a mechanical failure inside the pump or by
trouble failure of the hydraulic balancing device, if any
42. Excessive amount of grease or oil in the housing of an anti-friction bearing or
23-47- Mechanical lack of cooling, causing excessive bearing temperature
troubles 43. Lack of lubrication
44. Improper installation of antifriction bearings
45. Dirt getting into bearings
46. Rusting of bearings due to water getting into bushing
47. Excessive cooling of water-cooled bearing resulting in condensation in the
bearing housing of moisture from atmosphere

32
10 Spare Parts
The minimum stock of spare parts for any centrifugal pump should include the following:
For Gland Packing Unit
i. set of wear rings,
ii. set of shaft sleeves
iii. set of gland packing
iv. set of bearings
v. lantern ring
vi. gland
vii. split flange gaskets

For Mechanical Seal Unit

i. set of wear rings,
ii. set of mechanical seal
iii. set of bearing
iv. split flange gasket

It is often advisable to carry a complete spare rotating assembly for installation in the pump when examination
shows that the pump rotating assembly has become excessively worn, or if it becomes accidentally damaged.
Sufficient stock of spare gland packing for the stuffing boxes and split flange gasket should always be in stock.

For ordering spare parts please provide the pump model and pump serial number as stamped on the
nameplate.

Recommended stock of spare parts:

No. of pumps (including stand by pumps)

Qty/
Part 2 3 4 5 6 8 10 and more
Pump
No. of SPARE parts
BEARING END COVER (PE) 1 1 1 2 2 2 2 20%
BEARING END COVER (FE) 1 1 1 2 2 2 2 20%
LOCKING WASHER 1 1 1 2 2 3 4 50%
LOCK NUT 1 1 1 2 2 3 4 50%
SET OF BEARINGS 2 2 2 4 4 6 6 50%
WATER THROWER 2 2 2 4 4 6 6 30%
IMPELLER NUT 2 2 2 4 4 6 6 30%
THRUST COLLAR 1 1 1 2 2 2 3 30%
SHAFT 1 1 1 2 2 2 3 30%
MECHANICAL SEAL 2 Refer works
COUPLING KEY 1 1 1 2 2 2 3 30%
IMPELLER KEY 1 1 1 2 2 2 3 30%
SHAFT SLEEVE & NUT (SET) 2 2 2 2 4 4 4 30%
GLAND PACKING (SET) 2 4 4 4 6 6 8 50%
GLAND & LOGGING RING (SET) 2 2 2 4 4 4 6 30%
NECK RING 2 2 2 4 4 6 6 50%
IMPELLER (2 NOS. FOR 2
1 1 1 2 2 2 3 30%
STAGE)
CASING 1 1 1 1 2 2 2 20%
GASKET AND O RING (SET) 1 4 6 8 8 9 12 150%
GLAND PLATE 2 2 2 2 2 4 4 20%
BEARING BRACKET &
2 2 2 2 2 4 4 20%
HOUSING
33
11 Sectional Drawing
ASP Single Stage With Mechanical Seal Execution

34
ASP Single Stage With Packed Gland Execution

35
ASP Double Stage With Mechanical Seal Execution

36
ASP Double Stage With Packed Gland Execution

37
ASP Through Bore With Mechanical Seal Execution

38
Appendix A:
Recommended Tightening Torques and Induced Loads

Thread Stress Property Class 8.8 Property Class 10.9

Size Area
mm2 Torque Induced Load Torque Induced Load

Nm N Nm N

M4 8.78 3 3877 4.3 5695

M5 14.2 6 6361 8.9 9344

M6 20.1 10.3 9005 15.1 13230

M8 36.6 25 16400 37 24080

M10 58 50 26360 74 38700

M12 84.3 67 38300 128 56300

(M14) 115 139 52300 205 76800

M16 157 214 72300 316 106300

(M16) 192 304 91200 435 129900

M20 245 431 116400 615 165800

(M22) 303 586 144000 835 205100

M24 353 745 167700 1060 238700

(M27) 459 1090 218100 1560 310400

M30 561.0 1480 268600 2105 379400

(M33) 694.0 2013 329800 2865 469300

(M36) 617.0 2586 388200 3680 552500

(M39) 976.0 3348 463600 4760 660000

39
APPENDIX B:
Useful Formulae

Pressure = p = Head of water column x density x gravitational constant

Flow = Velocity x Cross Sectional Area = v. A
Velocity Head = v2/2g
1 USGPM = 4.404 m 3/hr = 1.2 IGPM
1 PSI = (feet x S.G) / 2.31

Affinity Laws:
2 3
Q1 N1 H1  N1  P1  N1 
 ,   ,  
Q2 N 2 H 2  N 2  P2  N 2 
Where, N = Speed, RPM
Q = Capacity
H = Head

Power Calculation:
Q ( LPS )  H (m) Q (m3 / hr )  H ( m)
P  kW
1.02  Efficiency 3.67  Efficiency

Shaft Stress:
S ( psi )  N  d 3 (inch)
P( hp)  , S = Shaft stress, d = Shaft diameter at coupling
321000
Specific Speed
N Q
Ns 
H3/ 4
where, N = pump speed, rpm
Q = capacity at BEP, full diameter, GPM
H = pump head per stage at BEP, full diameter, ft
Suction Specific Speed
N Q
Nss 
NPSHr 3 / 4
where, N = pump speed, rpm
Q = capacity at BEP, full diameter, GPM (half flow for double suction impeller)
NPSHr = Net Positive Suction Head required by the pump at BEP, ft

40
APPPENDIX C:
Material Equivalent Chart:

Material British Standard ASTM Standard DIN Standard

Cast Iron BS 1452 Gr260 A48 Class 35 GG25

Nodular Cast Iron BS 2789 Gr500 A536 60-45-12 GGG50

Cast Steel BS 3100 GrA1 A216 WCB GS-C25

BS 3100-316 C16 A743 GrCF8M G-X6CrMo165

Stainless Steel (Cast)
BS 3100-410 C21 A743 GrCA15 G-X 12Cr14

Ni-resist BS 3468 L-NiCuCr20 2 A436 Type 1 GCI –NiCuCr1562

BS 1400 GrLG2 B584 C83600 G-CuSn 5 ZnPb

Bronze
BS 1400 GrAB2 B148 958 G-Cu Al 10 Ni

Zinc Free Bronze BS 1400 GrCT1 B427 C90700 G-CuSn10

HT Steel BS 970-708 M40 A322 Gr4140 42 CrMo4

BS 970 410 S21 A 182 Type 410 X 10 Cr 13

Stainless Steel (Non-
BS 970 316 S 16 A276 Type 316 X5 CrNiMo1810
cast)
BS 970 304 S15 A276 Type 304 X5 CrNi189

41
APPPENDIX D:

PRODUCT RANGE:
Sr. Pump Sr. Pump Sr. Pump Sr. Pump
Stage Stage Stage Stage
No. Model No. Model No. Model No. Model
1 ASP 100A Single 17 ASP 200BS Single 33 ASP 300C Single 49 ASP 80BT Single
2 ASP 100AL Single 18 ASP 200C Single 34 ASP 300D Single 50 ASP 80CT Single
ASP
3 ASP 100B Single 19 ASP 200CS Single 35 Single 51 ASP 100AST Single
300DS
4 ASP 100C Single 20 ASP 200D Single 36 ASP 300E Single 52 ASP 150BT Single
5 ASP 125A Single 21 ASP 200DS Single 37 ASP 350C Single 53 ASP 200BT Single
6 ASP 125B Single 22 ASP 200E Single 38 ASP 350CS Single 54 ASP 65G Double
7 ASP 125BS Single 23 ASP 250A Single 39 ASP 350D Single 55 ASP 80G Double
8 ASP 125C Single 24 ASP 250AL Single 40 ASP 350E Single 56 ASP 80H Double
9 ASP 125D Single 25 ASP 250AS Single 41 ASP 400A Single 57 ASP 100G Double
10 ASP 150A Single 26 ASP 250B Single 42 ASP 400AS Single 58 ASP 100HA Double
11 ASP 150B Single 27 ASP 250C Single 43 ASP 400AL Single 59 ASP 100HB Double
ASP 100HB
12 ASP 150C Single 28 ASP 250D Single 44 ASP 400C Single 60 Double
(EL2)
13 ASP 150D Single 29 ASP 250E Single 45 ASP 400D Single 61 ASP 125G Double
14 ASP 150E Single 30 ASP 300A Single 46 ASP 50AT Single 62 ASP 150G Double
15 ASP 200A Single 31 ASP 300B Single 47 ASP 50BT Single 63 ASP 150H Double
16 ASP 200B Single 32 ASP 300BS Single 48 ASP 80AST Single 64 ASP 250G Double

42
 This manual has to be kept
with the end user/
maintenance staffs at site

For any clarification, routine/emergency repair/maintenance, please contact to your purchaser or:
WILO MATHER AND PLATT PUMPS PVT LTD
Shaila Tower, 3rd Floor, J1/16, EP Block, Sector V, Kolkata-700091, India
Phone: +91 33 3002 8903, Fax: +91 33 3002 8912
E-mail: tapas.bhar@matherplatt.com; surajit.sarkar@matherplatt.com & sohan.das@matherplatt.com
Web: www.matherplatt.com

Quality Management System ISO 9001: 2008

For Design, Manufacturing, Assembly and Marketing of Centrifugal Pumps

43
HOT WATER BOOSTER PUMP SET

PUMP MODEL: 2 x MHI 405

(HBP – 01, 02)

 Technical data
Contact
E-mail High-pressure multistage centrifugal pump
Phone MHI 405-1/E/3-400-50-2
Customer Project name Untitled project 2018-07-23 03:26:22.023

Project ID
Contact
E-mail
Phone
Installation location
Customer pos.no HBP -01, 02
Date 2018-07-23

Duty chart Requested data

Head -- Flow 100,00 l/min
H /m ∆ p / bar
Head 30,00 m
50 5 Media Water 100 %
Eff. 59,1% Fluid temperature 10,00 °C
40 4
Density 998,30 kg/m³
33,98 3,328 Kin. viscosity 1,00 mm²/s
30 3
Hydraulic data (Duty point)
A1 2
20 Flow 106,42 l/min
Head 33,98 m
10 1
Shaft power P2 1,04 kW
▕◄ Application range ►▏ Hydraulic efficiency 56,81 %
0 0
NPSH-values NPSH 1,86 m
NPSH / m
Product data
1,86
High-pressure multistage centrifugal pump
0
56,81 Hydraulic efficiency MHI 405-1/E/3-400-50-2
η /%
Max. operating pressure 10 bar
Inlet pressure max. 6 bar
0 Fluid temperature -30 °C ... + 110 °C
Shaft power P2 Max. ambient temperature 40 °C
P₂ 1,038
/ kW
0,5
Motordata per Motor/Pump
0
Motor efficiency level IE3
0 10 20 30 40 50 60 70 80 106,4
90 100 110 120 130 140 Q / l/min Mains connection 3~ 400 V / 50 Hz
Pump curves in accordance with ISO 9906, Appendix A Permitted voltage tolerance ±10 %
Max. speed 2900 1/min
Rated power P2 1,10 kW
Rated current 2,80 A
Power factor 0,83
Efficiency
50% / 75% / 100% 81,5/82,7/82,7%
Degree of protection IP 54
Insulation class F
Motor protection no
Fitting dimensions
Pipe connection on the suction side Rp 1¼, PN 10
Pipe connection on the pressure side Rp 1, PN 10
Materials
Pump housing 1.4301 [AISI304]

Impeller 1.4301 [AISI304]

Static seal EPDM
Pump shaft 1.4301 [AISI304]
Mechanical seal BQ1E3GG
Information for order placements
Weight approx. 15,1 kg
Item number 4210732

Dimensions mm

H 219 L2 110 Ø D2 1
H1 90 L3 157,5
H2 104 L4 52
L 457 L5 52
L1 252 Ø D1 1¼

Software version Spaix, Version 4.3.11 - 2018/06/18 (Build 184)

Subject to change Data version 08.09.2017 Pages 1/ 1
 Wilo-Economy-MHI 2../ 4../ 8../ 16..

D Einbau- und Betriebsanleitung CZ Návod k montáži a obsluze

GB Installation and operating instructions PL Instrukcja montażu i obsługi
F Notice de montage et de mise en service RUS Инструкция по монтажу и эксплуатации
NL Inbouw- en bedieningsvoorschriften DK Monterings- og driftsvejledning
E Instrucciones de instalación y funcionamiento NO Monterings- og driftsveiledningen
I Istruzioni di montaggio, uso e manutenzione
FIN Huolto- ja käyttöohje
S Monterings- och skötselinstruktioner
H Beépítési és üzemeltetési utasítás
GR Οδηγίες εγκατάστασης και λειτουργίας
2020406-Ed.2-04/10
Fig. 1

Fig. 2
Fig. 3

Fig. 4
 ENGLISH

1. General Motor power: see rating plate,

Maximum current: see rating plate,
Installation and service by qualified personnel only Fluid temperature: –15 °C to 110 °C
1.1 Applications with gaskets – EPDM
The pump is suitable for drinking water, heating water, industrial water, (KTW/WRAS),
condensate, water/glycol mixtures up to a ratio of 40% glycol as well –15 °C to 80 °C version with
as other liquids free from mineral oil and without abrasives or long- with gaskets – VITON
fibred substances. Max. permissible working pressure: 10 bar,
The main areas of use are in water supply installations, as a booster Max. permissible inlet pressure: 6 bar,
pump, as a boiler feed pump, in industrial circulation systems, in pro- Max. ambient temperature: 40 °C,
cess technology, in cooling water systems, in fire extinguishers and in Protective system: IP 54.
washing and sprinkler installations. Other voltages/frequencies and material properties are optional and/or
Approval from the manufacturer must be obtained beforehand if corro- available on request.
sive chemicals are to be pumped. When pumping viscous fluids (e.g. water/glycol mixtures) adjust the
pump data to allow for the higher viscosity.
1.2 Technical description
Only use branded glycol mixtures with corrosion inhibitors and follow
1.2.1 Performance and electrical data
the manufacturers instructions.
AC voltage: 1 ~ 230 V (± 10 %) / 50Hz or
For dimensions see table and Fig. 3.
Rotary current voltage: 3 ~ 230 / 400 V (± 10 %) / 50 Hz;

Pump Pump unit

Model Dimensions

A B C D E F G H

1~230 V 3~400 V 1~230 V 3~400 V 1~230 V 3~400 V 1~230 V 3~400 V

MHI mm

202 205 88 88 375 375 216 192 90 90 Rp1 110 Rp1

203 205 88 88 375 375 216 192 90 90 Rp1 110 Rp1

204 253 88 88 423 423 216 192 90 90 Rp1 158 Rp1

205 253 88 88 423 423 216 192 90 90 Rp1 158 Rp1

206 277 104 104 472 472 224 206 90 90 Rp1 182 Rp1

402 205 88 88 375 375 216 192 90 90 Rp11/4 110 Rp1

403 205 88 88 375 375 216 192 90 90 Rp11/4 110 Rp1

404 253 88 88 423 423 216 192 90 90 Rp11/4 158 Rp1

405 253 104 104 448 448 224 206 90 90 Rp11/4 158 Rp1

406 277 137 104 511 472 239 206 100 90 Rp11/4 182 Rp1

802 217 88 88 387 387 216 192 90 90 Rp11/2 122 Rp11/4

803 217 104 88 412 387 224 192 90 90 Rp11/2 122 Rp11/4

804 277 104 104 472 472 224 206 90 90 Rp11/2 182 Rp11/4

805 277 - 104 - 472 - 206 - 90 Rp11/2 182 Rp11/4

1602 237 - 103,5 - 432 - 206 - 90 Rp2 138 Rp11/2

1603 237 - 103,5 - 432 - 206 - 90 Rp2 138 Rp11/2

1604 282 - 136,5 - 515 - 221 - 100 Rp2 183 Rp11/2

When ordering spare parts, please give all the information on the rating plate.

8
 ENGLISH

1.2.2 Series specifications 2.5 Safety precautions for inspection and installation
MHI 4 06 1 / E / 3 ~ 400 - 50 - 2/XX/X The operator must ensure that all inspection and installation work is
MHI (Multistage carried out by authorized and qualified specialists who have carefully
Horizontal stainless steel studied these instructions. In principle, work should not be carried out
(Inox) centrifugal on a running pump or installation.
pump) design 2.6 Unauthorized alterations and manufacture of spare parts
Flow rate Alterations to the pump or installation may only be carried out with the
[m3/h] manufacturer's consent. The use of original spare parts and accesso-
ries authorized by the manufacturer will ensure safety. The use of other
Number of impellers
parts may invalidate claims invoking the manufacturer’s liability for any
Steel grade: consequences.
1 → 1.4301 (AISI 304)
2 → 1.4404 (AISI 316 L) 2.7 Improper use
The operational safety of the pump or installation supplied can only be
gaskets – EPDM (KTW/WRAS)
guaranteed if it is used in accordance with paragraph 1 of the operat-
gaskets – VITON
ing instructions. The limits given in the catalogue or data sheet must
Mains voltage under no circumstances be exceeded.
3 ~ 230/400 V
1 ~ 230 V
50Hz or 60Hz frequency
2 or 4 pole motor
3. Transport and storage
Manufacturer's key WARNING! During transport and in storage the pump must be
protected against moisture, frost and mechanical
damage.

