Wilo Helix V User manual

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Wilo-Helix V, FIRST V, 2.0-VE 22-36-52
4120943 • Ed.12/02/2022
en Installation and operating instructions

8
9
5
6
12
1
2
3
4
10
7
1
2
3
4
10
8
9
5
6
12
7
Fig. 1
FIRST

Fig. 2

Fig. 3
Fig. 6 Fig. 7
Fig. 5
HIGH
V
OLTAGE
LOW
V
OLTAGE
<ܾ
ܾ
L1 L2 L3
W1
V2U2W2
U1 V1
<

A
A
C
AK
AK
AK
AG
AG
AJ
AJ
AH
AH
B
C
B
D E
D E
F
F
D E
C
B
A
AG AH
AJ
F
Fig. 4
Type (mm)
A B C D E F G H J K
Helix V(F),
2.0-VE 22
PN16/PN25/
PN30 130 296 215 250 300 90 DN50 125 4 x M16
16 x
Ø14
Helix V(F),
2.0-VE 36
PN16 170
or
220
296
240
or
220
250 320 105 DN65 145
4 x M16
PN25/PN30 8 x M16
Helix V(F),
2.0-VE 52
PN16/PN25/
PN30
190
or
220
296
266
or
220
250 365 140 DN80 160 8 x M16
Type (mm)
A B C D E F G H J K
Helix FIRST
V(F) 22
PN16/PN25/
PN30 130 260 215 226 300 90 DN50 125 4 x M16
4 x Ø14
Helix FIRST
V(F) 36
PN16
170 294 240 226 320 105 DN65 145
4 x M16
PN25PN30 8 x M16
Helix FIRST
V(F) 52
PN16/PN25/
PN30
190
or
170
295
266
or
240
226 365 140 DN80 160 8 x M16
Type (mm)
A B C D E F G H J K
Helix V(F),
2.0-VE 22
PN16/PN25 130 262 215 226 300 90 DN50 125 4 x M16
4 x Ø14
Helix V(F),
2.0-VE 36
PN16
170 282 240 212 320 105 DN65 145
4 x M16
PN25 8 x M16
Helix V(F),
2.0-VE 52
PN16/PN25
190
or
170
306
266
or
240
234 365 140 DN80 160 8 x M16
Material code - 2 -3
Material code - 4 -5
Material code - 1

Fig. 8
Fig. 9 Fig. 10
x2
x4

9
English ............................................................................................................... 10

en
10 WILO SE 02/2022
Sommaire
1 General..................................................................................................................................................................................... 11
1.1 About this document ..................................................................................................................................................................................... 11
2 Safety....................................................................................................................................................................................... 11
2.1 Symbols and signal words in the operating instructions .......................................................................................................................... 11
2.2 Personnel qualification................................................................................................................................................................................... 12
2.3 Danger in the event of non-observance of the safety instructions........................................................................................................ 12
2.4 Safety consciousness on the job .................................................................................................................................................................. 12
2.5 Safety instructions for the user .................................................................................................................................................................... 12
2.6 Safety instructions for installation and maintenance work...................................................................................................................... 12
2.7 Unauthorised modification and manufacture of spare parts ................................................................................................................... 13
2.8 Improper use.................................................................................................................................................................................................... 13
3 Transport and interim storage .............................................................................................................................................. 13
4 Application .............................................................................................................................................................................. 13
4.1 Applications areas........................................................................................................................................................................................... 13
5 Technical data ......................................................................................................................................................................... 14
5.1 Type key........................................................................................................................................................................................................... 14
5.2 Data table......................................................................................................................................................................................................... 14
5.3 Scope of delivery............................................................................................................................................................................................. 15
5.4 Accessories ...................................................................................................................................................................................................... 15
6 Description and function ....................................................................................................................................................... 15
6.1 Product description ........................................................................................................................................................................................16
6.2 Design of product ........................................................................................................................................................................................... 16
7 Installation and electrical connection .................................................................................................................................. 16
7.1 Commissioning................................................................................................................................................................................................ 17
7.2 Installation ....................................................................................................................................................................................................... 17
7.3 Pipe connection .............................................................................................................................................................................................. 18
7.4 Motor connection for bare-shaft pump (without motor)......................................................................................................................... 18
7.5 Electrical connection...................................................................................................................................................................................... 19
7.6 Operation with frequency converter............................................................................................................................................................ 19
8 Commissioning........................................................................................................................................................................ 19
8.1 System filling - Venting................................................................................................................................................................................. 19
8.2 Starting up ....................................................................................................................................................................................................... 20
9 Maintenance............................................................................................................................................................................ 21
10 Faults, causes and remedies .................................................................................................................................................. 22
11 Spare parts............................................................................................................................................................................... 22
12 Disposal.................................................................................................................................................................................... 22

General en
Installation and operating instructions Wilo-Helix V, FIRST V, 2.0-VE 22-36-52 11
1 General
1.1 About this document