4. Description of product and accessories

2. Safety precautions
These instructions contain important information which must be
followed when installing and operating the pump. It is therefore im-
perative that they be read by both the installer and the operator before
the pump is installed or started up.
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 follow-
ed, could cause personal injury are indicated by the symbol:
Safety precautions warning of danger due to electricity are indicated
by the symbol:
Safety precautions which, if not followed, could damage the pump or
installation and cause it to malfunction are indicated by the word:
WARNING!
2.2 Qualified Personnel
The personnel installing the pump must have the appropriate qualifica-
tions for this work.
2.3 Risks incurred by failure to comply with the safety precautions
Failure to comply with the safety precautions could result in personal
injury or damage to the pump or installation. Failure to comply with the
safety precautions could also invalidate any claim for damages.
In particular, failure to comply with these safety precautions could give
rise, for example, to the following risks:
– the failure of important parts of the pump or installation,
– personal injury due to electrical and mechanical causes.
2.4 Safety precautions for the operator
Existing regulations for the prevention of accidents must be followed.
To prevent the risk of electric shock or electrocution, VDE regulations
and those of the local supply company must be followed.
4.1 Pump description (Fig. 1)
The pump is a multistage (2-6 stage) normal suction, horizontal high
pressure centrifugal pump with a block design with horizontal inlet (1)
and vertical pressure glands (2).
The hydraulic section is equipped with the given number of stage
housings (5) and impellers (6) in a modular construction. The impellers
are fitted on a single motor-pump shaft (7). The pressure casing (8)
surrounding the hydraulic section guarantees a fail-safe seal. All parts
in contact with the fluid, such as stage chambers, impellers and the
pressure casing, are made of chromium nickel steel. The shaft hole
through the pump casing is sealed to the motor with an axial face seal
(9). E = All parts in contact with the fluid have been cleared by KTW
and/or WRAS and are therefore suitable for use with drinking water.
The AC motors are equipped with a thermal cut-out. This switches off
the motor when the permissible temperature of the motor coil is
exceeded and switches it back on again automatically once it has
cooled down.
Low-water protection. The pump and in particular the axial face seal
must not run dry. Low-water protection should be provided by the
customer by fitting the relevant parts from the WILO range of accesso-
ries.
The speed of the pump can be controlled when connected to a fre-
quency converter or motor filter (see paragraph 5.3)
4.2 Components supplied
– EM or DM version of pump,
– Installation and Operating Instructions
4.3 Accessories
Accessories must be ordered separately.
– WV/COL switching unit with relevant accessories for automation,
– CO-ER switching unit with relevant accessories for automation,
– Low-water protection:
– WMS kit for direct connection to the supply pipe,
– WAEK 65 float switch with small switching unit (only for EM
version),
– WA 65 float switch,
– SK 277 with 3 dipped electrodes,
– WVA pressure switch,
– WILO fluid control (EK),
– Installation switching:
– WA 065 float switch
– WA OEK 65 float switch with small switching unit (only for EM
version).

9
 ENGLISH
5. Assembly and Installation
5.1 Installation
Fig. 2 shows a typical pump installation. Installation and assembly
instructions, which must be observed with this type of operation, are
listed as follows:
– Before installing the pump, make sure that all welding and soldering
on the pipe system has been completed and that the pipe system
has been completely flushed out. Foreign bodies and dirt will dama-
ge the pump.
– Install the pump in a dry place free of frost.
– Leave room for maintenance work to be carried out.
– The motor ventilator inlet must be kept clear, at least 0.30 m from
the wall to the rear.
– Install in a horizontal and flat position.
– The pump must be held in place with two 8 mm diameter screws,
on a vibration-absorbing base. Commercially available rubber-metal
connectors can also be used to hold it in place and absorb vibra-
tions.
– To ensure that the drain valve can be accessed, the pump must be
installed with the drain valve at least 20 mm above the floor.
– Isolating valves (1) should be installed in front of and behind the
pump, so that the pump can be easily changed and/or maintenance
work can be carried out more easily.
– A backflow preventer (2) should be installed immediately behind the
outlet pressure gland of the pump.
– The inlet and outlet pipes should be connected to the pump without
stress. Flexible lengths of pipe or bellow expansion joints of
restricted length can be used to ensure a low-vibration connection.
The weight of the pipework must be supported.
– The customer should take suitable measures to prevent low water
levels and hence guard against the pump running dry in order to
protect the axial face seal. The WILO range comprises various
accessories which can be used for this purpose.
– The customer should protect the pump at the inlet pipe with a
strainer (1mm mesh) or filter connection (5) to avoid the pipe
being damaged by any dirt which may be sucked in.
5.2 Electrical installation
– Electrical work must be carried out by a qualified and
licensed electrician in strict compliance with local regu-
lations.
– The electricity supply must be connected via a rigid supply cable
fitted with a coupler or an all-pole switch with a contact gap of at
least 3 mm in accordance with the local regulations in force (e.g. in
accordance with the latest edition of IEE wiring regulations).
– Check the mains current and voltage.
– Ensure compliance with the data on the pump rating plate.
– Make sure the pump is earthed.
– Mains fuse: 10A time-lag fuse.
– The customer should fit rotary current motors with a motor safety
switch which should be adjusted to the nominal current given on the
rating plate to prevent the motor from overheating.
AC motors are fitted with a thermal motor cut-out in the factory.
This cuts off the pump when the permissible temperature of the
motor coil is exceeded and switches it back on again automatically
once it has cooled down.
– A supply cable with an adequate ample external diameter (e.g. 05
VV-F 3/5 G 1.5 or AVMH-I 3/5x1.5) should be used to protect
against damp and to secure the mains lead cleat of the stuffing box.
– Connection to the mains must be carried out in accordance with the
plan of terminal connections for rotary or alternating current in the
terminal box of the pump (see also Fig. 4).
– Heat-resistant cable must be used if the pump is fitted in installa-
tions in which the temperature of the fluids pumped exceeds 90 °C.
– The supply cable must be laid in such a way that it never touches
the pipework and/or the pump and motor casing.
If necessary a fault current breaker (FI-switch) should be
provided.
10
5.3 Operation with frequency converter
The speed of the pump can be controlled when connected to a
frequency converter. Speed control limits: 40%nnom ≤ n ≤ 100%nnom.
See Installation and Operating Instructions of the frequency converter
for connection and operation.
To avoid overloading the motor coil to the extent that it is damaged
and to avoid increasing noise levels, the frequency converter must not
produce speeds due to increased voltage of over 500 V/μs and spikes
of û > 650 V. If such speeds due to increased voltage are possible, an
LC filter (motor filter) should be installed between the frequency
converter and the motor. The layout of the filter must be designed by
the manufacturer of the frequency converter or filter.
In control devices with frequency converters supplied by WILO, the
filter is already installed.
6. Commissioning
– Check that there is a sufficient level of water in the reservoir and/or
check the inlet pressure.
WARNING! The pump must not run dry, as this would destroy
the axial face seal.
– When used for the first time, if it is to be used to pump drinking
water the system must be flushed through, so that any dirty water
present will not contaminate the drinking water supply.
– Checking direction of rotation (only for rotary current motors): Check
that the pump rotates in the direction indicated by the arrow on the
pump casing by switching on for a short time. If this is not the case,
interchange 2 phases in the pump terminal box.
– Only for rotary current motors: Adjust the motor cut-out to the nomi-
nal current given on the rating plate.
– If available, position float switches or electrodes for protection
against low water levels in such a way that the pump cuts out if the
water level is so low that air would begin to be sucked in.
– Open the isolating valve at the inlet, open the vent screw (Figs 1 & 2,
3, SW 19) until the pumped fluid comes out, close the vent screw,
open the isolating valve at the outlet and switch on the pump.
– Depending on the fluid temperature and the system pres-
sure, if the vent screw is completely loosened hot liquid or
gas can escape or even shoot out at high pressure.
Beware of scalding.
– Depending on the operating conditions of the pump or
installation (fluid temperature), the entire pump may be-
come very hot.
Avoid touching the pipe owing to the risk of burning.
WARNING! The pump must not run for longer than 10 minutes
with a flow rate of Q = 0 m3/h. We recommend that
when running continuously the pump should be
kept at a minimal flow of 10 % nominal flow.
7. Maintenance
– The pump is almost maintenance free.
– During the running-in period, there may be some dripping from the
axial face seal. Should a more significant leak occur as a result of
substantial wear, have the axial face seal replaced by a specialist.
– Increased bearing noise and unusual vibrations indicate a worn
bearing. In this case, have the bearing replaced by a specialist.
– Before carrying out any maintenance work, switch off the pump and
ensure that it cannot be switched on again by unauthorized people.
Never carry out work on a running pump.
– When the pump is exposed to frost or is out of service for a long
period, the pump and pipework must be emptied in the cold
season. Empty the pump by releasing the drain valve (Figs 1 & 2, 4),
the inlet pipe by releasing the vent screw, and the outlet pipe by
opening the bleeding point.
 ENGLISH

8. Fault finding, causes and remedies

Fault Cause Remedy

Pump does not run no power check fuses, float switches and cables

motor safety switch activated eliminate motor overload

Pump runs but does not pump wrong direction of rotation interchange two phases of the mains
connection

pipe or pump components blocked by check and clean pipe and pump
foreign body

air in inlet pressure gland seal inlet pressure gland

inlet pipe too narrow fit a larger inlet pipe

Pump does not pump evenly inlet too high position the pump lower

Pressure is insufficient wrong choice of pump fit a more powerful pump

wrong direction of rotation interchange two phases of the mains

connection

flow is too small, inlet pipe blocked clean filter and inlet pipe

valve not sufficiently open open valve

foreign body blocking the pump clean the pump

Pump vibrates foreign body in the pump remove foreign body

pump not properly fixed to the base tighten anchor bolts

base is not sufficiently heavy fit a heavier base

Motor overheats, insufficient voltage check voltage

motor cut-out activates

pump sluggish:
foreign body clean pump
bearing damaged have pump repaired by customer services

ambient temperature too high provide cooling

If the fault cannot be remedied, please contact your local plumbing

and heating specialist or WILO customer services.
Figures:
1 Cross-section of the pump with reference numbers.
2. Positioning and pipework of the pump.
3. Drawing showing dimensions.
4. Plan of electrical connections. Subject to technical alterations.w

11
NL
EG-verklaring van overeenstemming
Hiermede verklaren wij dat dit aggregaat in de geleverde uitvoering
voldoet aan de volgende bepalingen:
EG-richtlijnen betreffende machines 2006/42/EG
De veiligheidsdoelstellingen van de laagspanningsrichtlijn worden
overeenkomstig bijlage I, nr. 1.5.1 van de machinerichtlijn 2006/42/EG
aangehouden.
Elektromagnetische compatibiliteit 2004/108/EG
gebruikte geharmoniseerde normen, in het bijzonder:
zie vorige pagina
P S
Declaração de Conformidade CE
Pela presente, declaramos que esta unidade no seu estado original, está
conforme os seguintes requisitos:
Directivas CEE relativas a máquinas 2006/42/EG
Os objectivos de protecção da directiva de baixa tensão são cumpridos de
acordo com o anexo I, nº 1.5.1 da directiva de máquinas 2006/42/CE.
Compatibilidade electromagnética 2004/108/EG
normas harmonizadas aplicadas, especialmente:
ver página anterior
FIN
CE-standardinmukaisuusseloste
Ilmoitamme täten, että tämä laite vastaa seuraavia asiaankuuluvia
määräyksiä:
EU–konedirektiivit: 2006/42/EG
Pienjännitedirektiivin suojatavoitteita noudatetaan
konedirektiivin 2006/42/EY liitteen I, nro 1.5.1 mukaisesti.
Sähkömagneettinen soveltuvuus 2004/108/EG
käytetyt yhteensovitetut standardit, erityisesti:
katso edellinen sivu.
CZ
Prohlášení o shod ES
I E
Dichiarazione di conformità CE
Con la presente si dichiara che i presenti prodotti sono conformi alle
seguenti disposizioni e direttive rilevanti:
Direttiva macchine 2006/42/EG
Gli obiettivi di protezione della direttiva macchine vengono rispettati
secondo allegato I, n. 1.5.1 dalla direttiva macchine 2006/42/CE.
Compatibilità elettromagnetica 2004/108/EG
norme armonizzate applicate, in particolare:
vedi pagina precedente
CE- försäkran
Härmed förklarar vi att denna maskin i levererat utförande motsvarar
följande tillämpliga bestämmelser:
EG–Maskindirektiv 2006/42/EG
Produkten uppfyller säkerhetsmålen i lågspänningsdirektivet enligt bilaga
I, nr 1.5.1 i maskindirektiv 2006/42/EG.
EG–Elektromagnetisk kompatibilitet – riktlinje 2004/108/EG
tillämpade harmoniserade normer, i synnerhet:
se föregående sida
DK
EF-overensstemmelseserklæring
Vi erklærer hermed, at denne enhed ved levering overholder følgende
relevante bestemmelser:
EU–maskindirektiver 2006/42/EG
Lavspændingsdirektivets mål om beskyttelse overholdes i henhold til bilag
I, nr. 1.5.1 i maskindirektivet 2006/42/EF.
Elektromagnetisk kompatibilitet: 2004/108/EG
anvendte harmoniserede standarder, særligt:
se forrige side
PL
Deklaracja Zgodnoci WE
Declaración de conformidad CE
Por la presente declaramos la conformidad del producto en su estado de
suministro con las disposiciones pertinentes siguientes:
Directiva sobre máquinas 2006/42/EG
Se cumplen los objetivos en materia de seguridad establecidos en la
Directiva de Baja tensión según lo especificado en el
Anexo I, punto 1.5.1 de la Directiva de Máquinas 2006/42/CE.
Directiva sobre compatibilidad electromagnética 2004/108/EG
normas armonizadas adoptadas, especialmente:
véase página anterior
N
EU-Overensstemmelseserklæring
Vi erklærer hermed at denne enheten i utførelse som levert er i
overensstemmelse med følgende relevante bestemmelser:
EG–Maskindirektiv 2006/42/EG
Lavspenningsdirektivets vernemål overholdes i samsvar med
vedlegg I, nr. 1.5.1 i maskindirektivet 2006/42/EF.
EG–EMV–Elektromagnetisk kompatibilitet 2004/108/EG
anvendte harmoniserte standarder, særlig:
se forrige side
H
EK-megfelelségi nyilatkozat
Ezennel kijelentjük, hogy az berendezés megfelel az alábbi irányelveknek:
Gépek irányelv: 2006/42/EK
A kisfeszültség irányelv védelmi elírásait a
2006/42/EK gépekre vonatkozó irányelv I. függelékének 1.5.1. sz. pontja
szerint teljesíti.
Elektromágneses összeférhetség irányelv: 2004/108/EK
alkalmazott harmonizált szabványoknak, különösen:
lásd az elz oldalt
RUS


     
Prohlašujeme tímto, že tento agregát vdodaném provedení odpovídá Niniejszym deklarujemy z pen odpowiedzialno
ci , e dostarczony wyrób
  ,  ! "#"  " $%
následujícím píslušným ustanovením: jest zgodny z nastpuj cymi dokumentami: &  ' # :
Smrnice ES pro strojní zaízení 2006/42/ES dyrektyw maszynow WE 2006/42/WE   EC    2006/42/EG
Cíle týkající se bezpe(nosti stanovené ve sm)rnici o elektrických zaízeních Przestrzegane s cele ochrony dyrektywy niskonapiciowej zgodnie z *#$ & $&, +  # &
nízkého nap)tí jsou dodrženy podle pílohy I, (. 1.5.1 sm)rnice o strojních za cznikiem I, nr 1.5.1 dyrektywy maszynowej 2006/42/WE. - &#+', $'' " &#+' I,
zaízeních 2006/42/ES. 3 1.5.1 #  7 7 2006/42/8G.
Smrnice o elektromagnetické kompatibilit 2004/108/ES dyrektyw dot. kompatybilnoci elektromagnetycznej 2004/108/WE 
  !" 2004/108/EG

použité harmoniza(ní normy, zejména: stosowanymi normami zharmonizowanymi, a w szczególno

ci: 9&- " #  #,  :
viz pedchozí strana patrz poprzednia strona . &#' #;

GR TR RO
#$%&'( ')**+,3&'(5 7(5 99 CE Uygunluk Teyid Belgesi EC-Declara;ie de conformitate
<=>?@JQRT UXZ XJ [\J]U@ ^QXU _’ ^QX{ X=@ |^X}_X^_= [^\}~J_= Bu cihazın teslim edildiƒi „ekliyle a„aƒıdaki standartlara uygun olduƒunu Prin prezenta declar…m c… acest produs a„a cum este livrat, corespunde cu
Z|^@J[JZT€ XZ ^|U>JQT ~Z^X}‚TZ : teyid ederiz: urm…toarele prevederi aplicabile:
<=(>?@5 EA >JQ *(XQY$*Q7Q 2006/42/EA AB-Makina Standartları 2006/42/EG Directiva CE pentru ma\ini 2006/42/EG
†Z ^[^ZX{_TZ [\J_X^_€^ X= J~=‡€^ ˆ^R=>{ X}_= X=\J‰@X^Z Alçak gerilim yönergesinin koruma hedefleri, 2006/42/AT makine Sunt respectate obiectivele de protecŽie din directiva privind joasa
_‰RŠ‹@^ RT XJ [^\}\X=R^ I, ^\. 1.5.1 X= J~=‡€^ _ˆTXZ|} RT X^ yönergesi Ek I, no. 1.5.1'e uygundur. tensiune conform Anexei I, Nr. 1.5.1 din directiva privind ma„inile
R=ˆ^@{R^X^ 2006/42/EG. 2006/42/CE.
]%@^7,_*Q>Y(7J^$ ')*`Q7+7(7Q EA-2004/108/EA Elektromanyetik Uyumluluk 2004/108/EG Compatibilitatea electromagneticx – directiva 2004/108/EG
@^\RJ@Z_R@^ ˆ\=_ZRJ[JZJ‰RT@^ [\UXQ[^, Z~Z^€XT\^: kısmen kullanılan standartlar için: standarde armonizate aplicate, îndeosebi:
‘>[T [\J=‡J‰RT@= _T>€~^ bkz. bir önceki sayfa vezi pagina precedent…

EST LV LT
EÜ vastavusdeklaratsioon EC - atbilst{bas deklar|cija EB atitikties deklaracija
Käesolevaga tõendame, et see toode vastab järgmistele asjakohastele Ar šo m’s apliecin“m, ka šis izstr“d“jums atbilst sekojošiem noteikumiem: Šiuo pažymima, kad šis gaminys atitinka šias normas ir direktyvas:
direktiividele:
Masinadirektiiv 2006/42/EÜ Maš{nu direkt{va 2006/42/EK Mašin} direktyv 2006/42/EB
Madalpingedirektiivi kaitse-eesmärgid on täidetud vastavalt masinate Zemsprieguma direkt—vas droš—bas m’r˜i tiek iev’roti atbilstoši Maš—nu Laikomasi Žemos ›tampos direktyvos keliamœ saugos reikalavimœ pagal
direktiivi 2006/42/EÜ I lisa punktile 1.5.1. direkt—vas 2006/42/EK pielikumam I, Nr. 1.5.1. Mašinœ direktyvos 2006/42/EB I priedo 1.5.1 punkt .
Elektromagnetilise ühilduvuse direktiiv 2004/108/EÜ Elektromagn~tisk|s savietojam{bas direkt{va 2004/108/EK Elektromagnetinio suderinamumo direktyv 2004/108/EB
kohaldatud harmoneeritud standardid, eriti: piem’roti harmoniz’ti standarti, tai skait“: pritaikytus vieningus standartus, o btent:
vt eelmist lk skat—t iepriekš’jo lappusi žr. ankstesniame puslapyje

SK SLO BG
ES vyhlásenie o zhode ES – izjava o skladnosti E-

 € 
Týmto vyhlasujeme, že konštrukcie tejto konštruk(nej série v dodanom Izjavljamo, da dobavljene vrste izvedbe te serije ustrezajo slede(im ž##,  &#% "#   :
vyhotovení vyhovujú nasledujúcim príslušným ustanoveniam: zadevnim dolo(ilom:
Stroje - smernica 2006/42/ES
Bezpe(nostné ciele smernice o nízkom napätí sú dodržiavané v zmysle
prílohy I, (. 1.5.1 smernice o strojových zariadeniach 2006/42/ES.
Elektromagnetická zhoda - smernica 2004/108/ES
Direktiva o strojih 2006/42/ES ‚ ƒ  2006/42/EO
Cilji Direktive o nizkonapetostni opremi so v skladu s Ÿ    #&#$   &#+ 
prilogo I, št. 1.5.1 Direktive o strojih 2006/42/EG doseženi. % %".  #+ I, 3 1.5.1  ž# 
7 2006/42/E¡.
Direktiva o elektromagnetni združljivosti 2004/108/ES E
   – ƒ  2004/108/E
používané harmonizované normy, najmä: uporabljeni harmonizirani standardi, predvsem: ¢## #:
pozri predchádzajúcu stranu glejte prejšnjo stran +. &# #;

M
Dikjarazzjoni ta’ konformità KE
B'dan il-mezz, niddikjaraw li l-prodotti tas-serje jissodisfaw id-
dispoizzjonijiet relevanti li £ejjin:
Makkinarju - Direttiva 2006/42/KE
j
L-objettivi g
tas-sigurta ££ Baxx huma konformi
tad-Direttiva dwar il-Vulta££ WILO SE
mal-Anness I, Nru 1.5.1 tad-Direttiva dwar il-Makkinarju 2006/42/KE.
Nortkirchenstraße 100
44263 Dortmund
Kompatibbiltà elettromanjetika - Direttiva 2004/108/KE
Germany
kif ukoll standards armonizzati b'mod partikolari:
ara l-pa£na ta' qabel
 WILO SE
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 WILO SE
Nortkirchenstraße 100
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Argentina Croatia Hungary Latvia Russia Switzerland
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T+ 54 11 4361 5929 wilo@wilo.hu
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BOOSTER PUMP CONTROLLER
NAME PLATE LIST
L1.POWER LAMP
L1 L2 L2.LOW LAVEL LAMP
L3.RUN NO.1 LAMP
L3 L4 L5 L6 L4.OVERLOAD NO.1 LAMP
L5.RUN NO.2 LAMP
ST1 SP1 ST2 SP2
L6.OVERLOAD NO.2 LAMP
61

ST1. START PUMP1

SW1 SW2
SP1. STOP PUMP1
ST2. START PUMP2
SP2. STOP PUMP2
SW1.MANUAL - OFF - AUTO # 1 SSW.
SW2.MANUAL - OFF - AUTO # 2 SSW.
44 28
 POWER SUPPLY
3PH/4W/380/220V/50HZ
R S T N
WIRING DIAGRAM BOOSTER PUMP
F4 1 A1

OL1 OL2 FLR 5

R3
SW1 SW2 SW1 SW2
MCB1 3P MAN 1 MAN2 AUTO1 AUTO2
R3 A3
9 K1 A1
6 13
G4 17
STOP1 R2 R1 STOP2 PS1 T1

TR
2 3 4 7 11 12 K2 A2
K1 K2 10

AC220V

AC24
18 A2 A2A
R4 15 16
START1 K1 R1 R2 K1 START2
PS2 R3
OL1 OL2 OL1 OL2 A5
R4
U1 V1 W1 U2 V2 W2 8 14 A4

L1 L4 L6 L2 K1 L3 L5 K2 R1 R2 G4 FLR R3 T1 R4

N A0

M1 M2 F = CONTROL FUSE
L1 = POWER LAMP
L2 = LOW LEVEL LAMP
L3 = RUN NO.1 LAMP
L4 = OVERLOAD NO.1 LAMP
L5 = RUN NO.2 LAMP K 1 = MAGNETIC MOTOR START NO.1 R4 = PRESSURE SWITCH RELAY NO.2
L6 = OVERLOAD NO.2 LAMP K 2 = MAGNETIC MOTOR START NO.2 TR = TRANFORMER 220 / 24 VAC
SW 1 = MANUAL - OFF - AUTO NO.1 SSW. R1 = AUTO RELAY NO.1 G4 = RATCHING RELAY
SW 2 = MANUAL - OFF - AUTO NO.2 SSW. R2 = AUTO RELAY NO.2 T1 = OFF DELAY TIMER
R3 = PRESSURE SWITCH RELAY NO.1 FLR = FLOATLESS RELAY

TERMINAL JUMPER
R S T N G U1 V1 W1 U2 V2 W2 N A1 A2 A2 A4 A2 A2A E1 E2 E3

MAIN 380/220VAC / N
NEUTRAL

ON
INTER-LOCK

JUMPER
PS1 PS2
M1 M2 LOW
CUT-OFF

COM
 SUBMERSIBLE PUMP

PUMP MODEL: STS 80/16-FDM

(SP – 01, 02)

 SUBMERSIBLE PUMP

PUMP MODEL: VP-50/13-075-V-3

PUMP MODEL: STS 80/18-EDM
PUMP MODEL: STS 80/12.5-FDM

(SP – 03 TO 08)
 Technical data

Contact - Submersible drainage pump

E-mail - VP 50/13-075-V-3
Phone -

Customer
Project name
Project ID
Installation location
-
-
-
SP - 03 TO 08
Contact - Customer pos.no -
E-mail -
Phone - Date 2017-05-11

Requested data
14
Flow 3 m³/h
12 Head 10 m
Media Waste water
10 Fluid temperature 0~40oC
Density -
8
Kin. Viscosity -
H(m)

6 Hydraulic data (Duty point)

4 Flow 3 m³/h
Head 10 m
2
Product data
0 Submersible drainage pump VP 50/13-075-V-3
0 5 10 15 20 25 Fluid temperature 0~40 oC
Q(m³/h) Max. submergence depth 30 m
Free ball passage 35.0 mm
Impeller type Vortex

Motor data
Mains connection 3 ~ 380V / 50Hz
Permitted voltage tolerance ±10%
Nominal speed 2800 rpm
Rated power P2 0.75 kW
154

Rated current 2.0 A

Activation type Direct
Degree of protection IP68
199 Float switch No
Motor protection Auto Cut
237 Insulation class B
Operating mode (immersed) S1
Operating mode (non-immersed) -
Max. starts per hour 10

Cable
Length of connecting cable 5 m
Cable type VCT
Type of connecting cable Non-detachable
Mains plug No
Plug type -
Connection dimensions
50

Discharge Port DN50

Pressure Rating PN6
425

Flange Type Female PF

Materials
Pump housing Cast Iron(FC200)
Impeller Cast Iron(FC200)
Motor housing SUS304
Shaft end SUS410
Static seal NBR
Mechanical seal CA/CE & SiC/SiC
99

Information for order placements

Weight approx. 16 kg
Item number 2995737
Operating and Maintenance Manual
for Wilo Submersible Pumps
2
3
4
5
6
7
8
9
10
11
12
13
WILO SE
Nortkirchenstraße 100
D-44263 Dortmund
Germany
T +49 231 4102-0
F +49 231 4102-7363
wilo@wilo.com
www.wilo.de
PACKAGE BOOSTER PUMP SET

PUMP MODEL: 2 x NL 32/160B

(BP – 01, 02)

 Technical data
Contact
E-mail Glanded standard pump
Phone NL 32/160B-5,5-2-24
Customer Project name Untitled project 2019-02-14 09:28:58.288

Project ID
Contact Installation location
E-mail Customer pos.no
Phone

Date 2019-02-14

Duty chart Requested data

Head - Ø 175 Flow 400,00 l/min
H /m ∆ p / bar
- Ø 168 Head 35,00 m
Eff. 63,9% Media Water 100 %
35,3
35 63,1%
62,6% - Ø 160 3,5
3,457
61,4% Fluid temperature 20,00 °C
30 A1
- Ø 150 3
60% Density 998,20 kg/m³
25 - Ø 140 2,5
58,9% Kin. viscosity 1,00 mm²/s
57,9% - Ø 130 2
20
- Ø 171 Hydraulic data (Duty point)
15 1,5
Flow 401,73 l/min
10 1 Head 35,30 m
5 0,5 Shaft power P2 3,69 kW
▕◄ Application range ►▏ Hydraulic efficiency 62,82 %
0 0
Shaft power P2 NPSH 1,95 m
P₂ / kW
3,685 Impeller size 171

2 Product data
Glanded standard pump
NL 32/160B-5,5-2-24
0
NPSH-values Max. operating pressure 16 bar
NPSH / m
Fluid temperature -20 °C ... + 120 °C
4 Max. ambient temperature 40 °C
Minimum Efficiency Index (MEI) ≥ 0.40
2
1,952
Motordata per Motor/Pump
0
Motor efficiency level IE3
0 50 100 150 200 250 300 350 401,7
400 450 500 550 Q / l/min Mains connection 3~ 400 V / 50 Hz
Permitted voltage tolerance ±10 %
Max. speed 2930 1/min
Rated power P2 5,50 kW
Rated current 10,60 A
Power factor 0,88
Efficiency
50% / 75% / 100% 88,3/89,7/90%
Degree of protection IP 55
Insulation class F
Motor protection yes
Fitting dimensions
Pipe connection on the suction side DN 50, PN 16
Pipe connection on the pressure side DN 32, PN 16
Port to Port
Materials
Pump housing EN-GJL-250

Impeller G-CuSn10
Lantern EN-GJL-250
Pump shaft X30Cr13
Mechanical seal AQ1EGG
Information for order placements
Weight approx. 142 kg
Item number 4114439

Dimensions mm

A 80 H2 160 L4 835
B2 360 H3 215 ØS4 19
B3 320 L 895 S1 150
DN1 50 L1 830 X 3
DN2 32 L2 145

Software version Spaix, Version 4.3.11 - 2019/01/31 (Build 242)

Subject to change Data version 10.12.2018 Pages 1/ 1
 Hydraulic data
Contact
E-mail Glanded standard pump
Phone NL 32/160B-5,5-2-24
Customer Project name Untitled project 2019-02-14 09:28:58.288

Project ID
Contact Installation location
E-mail Customer pos.no
Phone

Date 2019-02-14

Operating data
Speed Frequency Duty point Suction port Discharge port
2900 1/min 50 Hz Q = 400,00 l/min H = 35,00 m DN 50 DN 32

Power data referred to: Water (100%); 20 °C; 998,2 kg/m³; 1,001 mm²/s
Head - Ø 175
H /m ∆ p / bar
- Ø 168
- Ø 160
4
40 - Ø 150
- Ø 140
Eff. 63,9% - Ø 130 3,6
36
35,3 3,457
63,1% - Ø 171
62,6%
A1 3,2
32
61,4%
28 2,8
60%
24 2,4
58,9%
20 2
57,9%

16 1,6

12 1,2

8 0,8

4 0,4

▕◄ Application range ►▏
0 0
Shaft power P2
P₂ / kW

4
3,685
3,5
3
2,5
2
1,5
1
0,5
0
NPSH-values
NPSH / m

2
1,952

0
0 40 80 120 160 200 240 280 320 360 401,7
400 440 480 520 560 600 Q / l/min

Software version Spaix, Version 4.3.11 - 2019/01/31 (Build 242)

Subject to change Data version 10.12.2018 Pages 1/ 1
GB Installation and Operating Instructions

WILO SE 01/2013
Wilo SE 01/2013 2
 TABLE OF CONTENTS

1. General ..................................................................................... 2 5.3.8 Mounting pump and installation into pipe work10
5.3.9 Final work ............................................................10
1.1 About the document .................................................... 2
2. Safety ........................................................................................ 2 5.3.10 Hydrostatic pressure test...................................10

2.1 Symbols and signal words used in these operating 5.4 Pipe connection ......................................................... 10
instructions ................................................................................ 2 5.4.1 Suction line ..........................................................10
5.4.2 Discharge line .....................................................11
2.2 Qualified personnel ..................................................... 2
5.4.3 Inlet and Outlet connections .............................11
2.3 Risks incurred by failure to comply with the safety 5.4.4 Pressure control.................................................. 11
precautions ................................................................................ 2 6. Start up ....................................................................................12
2.4 Safety precaution for the operator ............................... 2
6.1 Requirements ............................................................ 12
2.5 Safety precautions for inspection and installation ....... 2
6.2 Use of trained staff .................................................... 12
2.6 Unauthorized alterations and manufacture of spare
parts…… ................................................................................... 2 6.3 Safety measures ....................................................... 12

2.7 Improper use ............................................................... 2 6.4 System filling – Venting ............................................. 12

2.8 List of tools .................................................................. 2 6.5 Motor connection ....................................................... 13

3. Transportation, interim storage and Handling ..................... 3 6.5.1 Electrical connection ..........................................13
6.5.2 Motor security aspect .........................................13
3.1 Safety measures ......................................................... 3 6.5.3 Operation with frequency converter .................13
3.2 Unpacking ................................................................... 3
6.6 Check list before switching on ................................... 13
3.3 Temporary storage ...................................................... 3
6.7 Starting up operation ................................................. 13
3.4 Handling ...................................................................... 3
6.8 Switching frequency .................................................. 13
3.5 Protection against corrosion ........................................ 3
6.9 Special instructions ................................................... 13
3.6 Removal of protective coating ..................................... 3
6.10 Shutting down............................................................ 14
3.7 Renewing corrosion protection .................................... 3 7. Maintenance and Service .....................................................14
4. Product description and Application ..................................... 4
7.1 Requirements ............................................................ 14
4.1 Safety instruction ......................................................... 4
7.2 Use of trained staff .................................................... 14
4.2 Technical data ............................................................. 4
7.3 Safety measures ....................................................... 14
4.2.1 Pump designation ................................................ 4
4.2.2 Data Table ............................................................ 4 7.4 Maintenance and inspection ...................................... 14
4.2.3 Scope of Supply ................................................... 6 8. Faults causes and remedies ................................................15
4.2.4 Accessories .......................................................... 6 8.1 Faults causes and remedies...................................... 15
4.3 Description and function .............................................. 6 8.2 Reasonable foreseen misuse .................................... 16
table 7 : standard material available ..................................... 6 9. Spare parts .............................................................................17
4.3.1 Product description .............................................. 6
9.1 Optional connections ................................................. 20
4.3.2 Shaft seal .............................................................. 6
5. Installation and electric connection ....................................... 7 9.2 Flange dimension: ..................................................... 20
9.3 Table of dimension: ................................................... 21
5.1 Unpacking ................................................................... 7
9.4 Lists, Tables, Type plates & Checklists ..................... 22
5.2 Bare shaft pump installation ........................................ 7
9.4.1 List of machine operators ..................................22
5.2.1 Motor selection ..................................................... 7
9.4.2 Type Plates..........................................................22
5.2.2 Coupling selection ............................................... 7
9.4.3 Levelling Records ...............................................22
5.2.3 Base plate criteria ................................................ 7
9.4.4 Alignment Protocol .............................................22
5.2.4 Engine driven pump............................................. 7
9.4.5 Pre-Starting Checks for Pump set....................23
5.3 Pump Set Installation .................................................. 7 9.4.6 Pump commissioning report .............................23
5.3.1 Safety measures .................................................. 7 9.4.7 Issue / Feedback report : (SR01-02) ...............24
5.3.2 General information ............................................. 7
5.3.3 Motor...................................................................... 9
5.3.4 Pump set assembly ............................................. 9
5.3.5 Coupling assembly .............................................. 9
5.3.6 Coupling alignment ............................................ 10
5.3.7 Checking before installation ............................. 10

Wilo SE 01/2013 1
 In particular, failure to comply with these safety instructions
could give rise, for example, to the following risks:
1. General • Failure of important pump or system functions,
• Personal injury due to electrical, mechanical and
bacteriological causes.

1.1 About the document

This Installation and Operating Instructions forms
form an integral
part of the unit. They must be kept close to the unit and in
readiness whenever required. Precise observance of these
instructions is a pre-condition
tion for use of the unit for intended
purpose and for its correct operation. These Installation and an
Operating Instructions conform to the relevant version of the
equipment and the underlying safety standards valid val at the
time of going for printing.
2. Safety
This leaflet contains all safety instructions which must be
followed when installing and operating g the pump. It is
therefore imperative that they be read by both the installer and
the operator before the pump is installed or operated. Both the
general safety instructions in this section and the more
specific safety points in the following
wing sections should
sho be
strictly observed.
2.1 Symbols and signal words used in these operating
instructions
Symbols
General danger symbol.
Hazards from electrical causes.
NOTE:....
Signal words:
DANGER! Imminently hazardous situation. Will result in
death or serious injury if not avoided.
WARNING! Risk of (serious) injury. ‘Warning’ implies that
failure to comply with the safety instructions is likely to
result in (severe) personal injury.
CAUTION! Risk of damage to the pump / installation.
‘Caution’ alerts the user of potential product damage due
to non-compliance
compliance with the safety instructions.
instructions
NOTE! Useful information on the handling of the product. It
alerts the user of potential difficulties.
2.2 Qualified personnel
The personnel installing the pump must have the appropriate
qualification for this work.
2.3 Risks incurred by failure to comply with the safety
precautions
Failure to comply with the safety precautions could result in
personal injury or damage to the pump or installation. Failure
to comply with the safety
afety precautions could also invalidate
in any
claim for damages.
2.4 Safety precaution for the operator
The relevant health and safety regulations must be observed.
Potential hazards caused by electrical energy must be
excluded. Local or general regulations [e.g. IEC,
IE VDE, etc.]
and directives from local energy supply companies are to be
followed.
• If high or low temperature pump / pump set
components involve hazards, needed care must be
taken to avoid accidental contact.
• Guards for moving parts (e.g. couplings) must not be
removed from the pump / pump set while in
operation. The guard locking solution should be not
removed from the guards.
guard
• Any leakage of hazardous (e.g. explosive, toxic, hot)
fluids (e.g. from the shaft seal) must be safely
drained so as to prevent any
an risk to persons or the
environment. Statutory regulations are to be
complied with.
• The pump should not,in any case, to be run without
liquid. The destruction of the sealing end shaft,
shaft which
can result from such a use,
use would cause leaks of fluid
endangering the safety of the people and the
environment.
2.5 Safety precautions for inspection and installation
The operator must ensure that all inspection and assembly
work is carried out by authorized and qualified specialists who
have carefully studied these
ese instructions. Work on a pump or
installation should only be carried out once the latter has been
brought to a standstill. Pumps and pump sets, which convey
hazardous media, must be decontaminated. On completion of
the work, all safety and protective guards
gu must be reinstalled
and made operative again.
Prior to re-starting
starting the machine, the instructions listed under
“first commissioning” are to be observed.
2.6 Unauthorized alterations and manufacture of spare
parts
Changes to the pump/ machinery 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
consequences.
2.7 Improper use
The operating safety of the pump or installation can only be
guaranteed if it is used in accordance with paragraph 4 of the
operating instructions. All values must neither exceed nor fall
below the limit values given in the catalogue or data sheet.
sh
2.8 List of tools
step tool
Foundation Straight edge+ mater level
Pump alignment comparator
Starting Ammeter/voltmeter
table 1 : tools

Wilo SE 01/2013 2
3. Transportation, interim storage and Handling

When receiving the material, check that there has been no

damage during the transport. If any defect has been stated,
take the required steps with the carrier within the allowed time.

CAUTION! If the delivered material is to be installed later

on, store it in a dry place and protect it from impacts and
any outside influences
luences (humidity, frost etc...).
Handle the pump carefully so as not to damage the unit
prior to installation.

3.1 Safety measures

DANGER !
• Never stay below the suspended load.
• Keep a safe distance while the load is being
transported. Fig 2: handling of pump set
• Use only suitable slings, which are in good condition.
• Adjust the length of the slings so that the pump 3.5 Protection against corrosion
and/or the pump set is suspended horizontally.
A protective coating is applied to the pumps (shaft, impeller
• Do not use the eye bolts on the pump components
eye, casing eye..).. Remove it before starting up.
up
for lifting the assembled pump or the complete set.
• Do not remove documents which are attached to the
3.6 Removal of protective coating
pump.
• Do not remove the protection covers from
f the pump To remove the protective coating, the pump should be filled
suction/ discharge; otherwise,
therwise, there may be a risk of and drained several times using appropriate agents, e.g.
contamination. solvent naphtha, diesel oil or alkaline detergent. Flush with
water, if necessary. The pump must be installed and started
3.2 Unpacking up immediately afterwards.
Before unpacking, a visual check of the packing is
3.7 Renewing corrosion protection
recommended. If transport damage is visible,
visibl the extent
should be noted on the receipt or on the delivery note. If the pump has been supplied with a protective coating and
Potential claims must be referred immediately with the carriers has to be stored,
d, a new protective coating should be applied
or the insurance company. after six months. For suitable protective coatings, please
contact us.
3.3 Temporary storage
If the pump or the pump unit is not installed immediately after
delivery, it must be stored in a dry and vibration free
environment.

3.4 Handling
The pump or pump set must be lifted and handled as shown in
the following sketches.

Fig 1: handling of bare shaft pump

Wilo SE 01/2013 3
4. Product description and Application Shaft sealing operating limits
Shaft sealing execution temperature limits
CAUTION!! The pump is to be used for operating
conditions stated by the customer and confirmed by the Packing ring seal - 40°C to +110C
supplier. Warranty is assumed within the scope of Wilo
condition of sales - 20°C to +120°C
Mechanical seal
up to 140°C for short period
4.1 Safety instruction Table 3 : limit of use
CAUTION!! Never touch the pump casing before a cooling
period. The pump
ump may only be used for application(s) NOTE: All operating limits mentioned in table 1 and 2 are
stated. Otherwise, hazards for people and environment not valid for all liquids,
iquids, which can be pumped.
must be avoided.
Flange location
CAUTION: Do not apply any thermal shock hock to the pump. Axial suction
ction flange, discharge flange facially
f upwards.
Never cool it with cold water. Do not exceed fluid density
stated, otherwise, there is a danger of motor overload. The Flanges
pump p must not be operated beyond its characteristic All cast iron casing, are according to EN1092-2
EN1092 PN16.
curve, otherwise,, there is a danger of cavitations and
motor damage. Direction of rotation
Clockwise seen from the drive end of the pump.
pump
4.2 Technical data
Vibrations
NL range pumps comply with VDI2056 and EN ISO5199 class
4.2.1 Pump designation
K for pumps with a driving power of up to 15 kW and class
cla M
with a driving power of more than 15 kW.
kW
4.2.1.1 Type key for pump with motor
NL32-200-B-0.75
0.75-4-05-XX B Noise Level
The noise level of the pumps comply with the directive 001/30-
Norm pump code 1992 of the EUROPUMP Commission - "DIN EN 809”
ø Discharge port The pump manufacturer does not take account the effects of
ø Max. impeller the installation in assessing the noise level.
Hydraulic version
Motor Power (kW)
2 or 4 poles The following table provides approximate maximum values:
05 – std mechanical seal (without spacer)
12 – std mechanical seal (with spacer)
Technical definition code
Index of technical revision

4.2.1.2 Type key for bare shaft pump (without motor)

NL32-200-B-0.75
0.75-4-05-XX B

Norm pump code

ø Discharge port
ø Max. impeller
Hydraulic version
Motor Power (kW)
2 or 4 poles
08 – std mechanical seal
06 – std gland pack version
Technical definition code
Index of technical revision
Fig 3 : noise level

Pump without motor

4.2.2 Data Table Note that additional noise can be generated by:
All the technical data of the pump / pump set are described in • The driver
the following chapter. If other information were necessary, do • A possible misalignment of the coupling
not hesitate to contact our technical department (contact N° • Pipe work (note: the larger the pipe diameter, the lower
end of the manual). the pipe noise)

Pressure temperature limit

Material Temperature Pressure Type

Body : cast iron - 20°C to 120°C 16 bars All models

Impeller : cast iron or 32- 125 to
bronze 120°C to 140°C 14 bars 150- 400

table 2 : limit of use

Wilo SE 01/2013 4
Permissible branch forces and moments
Value according to EN ISO 5199 – Class II – Annex B, Family N°2 for mounting on cast iron base plate and frame without grouting
for pumping temperature up to 110°C and up to 120°C for cast iron base plate / frames.

Table 4 : permissible forces and moments

Maximum permissible speed

Max speed Max speed Max speed
Size Size Size
in rpm in rpm in rpm
32-125 32-160 32-250 40-250 65-315 80-315
32-200 40-125 40-315 50-250 80-400 100-315
40-160 40-200 50-315 100-400 125-250
50-125 50-160 65-250 125-315 125-400
3600 3000 1800
50-200 65-125 80-250 150-200 150-250
65-160 65-200 100-250 150-315 150-400
80-160 80-200 125-200
100-160 100-200
Table 5 : maximum speed for each model

Wilo SE 01/2013 5
Operation ranges
Continuous operation
0,3 Qopt < Q < 1,1 Qopt
0,5 Qopt < Q < 1,1 Qopt
table 6 : operating range
Size of the pump
32-125 to 80-400
100-315 to 100-400
125-315 to 125-400
125-250 to 150-400
100-160 to 100-250
125-200 to 125-250
150-200
4.3.1 Product description
NL pumps are horizontal, single stage volute casing pumps
with nominal outputs and flange dimensions meeting EN733 /
DIN24255. Their back pull out construction enables the
disassembly of the complete bearing unit towards the drive
side without removing the e pump casing from the pipe work. NL
pumps are preferably used when pure or turbid liquids, not
containing solid particles, are handled. Impurities up to a grain
size of 3 mm can be handled, but it will shorten the overall
service life of the pump.

The value mentioned above may no longer apply for fluid with 4.3.2 Shaft seal
physical properties not similar to water properties.
Depending on the application, different shaft sealing
executions are offered (see 4.3).
4.2.3 Scope of Supply NOTE: Chapter 4.3 contains the codes for all variations of
The bare shaft pump is supplied with its key for driving.
driving mechanical seals. A stuffing box with lantern ring or
The pump set is supplied with coupling guard and foundation mechanical seals according to DIN.
bolt. It is advised to use the stuffing box version in the following
installation configurations:
4.2.4 Accessories • If the pump draws from a suction line,
• If the pump has a feed line with a pressure of less
Accessories for mechanical seal or gland pack leakage can be than 0.5 bar.
ordered for drainage. • If the pumped liquid is at or near its boiling point.

4.3 Description and function

Type Pump Casing Impeller Mat erial Sealing t ype

table 7 : standard material available
St andard Mechanical seal
EN GJL250 (GG25) MG12- G6- AQ1EGG
Packing rings
Graphit e +PTFE
EN GJL250 (GG25) G- CuSn5Pb5Zn5 (LG2)
Option or Mechanical seal
G- Cu Sn10 (CT1) MG12- G6- AQ1EGG

EN GJL250 Packing rings

Graphit e +PTFE

Wilo SE 01/2013 6
5. Installation and electric connection
5.2.4 Engine driven pump
5.1 Unpacking An engine
ngine driven pump set is the unitization of a bare shaft
Unpack the pump and dispose of the packaging in an pump and a Diesel engine on the same base plate.
environmentally responsible manner. Refer to the engine
ngine installation manual.
manual
The engine
ngine driven pump set is supplied with the foundation
bolts for grounding. Use the one supplied or equivalent of
5.2 Bare shaft pump installation bigger size.
ctrical earth connexion between engine,
Ensure a correct electrical
base plate and main earth.
For installation of the bare pump, it is recommended to use
WILO spare parts for coupling, coupling guard and base plate.
In any case, coupling guard should be compliant withw EN953
and Machine Directive.
Respect the lifting advice & 3.4 (fig 1) during the bare shaft
installation.

The pump must be installed on a base plate with suitable

wages and fixing devices. The motor and coupling used must
be CE compliant and a CE coupling guard must be installed.
This new assembled pump set, with motor and coupling, must
be aligned prior to any functioning and every time the pump
set is moved.

Fig 4
5.2.1 Motor selection
5.3 Pump Set Installation
The motor should be taken with enough power margin.
CAUTION! Installations and electrical connections
connection must
Pump power < 4 kW 4 ≤ P2 < 10 10 ≤ P2 < 40 40 ≤ P2 be made by authorized personnel according to the local
Motor P2 margin 25% 20% 15% 10% standards!
Table 8 : motor power margin WARNING!
Only appropriately authorized personnel may carry out
Example: this work.
a) Liquid : water at 40°C WARNING!
b) Duty point : 100 m3/h – 35 m – efficiency 78 % Electrical connections must be made according to the
c) hydraulic power : 12,5 kW European
ean Regulations and Directives for the Standards
d) Next rated motor power : 15 kW in Industry and in compliance with the instructions of the
e) Requested margin at duty point is 12,5 * 1,15 = 14,3 local power supply utilities of the country concerned.
kW
f) Next rated motor of 15 kW is correct 5.3.1 Safety measures

This motor should be a foot mounted motor B3 (IM1001) • Remove the flange obturators of the pump right before
compliant to IEC34-1. connecting the piping.
• Connect the pipe work carefully to prevent the pumped
liquid escaping during operation and endangering
operating personnel.
5.2.2 Coupling selection
• Ensure that the suction or inflow line and the discharge
line are closed by valves.
The coupling must be selected according to next criteria • Ensure that all electrical connections are “dead”.
Otherwise, there is a risk of electric shock.
g) Max torque acceptable • Respect all relevant internal plant regulations.

 
  .  • Avoid accidental contact with hot components by putting
Motor Power kW in place appropriate protections.
protections
 ∗ 9550 ∗ (1
Speed rpm
rpm
h) K1 : correction factor according to application CAUTION! Remove the protective coating by following
followi
(number of start/stop, torque shock) – For water the instructions of chapter 3.6.
3 Otherwise there is a risk of
pumps K1 =1 contamination.

5.3.2 General information

5.2.3 Base plate criteria
5.3.2.1 Assembly tools
Special tools are not required for assembly and installation.
Base plate should be dimensioned for
i) Lifting the pump set (bare pump + motor + coupling +
base frame) * 1,5 times 5.3.2.2 Permissible ambient conditions
j) Resist to efforts applied by the pipes ( table 3 of this The ambient temperature can range from -20°C to +50°C. The
manual) atmospheric
mospheric humidity should be as low as possible in order to
k) Be grounded to the floor and resist to the dynamic avoid corrosion.
load.
l) Installed in a vibration free environment.

Wilo SE 01/2013 7
5.3.2.3 Foundation
The pump must be installed on a flat floor or foundation free
from vibration.
Installation of the pump cannot be done in continuous
sequence because ‘two time periods’ are required to permit to
grout to set. The first period occurs after baseplate has been
leveled and foundation bolts half grouted. The second time lag
occurs after full grouting of baseplate,, which is after final
alignment of pump and driving unit after piping.
A suitable foundation for the pump must be prepared with
pockets to accommodate the foundation bolts. The strength of
the foundations must be adequate for the he static & dynamic
loads imposed and depend upon the local soil conditions.
Fig 5 : preparation of floor
The top surface over which the baseplate rests (fig5) must be
left rough to assist in keying of the final grout and sufficient
allowance must be made for the thickness of the steel packing
and leveling shims beneath the baseplate,, the requirement
req
being approximately 25mm.
Foundation work is usually completed before the pump arrives
on site but it is mentioned here because it is logical to begin
the installation procedure sequentially.
Fig 6 : foundation pocket
5.3.2.4 Baseplate
Pumps and drivers that are received with both machines
mounted on a common baseplate are checked for alignment
before shipment. However during shipment, storage it may get
disturbed. Also baseplatess are flexible to some extent and
may get distorted during transport and storage. Therefore it is
necessary to remove the pump and driver from the baseplate
and adapt procedure as given in section below.
below
Baseplate checks
It is insufficient to check level on the machined pads of
baseplate with a spirit level because it is possible that some
types of errors will not be revealed or will be accepted as
being within acceptable limits. These distortions
distortio are as
showed in fig 7. Therefore it is necessary to use I beam
straight edge along with engineers
ineers master level. (Fig. 8)
Wilo SE 01/2013
Fig 7 : baseplate check
Installation & leveling of baseplate
a) If the base frame is installed directly on the uneven
surface of foundation, it could distort. To avoid this
distortion and to provide suitable base for leveling,
the packer plates should be provided on mother
concrete. Minimum requirement being one on each
side of foundation bolts. Intermediate
Int packers should
be placed at 250 mm center to center. Thickness of
MS plates can be between 25 and 35 mm. (Fig.7)(Fig.7
Fig. 8 : leveling the base plate
b) Once the packer plates are positioned and leveled,
place the base frame on them. Insert foundation bolts
through hole in the base frame and insert nut. Ensure
that bolts protrude sufficiently to accommodate lock
nut and they are centrally
c disposed in the holes.
c) Level the baseplate as follows.
Use “I” beam straight edge and an engineers master level
(with accuracy of 0.02 mm / meter) for leveling the baseplate.
I-beam
beam should rest on the machined surfaces of the baseplate,
or on the leveling pads if provided.
These machined surfaces where level is being
checked must be clean and free from paint, burrs etc.
Check datum position of base frame as given in G.A. Adjust
the level of the baseplate by inserting shims between the bed
plate and the packer plate te until the bed plate is leveled and
supported on all the packing plates at the height required for
the connection of suction and discharge branches. For
checking the levels across two pads, I-beamI type straight
edge should be used extensively in conjunctions
conjunct with
engineer’s master level. Level should be achieved within 0.05
mm per 250 mm.
d) When the baseplate is leveled, grout the foundation
bolts only. Care should be taken so as not to disturb
the verticality of foundation bolts. For grouting use
rich mix
ix of 1: 1:2 of cement, sand and gravel below
8
 12 mm. Alternatively quick setting grout mix can be 5.3.3 Motor
used.
e) When the grout has set, gently but firmly tighten the Before assembly check the direction of rotation of the motor
foundation bolts. Care must be taken not to distort (indicated by an arrow on the pump casing). If this is not
the baseplate or loosen the foundation bolts in the possible the direction of rotation of the complete unit can only
grout by excessive tightening. be checked when the pump is filled. In any event, the
f) Carefully re-check the level of the bed and make operating instructions of the motor manufacturer must be
adjustments that are necessary by fine shimming. followed, since the motor is generally incorporated by Wilo into
g) Position the pump and motor on the baseplate. the pump set.
h) Refer instruction manual of coupling & motor
manufacturer.
i) When the baseplate is leveled and the satisfactory- 5.3.4 Pump set assembly
alignment is completed, proceed with connection o f Before starting the alignment, rotate each shaft independently
suction & delivery piping. Recheck the alignment to check there is no friction on the rotating elements.
after piping and run the final grout beneath the The coupling guard must be in accordance with the CE
baseplate. Allow minimum seven days time for regulation
curing. Grout mix in the proportion specified earlier It is advised to use the WILO coupling guard available as
for foundation bolt grouting should be used. It is accessories.
further recommend that all hollow pockets in the A wrong assembly or missing coupling guard will lead to a
baseplate shall be filled after curing of earlier grout. potentially dangerous product which can create injuries.
j) Pumps, which operate at high temperature, e.g.
boiler feed duty, are supported on feet machined in
line with the center of the shaft, which prevents
5.3.5 Coupling assembly
expansion causing misalignment. Transverse and
longitudinal keys are provided to locate the pump on Install the coupling avoiding hard blows; if necessary warm
the baseplate. The holding down bolts securing the them for an easier fitting. Arrange the pump and motor on a
pumps to the baseplate are arranged to allow the feet level base. The shaft ends must be perfectly concentric. The
to slide during expansion either by using spring distance between each half of the N-EUPEX B (FLENDER) or
washers or by locating the nuts on the bolts without RB (RATHI) coupling must be 2 - 3 mm. For spacer couplings,
nitting the feet. the distance between shaft is mentioned in &10-2 – value “X”
(100 or 140 mm)
5.3.2.5 Installation of the set
The following procedures outline recommended practice given
in BS-3170 in 1972 (Appendix A) for checking shaft alignment.
This method is independent of the truth of the coupling or
shaft and is therefore not affected by canted coupling faces or
eccentricity of the outside diameter of the coupling. Before fig 10 : pin & bush coupling
commencing the alignment, rotate each shaft independently to
check that the bearings run freely and that the shaft is true to
0.1mm or better. Check that no damage can be caused when
the shaft of the driven unit is turned. Coupling should be
loosely coupled and the halves must be free to move relative
to each other, otherwise gauge Indicators can be incorrect.
Where, tightly fitting pins or spring prevent loose coupling, the
springs or pins should be removed and a line scribed across
both half couplings and readings taken only when the two
marks are aligned..

5.3.2.6 Space required

The space required for the pump set is set out in the
foundation plan or installation drawing. Ensure easy access to
the shut off and regulation valves as well as to any measuring
instruments. Fig 11 : spacer coupling

5.3.2.7 Position in principle

The NL pumps are installed horizontally.
If other manufacturer couplings are used, follow the
manufacturer’s instructions (coupling should be compliant with
EN 349). After installation on the foundation and connecting
the pipe work, the coupling alignment must be checked and
realigned, if necessary. Moreover, after reaching the operating
temperature the alignment of the coupling must be checked
again. The coupling requires a guard that meets DIN31001 in
order to avoid accidental contact during operation.
In any event, the operating instructions of the coupling
manufacturer must be followed, since the coupling is a
component incorporated by Wilo.

Fig 9 :

Wilo SE 01/2013 9
5.3.6 Coupling alignment
For correct alignment, the
e following is required: a1=a2
a and
b1=b2

Fig 14 : alignment of pump casing with pipe work

Fig 12 : parallel alignment 5.3.9 Final work

• The following final steps must be undertaken:

• Check the tightness of the connecting flanges.
• Check for easy running of the pump (for that purpose
turns the motor fan or the coupling).
• Check the coupling alignment.
• Install the coupling guard.

5.3.10 Hydrostatic pressure test

When subjectingng the piping system to a hydrostatic
hydro pressure
test, exclude the pump from the pressure test. If it is not
Fig 13 : angular alignment possible to test the pipe work without the pump, ensure that
foreign material cannot enter the pump.
NOTE: The max. Permissible pressure for a pressure test
TIR : total indicated is 1.3 times the nominal pump pressure. The nominal
speed (rpm) Parallel Angular
tolerance tolerance
reading pump pressure is indicated in the technical data sheet and
<1000 0,15 mm 0,15 mm on the pump name plate.
TIR TIR
From 1000 to 0,15 mm 0,10 mm 5.4 Pipe connection
1800 TIR TIR
From 1800 to 0,10 mm 0,05 mm • Note the arrows on the pump branches indicating the
3600 TIR TIR
Power
direction of flow.
1450 rpm 2900 rpm Flender Rathi • Choose the nominal width of the pipe lines in accordance
3-55kW 3-55kw 2-4mm 2-6mm with the nominal widthth of the pump branches or larger
75- 75-150kW 2-6mm 2-6mm ones with the corresponding reductions.
150kW
• Flange sealing must not protrude on the inside.
Table 9 : distance
istance between coupling flange faces
• Ensure that the pipe work is clean before installing of the
pump.
• Support the pipe work in order to avoid distortions at the
5.3.7 Checking before installation pump components
omponents (risk of damage to pump components).
Before installing the pump in the plant, the following points • Avoid abrupt changes of cross section and direction.
must be checked: • Where different
ferent diameter pipe work are used, connections
• Is the electrical current to the drive motor switched off? should be done by eccentric transition pieces. This will
• Are suction and discharge lines emptied and closed by avoid the formation of air pockets in the
th pipe work (fig.
valves? 16).
• Is it possible to rotate the pump easily by hand (for this • For difficult pumping on the suction side, to stabilize the
purpose turn the fan of the motor or the coupling)? flow, a pipe length 15 times the diameter of the suction
• Have the latest internal / plant instructions been branch should be installed before the suction branch
observed? (fig.8).
• The flow rate in the suction line or in flow line must
mu not
5.3.8 Mounting pump and installation into pipe work exceed 2 – 3 m/s.
• Isolating valves must be provided and installed on suction
The following instructions must be carried out: and discharge ports in order to avoid draining the whole
• Remove the protective covers from the pump flanges and pipe system when servicing or exchanging the pump. pump
the auxiliary pipe work connections.
• Correctly insert the flange seals. 5.4.1 Suction line
• Connect the suction or feed line.
• Connect the discharge line. The pump must be aligned See the sketches below for the optimum layout of pump
with the pipe work. The pipe work must be supported so installation for flow and suction lift operation.
that distortion cannot occur when connecting the pump.

Wilo SE 01/2013 10
 Fig 15 : pump position

Bad suction layout which will cause air pocket and failure
to pump
Showing how the above fault can be avoided

Fig 16 : bad and good pipe configurations

Ensure that air pockets cannot be created. Unequal nominal

widths of the suction branch and suction line must be
compensated by eccentric transition pieces (fig.17).

Good suction layout, showing pipe rising all the way to the
pump.

Fig 17 : eccentric type

• It is recommended that a strainer is installed in front of the

pump with a filter surface of at least 3 times the pipe
cross section (approx.100 meshes/cm²).
• The suction opening of the suction line should be min. 20
cm below the liquid level. The strainer must be min. 10
cm from the bottom to avoid excessive inlet losses, which
could impair pumping performances. It is advisable to
check that there is no leakage. (fig 18)
• A shut-off valve should be installed in the feed line (fig
Showing how an air pocket may be formed when the
18). It must be closed for maintenance work. It should be
suction pipe is bigger than the pump branch.
installed in order to avoid air pockets forming in the
spindle cap, i.e. with the spindle in a horizontal position or
pointing vertically downward.

5.4.2 Discharge line

For flow regulation, a valve must be installed behind the
pump. If a non-return valves is used, it should close smoothly
to avoid water hammer.

5.4.3 Inlet and Outlet connections

The various connecting points are shown in the drawing. (fig
23)

5.4.4 Pressure control

Wilo SE 01/2013 11
For consistent pressure control,, it is advisable to install in the
pipe work measuring points in front of, and behind the pump.
6. Start up

6.1 Requirements
The pump or the pump set must be installed in accordance
with the recommendations listed in chapter 5.

6.2 Use of trained staff

Only appropriately trained staff can carry out the work
described in this chapter.
1: Eccentric reducer (suction) or
concentric reducer (discharge)
2: Isolating/shut-off
off valve 6.3 Safety measures
3: Suction line
4: Bend
5: Foot valve with strainer
CAUTION!
6: Regulating valve • Electrical connections must be made according to
7: Pressure point European Regulations and Directives for the Standards in
8 : Pipe Support
Industry and in compliance with the instructions of local
power supply utilities of the country concerned.
Fig 18 : typical installation • Only appropriately authorized personnel may carry out
this work.

WARNING!
• Fill the pump entirely;; otherwise the shaft seal could be
destroyed.
• Fill the supply lines correctly.
• Check the direction of rotation when the pump
p is filled.
• Fill the pump slowly if hot media are being pumped in
order to avoid distortions or heat shocks.
shock
• When handling explosive, toxic, hot, crystalline or
corrosive media, ensure that there is no risk to people or
the environment.
• Control the output
put at constant speed at the discharge side
only. The valve at the suction side must always be
completely open during operation to avoid any risk of
cavitation.
• If there is no bypass line, do not run the pump with the
control valve closed for any length of time.
• Safety measures should be taken by the end user to
ensure (for example by means of a relief valve) that the
permissible pump casing pressure is not exceeded during
operation.
• Repeat the alignment of the coupling at operating
temperature. Realign the motor to the pump, if necessary.

6.4 System filling – Venting

• Before the first use, the pump and its suction pipe must
be full of liquid to avoid any dry running. The pump and
the mechanical seal must be fully purged of gas.
• CAUTION! If the pump is purged of gas with a hot fluid,
prevent any risk of burning by containing the leakages. In
case of hot water, some steam can escape from the vent.
• Wear suitable clothes and protection such as gloves.
Please also use a face protector.
• Use pliers.
• Never touch the parts of the pump that can be hot.
• At the end of the purge, close tight the air vent.

WARNING!
Uncompleted gas purging can
ca reduce significantly the
lifetime of the pump.

Wilo SE 01/2013 12
 temperatures this rate may be higher (till the temperature is
6.5 Motor connection stable).. Pumping against a closed valve in the discharge line
is permitted only if a minimum output via a bypass line is
guaranteed.
ranteed. If the installation is protected with a pressure
6.5.1 Electrical connection relief valve, ensure that the pressure setting does
do not exceed
The motor must be connected at described in the circuit the resistance of the pump casing. The alignment of the
diagram in the terminal box. pump/motor must be checked when the functioning
temperature is a reached (motor is stopped during re-
alignment).
6.5.2 Motor security aspect
Installation manual of motor manufacturer must be followed for 6.8 Switching frequency
the following points:
The permissible switching frequency is listed in the table below
• Motor drainage hole for condensates. s. according to the pump size:
• Minimum distance from the wall for a correct cooling.
cooling
• For protection against drip water and to ensure a firm Max frequency of
Pump Size
gland grip the main supply cable must be of sufficiently switching onper hour
large size. The position of the cable entrance in electrical 32- 125 32- 160 32- 200 32- 250
connection box of the motor or the cable position has tot 40- 125 40- 160 40- 200 40- 250
50- 125 50- 160 50- 200 65- 125
protect the electrical connection box against drip water. 65- 160 65- 200 65- 250 80- 160 15
• Heat-resistant
resistant power cable must be used for pumps in 80- 200 80- 250 100- 160 100- 200
systems with water temperatures above 90° 90 C." 100- 250 100- 315 125- 200 150- 200
• Standard design pumpss must be installed in a frost,
frost dust- 150- 250
40- 315 50- 250 50- 315 65- 315
free, well-ventilated
ventilated and non potential explosive
80- 315 80- 400 100- 400 125- 250 8
environment. 125- 315 125- 400 150- 315 150- 400
Table 10 : max switching frequency
6.5.3 Operation with frequency converter
If the motor is driven by a frequency converter, the standard 6.9 Special instructions
practice for connection must be followed for security aspect During operation the following points must be checked:
and EMC compliance. • Ensure that the pump runs without vibration.
Follow the recommendation of the frequency converter • Control the liquid level in the suction line and/or in flow tank.
manufacturer. • Control the bearing temperature (max. temperature 120° 12 C,
for genuine bearing – for other ball bearing, respect the max
acceptable temperature ).
6.6 Check list before switching on
Shaft seal
Execution with pack gland :
Before switching on the pump, ensure that nobody can For correct operation of the pack gland as light leakage (20-40
be endangered by this starting. Before switching on the drops per minute) is essential. If the leakage
le is reduced too much
pump unit, the following points must be checked: by re-tightening
tightening the packing, the packing rings will be destroyed.
• Is all pipe work connected and are the unions tight? (fig 19)
• Has the shaft seal been installed?
• Are the supply lines, if any, to the shaft seal open? CAUTION!
• Is the coupling aligned correctly? For executions with stuffing box:
box If the leakage increases
• Is the pump including the pipe work filled properly? considerably and cannot be adjusted by retightening the
• Is the shut-off
off valve in the discharge line closed? gland, the packing is worn and must be replaced by a new
• Is the shut-off valve in the suction line completely one.
opened?
• Is the motor ready for operation?
• Is the direction of rotation of the motor correct? (Check by
running the motor for a short time)
• Are the gland fingers lightly tight?

6.7 Starting up operation

• For starting, proceed as follows:
• Open fully the valve on the suction side.
• Close the valve on the discharge side.
• Switch on the motor.
• Check the pressure gauges at the pressure measuring
points. If the pumping pressure does not increase
consistently with increasing speed,
eed, switch off the motor and
vent the pump one more time.
• After reaching operating speed, regulate the operating point
of the pump by adjusting the valve in the discharge line (see
technical data for permissible range of operation).
• For “running in” the packing,
acking, the gland should be tightened
only slightly (even in the case of considerable leakage
initially). After approx. 30 minutes tighten the gland to such
an extent that it leaks only slightly. Check it several times,
until leakage from the packing is aboutout 20 to 40 drops a
minute. In extreme operating conditions and high
Fig 19 : gland packing tightening.
Execution with mechanical seal:
During running, a slight leakage may occur. If the pump is
equipped with an external flush, quench or heating, the flush,
quench or heating supply has to be switched on before the pump
is started. The mechanical seal must be allowed to cool before the
next restart.
For executions with mechanical seal:
seal If the initial leakage does
not disappear within 5 minutes of operation, stop the pump,
dismantle the seal and check for damage of the seal faces and
auxiliary sealing.

Wilo SE 01/2013 13
A drainage hole in the bearing bracket can collect the leakage
from the shaft seal. In case of hot or dangerous or polluting
liquids,, this drainage must be connected to a disposal device.

6.10 Shutting down

Before shutting down, close the valve on the discharge side. After
shutting down, all valves may be closed. The valves of the
auxiliary optional pipe work connections, (quench, heating,
external flush), have to be closed in the last place. If
I there is a risk
of very low ambient temperatures, remove the pump and then
drain it using the threaded plug 90.30 (fig 22)..

WARNING!
When handling explosive, toxic, hot, crystalline or corrosive
media, ensure that people and the environment are not
endangered. Even if the pump has been drained using the
threaded plug 90.30, residues can remain in the pump. For
transport, the pump must be free from any dangerous
material. In case of extended periods out of service, protect
the pump against corrosion.

7. Maintenance and Service

7.1 Requirements
The pump or the pump set must be shut down according to
procedure in chapter 6.9.

7.2 Use of trained staff

CAUTION! Only appropriately trained and skilled staff
should undertake the work described in this chapter. Only
authorized personnel must undertake electrical work
associated with maintenance of the pump / pump set.
• risk of scalding by putting in operation,
• risk of scalding in case of maintenance or change of
mechanical seal.

7.3 Safety measures

WARNING!
• For explosive, toxic, hot, crystalline as well as different
pumping media ensure that people and the environment are
not endangered.
• Flush the pump with clean liquid before dismantling.
• The working place for disassembly or assembly must be
clean.
• Before reinstallation, the pump must be free of any
dangerous material.
• Guard should be replaced in the correct position to maintain
the initial protection in accordance with the standard.

7.4 Maintenance and inspection

The pump requires
quires only limited maintenance. However it is
advised to:
• Check frequently if the pump turns freely without vibrations.
• Check driving alignment / pump frequently.
• Make sure every month that the mechanical seal does not
leaking.
• Check every week the leak flow of the gland packing.
• Please, refer to the motor instruction manual to be informed
about the maintenance planning recommended by the
manufacturer of this equipment.

Wilo SE 01/2013 14
8. Faults causes and remedies

8.1 Faults causes and remedies

CAUTION! Only appropriately trained personnel must undertake trouble shooting
Problems Causes Remedies
Output too low Back pressure too high Regulate a new the operating point
Pump or pipe work ,not completely filled Vent and fill the pump as well as the suction or
in flow line
Suction lift too high or positive suction head Check the liquid level; open the shut off valves
too low on the suction side. Clean the filters / strainers
Impeller sealing gap too large Replace worn parts
Wrong direction of rotation Change the motor connection
Pump does not prime Pump casing ,shaft seal, foot valve or Replace the casing seal. Check the shaft seal.
or only intermittently suction line leaks Check the flange connections
Suction lift too high or positive suction head Check the liquid level; open the shut off valves
too low. on the suction side. Clean the filters on the
suction side
Loose or jammed parts in the pump Open and clean the pump
Pump leaks Casing bolts not correctly tightened Check the tightening torque of the casing bolts
Mechanical seal leaks Check the seal surfaces and rubber material of
the mechanical seal. In case of damages
exchange mechanical seal
Temperature of the Pump or pipe work not completely filled Vent and fill the pump as well as the suction line
pump increases or in flow line
Suction lift too high or positive suction head Check the liquid level; open the shut off valves
too low on the suction side. Clean the filters on the
suction side
Pump is running against closed valve Open the shut off valve on discharge side
Noisy pump Pump or pipe work not completely filled Purge of air the pump and the pipe work
Suction lift too high or positive suction head Check the liquid level; open the shut off valves
too low on the suction side. Clean the filters on the
suction side
Pump is not properly leveled or is distorted Check the pump leveling and alignment
Foreign material in the pump Dismantle and clean the pump
The motor contactor Pump is not properly leveled or is distorted Check the pump leveling and alignment
trips
Earth fault Check the earth connection. Check the potential
causes such as damaged wirings or cables,
leakages on electrical parts
Operating conditions outside of performance Refer to pump operating conditions stated in
range of pump technical data
Loose or jammed parts in the pump Open and clean the pump

Wilo SE 01/2013 15
 8.2 Reasonable foreseen misuse
Some of the possible misuses are already describes in faults and remedies.
The company will be under no liability in respect of any defect in the product arising from accidental or willful damage of misused
Description risk
level
Pump set Installation and commissioning
Lifting the pump set by motor and
pump.
(Belts around the motor housing and
around the pump suction flange)
Dry run work at the commissioning
Not flat floor surface for the base
frame
Bare shaft pump installation
Bad alignment of motor shaft and
pump shaft
Pump operating
No removal of water during frozen
period
Fluid density too high
Real working point different from
target Working point.
Maintenance
Tightening the gland during running
condition for precise leakage control
Starting the pump after a long period
without water
Wilo SE 01/2013
consequence Remedies
high Major alignment problem with the Re-align/
coupling
critical DON'T USE THE MOTOR LIFTING DANGER
RING TO LIFT THE PUMP SET
medium May destroy or damage the life time of Check the leakage
mechanical seal Replace mechanical seal
medium misalignment of coupling at the time of Pour base frame with cement for
base frame bolting - Noisy pump, early good flooring.
ageing for coupling Re-align after full floor fixation and
dry cement.
medium Use of too many shims to compensate Ensure the stability of the motor.
the level for alignment Don't use more than 4 shims : 1 thick
shim for major height compensation
and additional 1 to 3 shims for final
adjustment
high may leak at the casing/back cover screw back cover bolt to right torque
gasket value
high may have damage the cast iron part Inspect and replace the damage part
medium Motor protection tripped Reduce the flow
Replace with higher power motor.
medium Motor protection tripped Reduce the flow
Replace with higher power motor.
medium Bearing bracket quite hot ( at the Increase the flow if possible
place of ball bearing) ==> too much change the model of pump for a lower
axial flow pump.
high SECURITY RISK Maintenance person tightening the
risk to touch the shaft with the tools gland during the rotation of the pump
during tightening must be well aware of the risk taken.
medium Some friction at impeller eye ( front Put the pump in water to dissolve
and rear) – some noise corrosion
Open and clean the pump
16
9. Spare parts

Pump Set After Sales Parts

Position Description
(1) – (2) Coupling
(2) Coupling guard
Base Frame
Base frame spacer
Foundation bolts
(1)- (2) Base Frame shims
(1)
• Recommended spare part for
maintenance
(2)
• Identified as Safety spare parts

Fig 20 ; pump set

Bare Shaft After Sales Parts

When ordering spare parts give the following information:
Position number *
The complete pump designation *
The serial number*
(* which can be found on the nameplate fixed to the pump)

Position Description Position Description

10.20 Volute casing 50.70(1) Thrower
16.10 Casing Cover 52.40 (1) Shaft sleeve
18.30 Pump Foot 55.40 Washer
21.00(1) Shaft 68.10 (2) Protection screen
23.00(1) Impeller 90.10 Hexagonal screw
32.10(1) Ball Bearing 90.11 Hexagonal screw
33.00 Bearing housing 90.12 Hexagonal screw
36.00 Bearing cover 90.13 Hexagonal screw
40.00(1) Volute flat gasket 90.21 stud
40.03(1) flushing flat gasket 90.23 Hexagonal screw
42.20 V. Seal 90.30 threaded plug
43.30(1)(2) Mechanical seal 91.40 Allen head screw
45.10 Packing housing 92.01 Hexagonal screw
45.20 Gland 92.20(1) impeller nut
45.70(1) Pressure Ring 93.01(1) Washer
45.80(1) Lantern Ring 94.00(1) Coupling key
46.10(1) Packing ring 94.01(1) Impeller key
50.50(1) Support washer for ball bearing
(1)
• Recommended spare part for maintenance
(2)
• Identified as Safety spare parts

Wilo SE 01/2013 17
Fig 21 : Cross sectional drawing

Wilo SE 01/2013 18
Fig 22 : exploded view

1A Bare shaft pump 9A Washer

2A Coupling 10A Lock nut
3A Motor 11A Hex nut
4A Base frame 12A Coupling guard
5A Spacer C plate 13A Non losable fixing
set
6A Key (pump shaft) 14A Hex head Screw
7A Key (motor shaft) 15A Washer
18A Hex Head Screw

Wilo SE 01/2013 19
 Annex

9.1 Optional connections

Fig 23 : Optional connection

Um1 : Pressure gauge. Only on request

Um2 : Pressure gauge. Only on request
Ue : Drainage
Us : Sensor

pump type Um1 Um2 Ue Us pump type Um1 Um2 Ue Us pump type Um1 Um2 Ue Us
32- 125 65- 125 100- 250
32- 160 65- 160 100- 315
32- 200 65- 200 100- 400
32- 250 65- 250 125- 200
40- 125 65- 315 125- 250
40- 160 80- 160 125- 315 G1/4 G3/8 M8
G1/4 G3/8 M8
40- 200 80- 200 125- 400
G1/4 G1/4 M8
40- 250 80- 250 150- 200
40- 315 80- 315 150- 250
50- 125 80- 400 150- 315
50- 160 100- 160 150- 400
50- 200 100- 200
50- 250
50- 315

9.2 Flange dimension:

Flange connection according to EN1092- 2 PN16

DN2/DN1 32 40 50 65 80 100 125 150 200
D 140 150 165 185 200 220 250 285 340
k 100 110 125 145 160 180 210 240 295
d2 x nber M16x4 M16x4 M16x4 M16x4 M16x8 M16x8 M16x8 M20x8 M20x12

Wilo SE 01/2013 20
9.3 Table of dimension:

Fig 24 : table of dimension

1) Transnorm pump sizes, not included in DIN 24255/EN733. Flanges drilled according to ANSI150 on request.
• Holes for bolt of the dimensions indicated

Wilo SE 01/2013 21
9.4 Lists, Tables, Type plates & Checklists 9.4.3 Levelling Records

9.4.1 List of machine operators

Required accuracy of level is 0.05 mm / 250 mm
All persons working on or with the product confirms with their
signatures that they have received, read and understood this
operating and maintenance manual. In addition they obligate
themselves to conscientiously follow the instructions provided. Non-
observation releases the manufacturer from any warranty obligations.

Name Starting date Signature

Level achieved:

Level Bottle used:

StraightEdge used:

Checked by:

Verified by:

9.4.4 Alignment Protocol

Table 1: List of machine operators

9.4.2 Type Plates PUMP & MOTOR / ENGINE/ TURBINE ALIGNMENT

READINGS.
Type plate for bare/unitized pump set
PUMP SR. NO: PUMP TYPE :
DRIVER SR.NO:

MAKE: TYPE:
1 A)Before connecting Suction & Delivery Piping:
2 3
RADIAL AXIAL
4 5

6 7

8 9

10 11 Gap between coupling halves:

B)After connecting Suction & Delivery Piping:

12
RADIAL AXIAL

1 Machine type 7 Maximum pressure

2 Rated discharge 8 Impeller diameter
3 Rated speed 9 Pump weight
4 Rated head 10 Pump Serial Number
5 Rated Power 11 Year of manufacture Gap between coupling halves:
6 Operating temperature 12 CE mark
Required:

Acceptable Limit:

Wilo SE 01/2013 22
9.4.5 Pre-Starting Checks for Pump set 16 Coupling of pump and
Activities drive and free rotation
Sl Checked Remarks
of shafts in coupled
No on
condition
1 Alignment with and 17 Suction valve is fully
without piping opened
2 Flushing of pipe lines 18 Pump is fully primed
and ensure no and all air is vented
leakages
19 Delivery valve is
3 Availability of sufficient closed (if required)
liquid in sump /
suction as per 20 Emergency shut down
specifications. is possible.

4 Installation of all
instruments
9.4.6 Pump commissioning report
Suction and delivery
pressure gauges Date: -- -- ----
Pressure switches
Temperature gauges Pump Details Details of
Any other as supplied Pump Sr.No. Motor
/ specified. Type of pump Motor make
5 Operation of suction, Head Sr. no.
delivery and inline Capacity Motor frame
valves Rpm size
6 Proper supports for Construction KW / HP
piping and other allied RPM
equipments. Voltage
7 Availability of flushing Details of Piping Details
/ sealing liquid for System Suction pipe
stuffing box. Application size
8 Availability of sufficient Liquid Delivery pipe
cooling liquid for pH Value size
Flooded/Lift
bearings as specified Suction Valves
9 Free rotation of pump Expansion
and drive shafts joints
10 Lubrication of Pump Motor
bearings operating operating
parameters parameters
11 Checking of insulation
resistance of motor Suction Current
pressure Voltage
12 Proper cable Discharge
termination RPM
pressure DE bearing
13 Motor protection relay RPM temperature
settings DE bearing NDE bearing
14 Check all interlocks as temperature temperature
specified / provided NDE bearing Winding
15 No load trial operation temperature temperature
of drive Duration of (maximum)
Direction of rotation is trial run
ok
Noise and vibration Checked by:
within limits
Verified by:
Bearing temperatures
and winding
temperatures are
within limits
Overall operation is
satisfactory

Wilo SE 01/2013 23
9.4.7 Issue / Feedback report : (SR01-02)

Date: -- -- ----
1 Client / Site : 9 Operation details
a Application of pump :
2 Nature of complaint : b Solo / parallel / series :
operation
3 Date of receipt of pump at :
site & date of c Liquid specification Specific gravity:
commissioning (Chemical analysis pH value :
4 Was : report) Viscosity :
erection/commissioning Solid contents :
in M & P’s scope Temperature :
5 Pump details d Operation parameters Suction Pr. :
Pump type: Head: Del. Pr. :
P.D. No: RPM: Discharge :
Flow: Efficiency: Motor current :
6 Prime mover details Motor / Engine / Volts :
Make: Turbine Frequency :
Sr. No.: RPM: Speed :
Frame size / Type: Volts: Vibrations
KW/HP rating: Full load current: Overall readings :
Insulating class: Filtered readings :
7 Site layout (Enclose drawings / Sketch / Bearing temp. :
a Suction pipe details, valves photographs) e Parameters at close Suction pr. :
b Discharge pipe details, : valve / minimum flow Disch Pr. :
c valves : condition Motor current :
d Expansion joints, strainer : Volts :
e etc. : Flooded / Suc. lift Minimum flow :
Suction sump details Details: 10 Routine or major :
f Suction conditions : overhauls carried out if
any (Give details)
Static head (Elevation 11 Any other details or :
difference between pump observation
centreline & discharge 12 Investigation :
point) engineers report
8 Installation details 13 Spare requirement :
a Base frame Loose /Anchored with
b Base frame levelling foundation bolts 14 Course of action :
c readings : finalized
d No of packers below base : 15 Service Charges :
frame
Alignment readings :
e -With pipe connection : Prepared by:
-Without pipe connection :
Coupling type & gap
between couplings halves Checked by:

Wilo SE 01/2013 24
 REMARQUES – NOTES:

Wilo SE 01/2013 25
 English

Wilo SE
Nortkirchenstraße 1+
D 44263 Dortmund
Germany
T+49 231/4102 0
F+49 231/3102 7363
www.wilo.com

Wilo - International (Subsidiaries)

Austria Croatia Greece Korea Portugal Sweden
WILO Pumpen Österreich Wilo Hrvatska d.o.o. WILO Hellas WILO PUMPS LTD. Bombas Wilo Salmson WILO Sverige AB
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France sales@wilo.ie Ukraina WILO Ukraina t.o.w
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F+359 2 9701979 info@wilo.fr Milano F+31 88 9456199 F+421 2/3301 4524
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Canada WILO Georgia, wilo.italia@wilo.it Norway Slovenia Jebel Ali –Dubai
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F+1 403 277 9456 info@wilo.ge KZ 05+02 Almaty F+47 22 80 45 90 F+386 1 583 81 38
Bill.lowe@wilo na.com Republic of Kazakhstan wilo@wilo.no wilo.adriatic@wilo.si USA
Great Britain T+7 727 2785961 WILO EMU LLC
China WILO U.K. Ltd F+7 727 – 2785960 Poland Spain Thomasville, Georgia 31792
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T+86 10 804939+ F+44 1283 523099 T+48 22 702 61 61 T+34 91 879 71+ Terry.rouse@wilo emu.com
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wilobj@wilo.com.cn wilo@wilo.pl wilo.iberica@wilo.es

Wilo - International (Representation offices)

Albanie Bosnie Herzegovine Macedonia Moldava Tajikistan Uzbekistan
WILO Adriatic Rep. office Wilo Adriatic Rep. office Wilo Adriatic Rep. office MD 2012 Chisinau WILO Representation office 1+015 Tashkent
Tirana BA 71+0 Sarajevo MK 1+0 Skopje T+373 22 223501 734055 Dushanbe T+998 71 1206774
T+355 42 268 774 T+387 033 71 45 10 T+389 2 3 12 20 58 F+373 22 223501 T+992 37 2312354 F+998 71 1403593
F+355 42 268 774 F+387 033 71 45 11 F+389 2 3 12 20 58 sergiu.zagurean@wilo.md F+992 37 8813515 wilo@wilo tm.info
rajf.murataj@wilo.al zeljko.cvjetkovic@wilo.ba valerij.vojneski@wilo.com.mk info@wilo.tj
Mongolia
Armenia Georgia Mexico Ulaanbaatar Turkmenistan
375+1 Yerevan 0177 Tbilisi WILO Representation office T+976 11 314843 1+015 Tashkent
T+374 10 544336 T/F+995 32 536459 073+ México, D.F., México F+976 11 314843 T+998 71 1206774
F+374 10 544337 info@wilo.ge T+52 55 55863209 wilo@magicnet.mn F+998 71 1403593
info@wilo.am F+52 55 5586 3209 wilo@wilo tm.info
roberto.valenzuela@wilo.com.
mx

WILO SE 04/2009
 English
Wilo SE
Nortkirchenstraße 1+
D 44263 Dortmund
Germany
T+49 231/4102 0
F+49 231/3102 7363
www.wilo.com

       

  

G1 Nord G3 Sachse/Thüringen G5 Südwest G7 West

WILO SE WILO SE WILO SE WILO SE
Vertriebsbüro Hamburg Vertriebsbüro Dresden Vertriebsbüro Stuttgart Vertriebsbüro Düsseldorf
Beim Strohhause 27 Frankenring 8 Hertichstrasse 10 Westring 19
D-2+97 Hamburg D-01723 Kesselsdorf D-71229 Leonberg D-40721 Hilden
T 0 40/55 59 49 0 T 03 52 04/705 0 T 07152 / 9471-0 T 0 21 03/90 92 0
F 0 40/55 59 49 49 F 03 52 04/705 70 F 07152 / 9471-41 F 0 21 03/90 92 15

G2 Ost G4 Südost G6 Rhein-Main G8 Nordwest

WILO SE WILO SE WILO SE WILO SE
Vertriebsbüro Berlin Vertriebsbüro München Vertriebsbüro Frankfurt Vertriebsbüro Hannover
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D-12051 Berlin D-80797 München D-61440 Oberursel / Taunus D-30659 Hannover-Lahe
T 0 30/62 89 37 0 T 0 89/42 + 09 0 T 06171/70460 T 05 11/43 88 40
F 0 30/62 89 37 70 F 0 89/42 + 09 44 F 06171/7046-65 F 05 11/43 88 444

Zentrale Auftragsbearbeitung Wilo-Kundendienst Wilo-International Die Adressesen finden Sie unter

WILO SE WILO SE Österreich         

Nortkirchenstraße 1+ Wilo-Service Center WILO Pumpen Österreich GmbH

D-44263 Dortmund Nortkirchenstraße 1+ Eitnergasse 13
         

T +49 231/4102-0 D-44263 Dortmund A-1230 Wien

F +49 231/3102-7363 T +43 5 07507-0
-Kundendienststeuerung F +43 5 07507-15
Wilo-Kompetenz-Team -Wartung und Inbetriebnahme
- Antworten auf alle Fragen -Werksreparaturen WILO Pumpen Österreich GmbH
Rund um das Product -Ersatzteilberatung Vertriebsbüro Salzburg
Lieferzeiten Versand Gniglerstraße 56
Verkaufspreise T 01805 W.I.IL.O.K.D. 5020 Salzburg
-Abwicklung lhrer Aufträge 9.4.5.6.5.3. T +43 5 07507-0
-Ersatzteilbestellungen – mit 24 – 0231 4102 79+ F +43 5 07507-15
Stunden Lieferzeit für alle gängigen F 0231 4102 7126
Ersatzteile WILO Pumpen Österreich GmbH
-Versand von Informationsmaterial Werktags erreichbar von Vertriebsbüro Oberösterreich
T 01807 R.U.F.W.I.L.O. 7-17Uhr Trattnachtalstraße 7
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F 0231 4102 7666 Feiertags 9-14 Uhr T +43 5 07507-0
Electronische Bereitschaft mit F +43 5 07507-15
Werktags erreichbar Rückruf-Garantie!
Von 7-18 Uhr Schweiz
EMB Pumpen AG
Gerstenweg 7
CH-4310 Rheinfelden
T +4161/8368020
F +41 61/8368021

WILO SE 04/2009
BOOSTER PUMP CONTROLLER
NAME PLATE LIST
L1.POWER LAMP
L1 L2 L2.LOW LAVEL LAMP
L3.RUN NO.1 LAMP
L3 L4 L5 L6 L4.OVERLOAD NO.1 LAMP
L5.RUN NO.2 LAMP
ST1 SP1 ST2 SP2
L6.OVERLOAD NO.2 LAMP
61

ST1. START PUMP1

SW1 SW2
SP1. STOP PUMP1
ST2. START PUMP2
SP2. STOP PUMP2
SW1.MANUAL - OFF - AUTO # 1 SSW.
SW2.MANUAL - OFF - AUTO # 2 SSW.
44 28
 POWER SUPPLY
3PH/4W/380/220V/50HZ
R S T N
WIRING DIAGRAM BOOSTER PUMP
F4 1 A1

OL1 OL2 FLR 5

R3
SW1 SW2 SW1 SW2
MCB1 3P MAN 1 MAN2 AUTO1 AUTO2
R3 A3
9 K1 A1
6 13
G4 17
STOP1 R2 R1 STOP2 PS1 T1

TR
2 3 4 7 11 12 K2 A2
K1 K2 10

AC220V

AC24
18 A2 A2A
R4 15 16
START1 K1 R1 R2 K1 START2
PS2 R3
OL1 OL2 OL1 OL2 A5
R4
U1 V1 W1 U2 V2 W2 8 14 A4

L1 L4 L6 L2 K1 L3 L5 K2 R1 R2 G4 FLR R3 T1 R4

N A0

M1 M2 F = CONTROL FUSE
L1 = POWER LAMP
L2 = LOW LEVEL LAMP
L3 = RUN NO.1 LAMP
L4 = OVERLOAD NO.1 LAMP
L5 = RUN NO.2 LAMP K 1 = MAGNETIC MOTOR START NO.1 R4 = PRESSURE SWITCH RELAY NO.2
L6 = OVERLOAD NO.2 LAMP K 2 = MAGNETIC MOTOR START NO.2 TR = TRANFORMER 220 / 24 VAC
SW 1 = MANUAL - OFF - AUTO NO.1 SSW. R1 = AUTO RELAY NO.1 G4 = RATCHING RELAY
SW 2 = MANUAL - OFF - AUTO NO.2 SSW. R2 = AUTO RELAY NO.2 T1 = OFF DELAY TIMER
R3 = PRESSURE SWITCH RELAY NO.1 FLR = FLOATLESS RELAY

TERMINAL JUMPER
R S T N G U1 V1 W1 U2 V2 W2 N A1 A2 A2 A4 A2 A2A E1 E2 E3

MAIN 380/220VAC / N
NEUTRAL

ON
INTER-LOCK

JUMPER
PS1 PS2
M1 M2 LOW
CUT-OFF

COM
COLD WATER TRANSFER PUMP

PUMP MODEL: MHI 404-1/E/3

(TP – 01, 02)

 Technical data
Contact
E-mail High-pressure multistage centrifugal pump
Phone MHI 404-1/E/3-400-50-2
Customer Project name Untitled project 2019-02-14 09:28:58.288

Project ID
Contact Installation location
E-mail Customer pos.no
Phone

Date 2019-02-14

Duty chart Requested data

Head -- Flow 75,00 l/min
H /m ∆ p / bar
Head 30,00 m
40 4
Media Water 100 %
Eff. 58,8% 3,5 Fluid temperature 20,00 °C
33,95 3,325
30 3 Density 998,20 kg/m³
2,5 Kin. viscosity 1,00 mm²/s
A1
20 2 Hydraulic data (Duty point)
1,5 Flow 79,79 l/min
10 1 Head 33,95 m
0,5 Shaft power P2 0,76 kW
▕◄ Application range ►▏ Hydraulic efficiency 58,45 %
0 0
NPSH-values NPSH 0,56 m
NPSH / m
Product data
0,564 High-pressure multistage centrifugal pump
0
58,45 Hydraulic efficiency MHI 404-1/E/3-400-50-2
η /%
Max. operating pressure 10 bar
Inlet pressure max. 6 bar
0 Fluid temperature -30 °C ... + 110 °C
Shaft power P2 Max. ambient temperature 40 °C
P₂ 0,757
/ kW
0,4
Motordata per Motor/Pump
0
Motor efficiency level IE3
0 10 20 30 40 50 60 70 79,79
80 90 100 110 120 130 140 Q / l/min Mains connection 3~ 400 V / 50 Hz
Pump curves in accordance with ISO 9906, Appendix A Permitted voltage tolerance ±10 %
Max. speed 2900 1/min
Rated power P2 0,75 kW
Rated current 1,95 A
Power factor 0,82
Efficiency
50% / 75% / 100% 79,5/80,7/80,7%
Degree of protection IP 54
Insulation class F
Motor protection no
Fitting dimensions
Pipe connection on the suction side Rp 1¼, PN 10
Pipe connection on the pressure side Rp 1, PN 10
Materials
Pump housing 1.4301 [AISI304]

Impeller 1.4301 [AISI304]

Static seal EPDM
Pump shaft 1.4301 [AISI304]
Mechanical seal BQ1E3GG
Information for order placements
Weight approx. 13,6 kg
Item number 4210725

Dimensions mm

H 219 L2 110 Ø D2 1
H1 90 L3 157,5
H2 104 L4 52
L 457 L5 52
L1 252 Ø D1 1¼

Software version Spaix, Version 4.3.11 - 2019/01/31 (Build 242)

Subject to change Data version 10.12.2018 Pages 1/ 1
 BACKWASH PUMP

PUMP MODEL: MHI 804-1/E/3

(BWP – 01)
 Technical data
Contact
E-mail High-pressure multistage centrifugal pump
Phone MHI 804-1/E/3-400-50-2
Customer Project name Untitled project 2019-02-14 09:28:58.288

Project ID
Contact Installation location
E-mail Customer pos.no
Phone

Date 2019-02-14

Duty chart Requested data

Head -- Flow 150,00 l/min
H /m ∆ p / bar
Head 35,00 m
4 Media Water 100 %
40
Fluid temperature 20,00 °C
34,63 Eff. 62,2% 3,391
3 Density 998,20 kg/m³
30 A1 Kin. viscosity 1,00 mm²/s

20 2 Hydraulic data (Duty point)

Flow 149,20 l/min
10 1 Head 34,63 m
Shaft power P2 1,36 kW
▕◄ Application range ►▏ Hydraulic efficiency 61,70 %
0 0
NPSH-values NPSH 1,00 m
NPSH / m
Product data
1
0,998
High-pressure multistage centrifugal pump
0
Hydraulic efficiency MHI 804-1/E/3-400-50-2
η61,7
/%
Max. operating pressure 10 bar
Inlet pressure max. 6 bar
0 Fluid temperature -30 °C ... + 110 °C
Shaft power P2 Max. ambient temperature 40 °C
P₂ /1,36
kW

0,5
Motordata per Motor/Pump
0
Motor efficiency level IE3
0 20 40 60 80 100 120 149,2
140 160 180 200 220 240 Q / l/min Mains connection 3~ 400 V / 50 Hz
Pump curves in accordance with ISO 9906, Appendix A Permitted voltage tolerance ±10 %
Max. speed 2900 1/min
Rated power P2 1,50 kW
Rated current 3,70 A
Power factor 0,84
Efficiency
50% / 75% / 100% 83/84,2/84,2%
Degree of protection IP 54
Insulation class F
Motor protection no
Fitting dimensions
Pipe connection on the suction side Rp 1½, PN 10
Pipe connection on the pressure side Rp 1¼, PN 10
Materials
Pump housing 1.4301 [AISI304]

Impeller 1.4301 [AISI304]

Static seal EPDM
Pump shaft 1.4301 [AISI304]
Mechanical seal BQ1E3GG
Information for order placements
Weight approx. 18,9 kg
Item number 4210747

Dimensions mm

H 240 L2 148 Ø D2 1¼
H1 90 L3 181,5
H2 104 L4 52
L 523 L5 52
L1 276 Ø D1 1½

Software version Spaix, Version 4.3.11 - 2019/01/31 (Build 242)

Subject to change Data version 10.12.2018 Pages 1/ 1
 Wilo-Economy-MHI 2../ 4../ 8../ 16..

D Einbau- und Betriebsanleitung CZ Návod k montáži a obsluze

GB Installation and operating instructions PL Instrukcja montażu i obsługi
F Notice de montage et de mise en service RUS Инструкция по монтажу и эксплуатации
NL Inbouw- en bedieningsvoorschriften DK Monterings- og driftsvejledning
E Instrucciones de instalación y funcionamiento NO Monterings- og driftsveiledningen
I Istruzioni di montaggio, uso e manutenzione
FIN Huolto- ja käyttöohje
S Monterings- och skötselinstruktioner
H Beépítési és üzemeltetési utasítás
GR Οδηγίες εγκατάστασης και λειτουργίας
2020406-Ed.2-04/10
Fig. 1

Fig. 2
Fig. 3

Fig. 4
 ENGLISH

1. General Motor power: see rating plate,

Maximum current: see rating plate,
Installation and service by qualified personnel only Fluid temperature: –15 °C to 110 °C
1.1 Applications with gaskets – EPDM
The pump is suitable for drinking water, heating water, industrial water, (KTW/WRAS),
condensate, water/glycol mixtures up to a ratio of 40% glycol as well –15 °C to 80 °C version with
as other liquids free from mineral oil and without abrasives or long- with gaskets – VITON
fibred substances. Max. permissible working pressure: 10 bar,
The main areas of use are in water supply installations, as a booster Max. permissible inlet pressure: 6 bar,
pump, as a boiler feed pump, in industrial circulation systems, in pro- Max. ambient temperature: 40 °C,
cess technology, in cooling water systems, in fire extinguishers and in Protective system: IP 54.
washing and sprinkler installations. Other voltages/frequencies and material properties are optional and/or
Approval from the manufacturer must be obtained beforehand if corro- available on request.
sive chemicals are to be pumped. When pumping viscous fluids (e.g. water/glycol mixtures) adjust the
pump data to allow for the higher viscosity.
1.2 Technical description
Only use branded glycol mixtures with corrosion inhibitors and follow
1.2.1 Performance and electrical data
the manufacturers instructions.
AC voltage: 1 ~ 230 V (± 10 %) / 50Hz or
For dimensions see table and Fig. 3.
Rotary current voltage: 3 ~ 230 / 400 V (± 10 %) / 50 Hz;

Pump Pump unit

Model Dimensions

A B C D E F G H

1~230 V 3~400 V 1~230 V 3~400 V 1~230 V 3~400 V 1~230 V 3~400 V

MHI mm

202 205 88 88 375 375 216 192 90 90 Rp1 110 Rp1

203 205 88 88 375 375 216 192 90 90 Rp1 110 Rp1

204 253 88 88 423 423 216 192 90 90 Rp1 158 Rp1

205 253 88 88 423 423 216 192 90 90 Rp1 158 Rp1

206 277 104 104 472 472 224 206 90 90 Rp1 182 Rp1

402 205 88 88 375 375 216 192 90 90 Rp11/4 110 Rp1

403 205 88 88 375 375 216 192 90 90 Rp11/4 110 Rp1

404 253 88 88 423 423 216 192 90 90 Rp11/4 158 Rp1

405 253 104 104 448 448 224 206 90 90 Rp11/4 158 Rp1

406 277 137 104 511 472 239 206 100 90 Rp11/4 182 Rp1

802 217 88 88 387 387 216 192 90 90 Rp11/2 122 Rp11/4

803 217 104 88 412 387 224 192 90 90 Rp11/2 122 Rp11/4

804 277 104 104 472 472 224 206 90 90 Rp11/2 182 Rp11/4

805 277 - 104 - 472 - 206 - 90 Rp11/2 182 Rp11/4

1602 237 - 103,5 - 432 - 206 - 90 Rp2 138 Rp11/2

1603 237 - 103,5 - 432 - 206 - 90 Rp2 138 Rp11/2

1604 282 - 136,5 - 515 - 221 - 100 Rp2 183 Rp11/2

When ordering spare parts, please give all the information on the rating plate.

8
 ENGLISH

1.2.2 Series specifications 2.5 Safety precautions for inspection and installation
MHI 4 06 1 / E / 3 ~ 400 - 50 - 2/XX/X The operator must ensure that all inspection and installation work is
MHI (Multistage carried out by authorized and qualified specialists who have carefully
Horizontal stainless steel studied these instructions. In principle, work should not be carried out
(Inox) centrifugal on a running pump or installation.
pump) design 2.6 Unauthorized alterations and manufacture of spare parts
Flow rate Alterations to the pump or installation may only be carried out with the
[m3/h] manufacturer's consent. The use of original spare parts and accesso-
ries authorized by the manufacturer will ensure safety. The use of other
Number of impellers
parts may invalidate claims invoking the manufacturer’s liability for any
Steel grade: consequences.
1 → 1.4301 (AISI 304)
2 → 1.4404 (AISI 316 L) 2.7 Improper use
The operational safety of the pump or installation supplied can only be
gaskets – EPDM (KTW/WRAS)
guaranteed if it is used in accordance with paragraph 1 of the operat-
gaskets – VITON
ing instructions. The limits given in the catalogue or data sheet must
Mains voltage under no circumstances be exceeded.
3 ~ 230/400 V
1 ~ 230 V
50Hz or 60Hz frequency
2 or 4 pole motor
3. Transport and storage
Manufacturer's key WARNING! During transport and in storage the pump must be
protected against moisture, frost and mechanical
damage.

4. Description of product and accessories

2. Safety precautions
These instructions contain important information which must be
followed when installing and operating the pump. It is therefore im-
perative that they be read by both the installer and the operator before
the pump is installed or started up.
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 follow-
ed, could cause personal injury are indicated by the symbol:
Safety precautions warning of danger due to electricity are indicated
by the symbol:
Safety precautions which, if not followed, could damage the pump or
installation and cause it to malfunction are indicated by the word:
WARNING!
2.2 Qualified Personnel
The personnel installing the pump must have the appropriate qualifica-
tions for this work.
2.3 Risks incurred by failure to comply with the safety precautions
Failure to comply with the safety precautions could result in personal
injury or damage to the pump or installation. Failure to comply with the
safety precautions could also invalidate any claim for damages.
In particular, failure to comply with these safety precautions could give
rise, for example, to the following risks:
– the failure of important parts of the pump or installation,
– personal injury due to electrical and mechanical causes.
2.4 Safety precautions for the operator
Existing regulations for the prevention of accidents must be followed.
To prevent the risk of electric shock or electrocution, VDE regulations
and those of the local supply company must be followed.
4.1 Pump description (Fig. 1)
The pump is a multistage (2-6 stage) normal suction, horizontal high
pressure centrifugal pump with a block design with horizontal inlet (1)
and vertical pressure glands (2).
The hydraulic section is equipped with the given number of stage
housings (5) and impellers (6) in a modular construction. The impellers
are fitted on a single motor-pump shaft (7). The pressure casing (8)
surrounding the hydraulic section guarantees a fail-safe seal. All parts
in contact with the fluid, such as stage chambers, impellers and the
pressure casing, are made of chromium nickel steel. The shaft hole
through the pump casing is sealed to the motor with an axial face seal
(9). E = All parts in contact with the fluid have been cleared by KTW
and/or WRAS and are therefore suitable for use with drinking water.
The AC motors are equipped with a thermal cut-out. This switches off
the motor when the permissible temperature of the motor coil is
exceeded and switches it back on again automatically once it has
cooled down.
Low-water protection. The pump and in particular the axial face seal
must not run dry. Low-water protection should be provided by the
customer by fitting the relevant parts from the WILO range of accesso-
ries.
The speed of the pump can be controlled when connected to a fre-
quency converter or motor filter (see paragraph 5.3)
4.2 Components supplied
– EM or DM version of pump,
– Installation and Operating Instructions
4.3 Accessories
Accessories must be ordered separately.
– WV/COL switching unit with relevant accessories for automation,
– CO-ER switching unit with relevant accessories for automation,
– Low-water protection:
– WMS kit for direct connection to the supply pipe,
– WAEK 65 float switch with small switching unit (only for EM
version),
– WA 65 float switch,
– SK 277 with 3 dipped electrodes,
– WVA pressure switch,
– WILO fluid control (EK),
– Installation switching:
– WA 065 float switch
– WA OEK 65 float switch with small switching unit (only for EM
version).

9
 ENGLISH
5. Assembly and Installation
5.1 Installation
Fig. 2 shows a typical pump installation. Installation and assembly
instructions, which must be observed with this type of operation, are
listed as follows:
– Before installing the pump, make sure that all welding and soldering
on the pipe system has been completed and that the pipe system
has been completely flushed out. Foreign bodies and dirt will dama-
ge the pump.
– Install the pump in a dry place free of frost.
– Leave room for maintenance work to be carried out.
– The motor ventilator inlet must be kept clear, at least 0.30 m from
the wall to the rear.
– Install in a horizontal and flat position.
– The pump must be held in place with two 8 mm diameter screws,
on a vibration-absorbing base. Commercially available rubber-metal
connectors can also be used to hold it in place and absorb vibra-
tions.
– To ensure that the drain valve can be accessed, the pump must be
installed with the drain valve at least 20 mm above the floor.
– Isolating valves (1) should be installed in front of and behind the
pump, so that the pump can be easily changed and/or maintenance
work can be carried out more easily.
– A backflow preventer (2) should be installed immediately behind the
outlet pressure gland of the pump.
– The inlet and outlet pipes should be connected to the pump without
stress. Flexible lengths of pipe or bellow expansion joints of
restricted length can be used to ensure a low-vibration connection.
The weight of the pipework must be supported.
– The customer should take suitable measures to prevent low water
levels and hence guard against the pump running dry in order to
protect the axial face seal. The WILO range comprises various
accessories which can be used for this purpose.
– The customer should protect the pump at the inlet pipe with a
strainer (1mm mesh) or filter connection (5) to avoid the pipe
being damaged by any dirt which may be sucked in.
5.2 Electrical installation
– Electrical work must be carried out by a qualified and
licensed electrician in strict compliance with local regu-
lations.
– The electricity supply must be connected via a rigid supply cable
fitted with a coupler or an all-pole switch with a contact gap of at
least 3 mm in accordance with the local regulations in force (e.g. in
accordance with the latest edition of IEE wiring regulations).
– Check the mains current and voltage.
– Ensure compliance with the data on the pump rating plate.
– Make sure the pump is earthed.
– Mains fuse: 10A time-lag fuse.
– The customer should fit rotary current motors with a motor safety
switch which should be adjusted to the nominal current given on the
rating plate to prevent the motor from overheating.
AC motors are fitted with a thermal motor cut-out in the factory.
This cuts off the pump when the permissible temperature of the
motor coil is exceeded and switches it back on again automatically
once it has cooled down.
– A supply cable with an adequate ample external diameter (e.g. 05
VV-F 3/5 G 1.5 or AVMH-I 3/5x1.5) should be used to protect
against damp and to secure the mains lead cleat of the stuffing box.
– Connection to the mains must be carried out in accordance with the
plan of terminal connections for rotary or alternating current in the
terminal box of the pump (see also Fig. 4).
– Heat-resistant cable must be used if the pump is fitted in installa-
tions in which the temperature of the fluids pumped exceeds 90 °C.
– The supply cable must be laid in such a way that it never touches
the pipework and/or the pump and motor casing.
If necessary a fault current breaker (FI-switch) should be
provided.
10
5.3 Operation with frequency converter
The speed of the pump can be controlled when connected to a
frequency converter. Speed control limits: 40%nnom ≤ n ≤ 100%nnom.
See Installation and Operating Instructions of the frequency converter
for connection and operation.
To avoid overloading the motor coil to the extent that it is damaged
and to avoid increasing noise levels, the frequency converter must not
produce speeds due to increased voltage of over 500 V/μs and spikes
of û > 650 V. If such speeds due to increased voltage are possible, an
LC filter (motor filter) should be installed between the frequency
converter and the motor. The layout of the filter must be designed by
the manufacturer of the frequency converter or filter.
In control devices with frequency converters supplied by WILO, the
filter is already installed.
6. Commissioning
– Check that there is a sufficient level of water in the reservoir and/or
check the inlet pressure.
WARNING! The pump must not run dry, as this would destroy
the axial face seal.
– When used for the first time, if it is to be used to pump drinking
water the system must be flushed through, so that any dirty water
present will not contaminate the drinking water supply.
– Checking direction of rotation (only for rotary current motors): Check
that the pump rotates in the direction indicated by the arrow on the
pump casing by switching on for a short time. If this is not the case,
interchange 2 phases in the pump terminal box.
– Only for rotary current motors: Adjust the motor cut-out to the nomi-
nal current given on the rating plate.
– If available, position float switches or electrodes for protection
against low water levels in such a way that the pump cuts out if the
water level is so low that air would begin to be sucked in.
– Open the isolating valve at the inlet, open the vent screw (Figs 1 & 2,
3, SW 19) until the pumped fluid comes out, close the vent screw,
open the isolating valve at the outlet and switch on the pump.
– Depending on the fluid temperature and the system pres-
sure, if the vent screw is completely loosened hot liquid or
gas can escape or even shoot out at high pressure.
Beware of scalding.
– Depending on the operating conditions of the pump or
installation (fluid temperature), the entire pump may be-
come very hot.
Avoid touching the pipe owing to the risk of burning.
WARNING! The pump must not run for longer than 10 minutes
with a flow rate of Q = 0 m3/h. We recommend that
when running continuously the pump should be
kept at a minimal flow of 10 % nominal flow.
7. Maintenance
– The pump is almost maintenance free.
– During the running-in period, there may be some dripping from the
axial face seal. Should a more significant leak occur as a result of
substantial wear, have the axial face seal replaced by a specialist.
– Increased bearing noise and unusual vibrations indicate a worn
bearing. In this case, have the bearing replaced by a specialist.
– Before carrying out any maintenance work, switch off the pump and
ensure that it cannot be switched on again by unauthorized people.
Never carry out work on a running pump.
– When the pump is exposed to frost or is out of service for a long
period, the pump and pipework must be emptied in the cold
season. Empty the pump by releasing the drain valve (Figs 1 & 2, 4),
the inlet pipe by releasing the vent screw, and the outlet pipe by
opening the bleeding point.
 ENGLISH

8. Fault finding, causes and remedies

Fault Cause Remedy

Pump does not run no power check fuses, float switches and cables

motor safety switch activated eliminate motor overload

Pump runs but does not pump wrong direction of rotation interchange two phases of the mains
connection

pipe or pump components blocked by check and clean pipe and pump
foreign body

air in inlet pressure gland seal inlet pressure gland

inlet pipe too narrow fit a larger inlet pipe

Pump does not pump evenly inlet too high position the pump lower

Pressure is insufficient wrong choice of pump fit a more powerful pump

wrong direction of rotation interchange two phases of the mains

connection

flow is too small, inlet pipe blocked clean filter and inlet pipe

valve not sufficiently open open valve

foreign body blocking the pump clean the pump

Pump vibrates foreign body in the pump remove foreign body

pump not properly fixed to the base tighten anchor bolts

base is not sufficiently heavy fit a heavier base

Motor overheats, insufficient voltage check voltage

motor cut-out activates

pump sluggish:
foreign body clean pump
bearing damaged have pump repaired by customer services

ambient temperature too high provide cooling

If the fault cannot be remedied, please contact your local plumbing

and heating specialist or WILO customer services.
Figures:
1 Cross-section of the pump with reference numbers.
2. Positioning and pipework of the pump.
3. Drawing showing dimensions.
4. Plan of electrical connections. Subject to technical alterations.w

11
NL
EG-verklaring van overeenstemming
Hiermede verklaren wij dat dit aggregaat in de geleverde uitvoering
voldoet aan de volgende bepalingen:
EG-richtlijnen betreffende machines 2006/42/EG
De veiligheidsdoelstellingen van de laagspanningsrichtlijn worden
overeenkomstig bijlage I, nr. 1.5.1 van de machinerichtlijn 2006/42/EG
aangehouden.
Elektromagnetische compatibiliteit 2004/108/EG
gebruikte geharmoniseerde normen, in het bijzonder:
zie vorige pagina
P S
Declaração de Conformidade CE
Pela presente, declaramos que esta unidade no seu estado original, está
conforme os seguintes requisitos:
Directivas CEE relativas a máquinas 2006/42/EG
Os objectivos de protecção da directiva de baixa tensão são cumpridos de
acordo com o anexo I, nº 1.5.1 da directiva de máquinas 2006/42/CE.
Compatibilidade electromagnética 2004/108/EG
normas harmonizadas aplicadas, especialmente:
ver página anterior
FIN
CE-standardinmukaisuusseloste
Ilmoitamme täten, että tämä laite vastaa seuraavia asiaankuuluvia
määräyksiä:
EU–konedirektiivit: 2006/42/EG
Pienjännitedirektiivin suojatavoitteita noudatetaan
konedirektiivin 2006/42/EY liitteen I, nro 1.5.1 mukaisesti.
Sähkömagneettinen soveltuvuus 2004/108/EG
käytetyt yhteensovitetut standardit, erityisesti:
katso edellinen sivu.
CZ
Prohlášení o shod ES
I E
Dichiarazione di conformità CE
Con la presente si dichiara che i presenti prodotti sono conformi alle
seguenti disposizioni e direttive rilevanti:
Direttiva macchine 2006/42/EG
Gli obiettivi di protezione della direttiva macchine vengono rispettati
secondo allegato I, n. 1.5.1 dalla direttiva macchine 2006/42/CE.
Compatibilità elettromagnetica 2004/108/EG
norme armonizzate applicate, in particolare:
vedi pagina precedente
CE- försäkran
Härmed förklarar vi att denna maskin i levererat utförande motsvarar
följande tillämpliga bestämmelser:
EG–Maskindirektiv 2006/42/EG
Produkten uppfyller säkerhetsmålen i lågspänningsdirektivet enligt bilaga
I, nr 1.5.1 i maskindirektiv 2006/42/EG.
EG–Elektromagnetisk kompatibilitet – riktlinje 2004/108/EG
tillämpade harmoniserade normer, i synnerhet:
se föregående sida
DK
EF-overensstemmelseserklæring
Vi erklærer hermed, at denne enhed ved levering overholder følgende
relevante bestemmelser:
EU–maskindirektiver 2006/42/EG
Lavspændingsdirektivets mål om beskyttelse overholdes i henhold til bilag
I, nr. 1.5.1 i maskindirektivet 2006/42/EF.
Elektromagnetisk kompatibilitet: 2004/108/EG
anvendte harmoniserede standarder, særligt:
se forrige side
PL
Deklaracja Zgodnoci WE
Declaración de conformidad CE
Por la presente declaramos la conformidad del producto en su estado de
suministro con las disposiciones pertinentes siguientes:
Directiva sobre máquinas 2006/42/EG
Se cumplen los objetivos en materia de seguridad establecidos en la
Directiva de Baja tensión según lo especificado en el
Anexo I, punto 1.5.1 de la Directiva de Máquinas 2006/42/CE.
Directiva sobre compatibilidad electromagnética 2004/108/EG
normas armonizadas adoptadas, especialmente:
véase página anterior
N
EU-Overensstemmelseserklæring
Vi erklærer hermed at denne enheten i utførelse som levert er i
overensstemmelse med følgende relevante bestemmelser:
EG–Maskindirektiv 2006/42/EG
Lavspenningsdirektivets vernemål overholdes i samsvar med
vedlegg I, nr. 1.5.1 i maskindirektivet 2006/42/EF.
EG–EMV–Elektromagnetisk kompatibilitet 2004/108/EG
anvendte harmoniserte standarder, særlig:
se forrige side
H
EK-megfelelségi nyilatkozat
Ezennel kijelentjük, hogy az berendezés megfelel az alábbi irányelveknek:
Gépek irányelv: 2006/42/EK
A kisfeszültség irányelv védelmi elírásait a
2006/42/EK gépekre vonatkozó irányelv I. függelékének 1.5.1. sz. pontja
szerint teljesíti.
Elektromágneses összeférhetség irányelv: 2004/108/EK
alkalmazott harmonizált szabványoknak, különösen:
lásd az elz oldalt
RUS


     
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ci , e dostarczony wyrób
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Smrnice ES pro strojní zaízení 2006/42/ES dyrektyw maszynow WE 2006/42/WE   EC    2006/42/EG
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nízkého nap)tí jsou dodrženy podle pílohy I, (. 1.5.1 sm)rnice o strojních za cznikiem I, nr 1.5.1 dyrektywy maszynowej 2006/42/WE. - &#+', $'' " &#+' I,
zaízeních 2006/42/ES. 3 1.5.1 #  7 7 2006/42/8G.
Smrnice o elektromagnetické kompatibilit 2004/108/ES dyrektyw dot. kompatybilnoci elektromagnetycznej 2004/108/WE 
  !" 2004/108/EG

použité harmoniza(ní normy, zejména: stosowanymi normami zharmonizowanymi, a w szczególno

ci: 9&- " #  #,  :
viz pedchozí strana patrz poprzednia strona . &#' #;

GR TR RO
#$%&'( ')**+,3&'(5 7(5 99 CE Uygunluk Teyid Belgesi EC-Declara;ie de conformitate
<=>?@JQRT UXZ XJ [\J]U@ ^QXU _’ ^QX{ X=@ |^X}_X^_= [^\}~J_= Bu cihazın teslim edildiƒi „ekliyle a„aƒıdaki standartlara uygun olduƒunu Prin prezenta declar…m c… acest produs a„a cum este livrat, corespunde cu
Z|^@J[JZT€ XZ ^|U>JQT ~Z^X}‚TZ : teyid ederiz: urm…toarele prevederi aplicabile:
<=(>?@5 EA >JQ *(XQY$*Q7Q 2006/42/EA AB-Makina Standartları 2006/42/EG Directiva CE pentru ma\ini 2006/42/EG
†Z ^[^ZX{_TZ [\J_X^_€^ X= J~=‡€^ ˆ^R=>{ X}_= X=\J‰@X^Z Alçak gerilim yönergesinin koruma hedefleri, 2006/42/AT makine Sunt respectate obiectivele de protecŽie din directiva privind joasa
_‰RŠ‹@^ RT XJ [^\}\X=R^ I, ^\. 1.5.1 X= J~=‡€^ _ˆTXZ|} RT X^ yönergesi Ek I, no. 1.5.1'e uygundur. tensiune conform Anexei I, Nr. 1.5.1 din directiva privind ma„inile
R=ˆ^@{R^X^ 2006/42/EG. 2006/42/CE.
]%@^7,_*Q>Y(7J^$ ')*`Q7+7(7Q EA-2004/108/EA Elektromanyetik Uyumluluk 2004/108/EG Compatibilitatea electromagneticx – directiva 2004/108/EG
@^\RJ@Z_R@^ ˆ\=_ZRJ[JZJ‰RT@^ [\UXQ[^, Z~Z^€XT\^: kısmen kullanılan standartlar için: standarde armonizate aplicate, îndeosebi:
‘>[T [\J=‡J‰RT@= _T>€~^ bkz. bir önceki sayfa vezi pagina precedent…

EST LV LT
EÜ vastavusdeklaratsioon EC - atbilst{bas deklar|cija EB atitikties deklaracija
Käesolevaga tõendame, et see toode vastab järgmistele asjakohastele Ar šo m’s apliecin“m, ka šis izstr“d“jums atbilst sekojošiem noteikumiem: Šiuo pažymima, kad šis gaminys atitinka šias normas ir direktyvas:
direktiividele:
Masinadirektiiv 2006/42/EÜ Maš{nu direkt{va 2006/42/EK Mašin} direktyv 2006/42/EB
Madalpingedirektiivi kaitse-eesmärgid on täidetud vastavalt masinate Zemsprieguma direkt—vas droš—bas m’r˜i tiek iev’roti atbilstoši Maš—nu Laikomasi Žemos ›tampos direktyvos keliamœ saugos reikalavimœ pagal
direktiivi 2006/42/EÜ I lisa punktile 1.5.1. direkt—vas 2006/42/EK pielikumam I, Nr. 1.5.1. Mašinœ direktyvos 2006/42/EB I priedo 1.5.1 punkt .
Elektromagnetilise ühilduvuse direktiiv 2004/108/EÜ Elektromagn~tisk|s savietojam{bas direkt{va 2004/108/EK Elektromagnetinio suderinamumo direktyv 2004/108/EB
kohaldatud harmoneeritud standardid, eriti: piem’roti harmoniz’ti standarti, tai skait“: pritaikytus vieningus standartus, o btent:
vt eelmist lk skat—t iepriekš’jo lappusi žr. ankstesniame puslapyje

SK SLO BG
ES vyhlásenie o zhode ES – izjava o skladnosti E-

 € 
Týmto vyhlasujeme, že konštrukcie tejto konštruk(nej série v dodanom Izjavljamo, da dobavljene vrste izvedbe te serije ustrezajo slede(im ž##,  &#% "#   :
vyhotovení vyhovujú nasledujúcim príslušným ustanoveniam: zadevnim dolo(ilom:
Stroje - smernica 2006/42/ES
Bezpe(nostné ciele smernice o nízkom napätí sú dodržiavané v zmysle
prílohy I, (. 1.5.1 smernice o strojových zariadeniach 2006/42/ES.
Elektromagnetická zhoda - smernica 2004/108/ES
Direktiva o strojih 2006/42/ES ‚ ƒ  2006/42/EO
Cilji Direktive o nizkonapetostni opremi so v skladu s Ÿ    #&#$   &#+ 
prilogo I, št. 1.5.1 Direktive o strojih 2006/42/EG doseženi. % %".  #+ I, 3 1.5.1  ž# 
7 2006/42/E¡.
Direktiva o elektromagnetni združljivosti 2004/108/ES E
   – ƒ  2004/108/E
používané harmonizované normy, najmä: uporabljeni harmonizirani standardi, predvsem: ¢## #:
pozri predchádzajúcu stranu glejte prejšnjo stran +. &# #;

M
Dikjarazzjoni ta’ konformità KE
B'dan il-mezz, niddikjaraw li l-prodotti tas-serje jissodisfaw id-
dispoizzjonijiet relevanti li £ejjin:
Makkinarju - Direttiva 2006/42/KE
j
L-objettivi g
tas-sigurta ££ Baxx huma konformi
tad-Direttiva dwar il-Vulta££ WILO SE
mal-Anness I, Nru 1.5.1 tad-Direttiva dwar il-Makkinarju 2006/42/KE.
Nortkirchenstraße 100
44263 Dortmund
Kompatibbiltà elettromanjetika - Direttiva 2004/108/KE
Germany
kif ukoll standards armonizzati b'mod partikolari:
ara l-pa£na ta' qabel
 WILO SE
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Wilo – International (Subsidiaries)

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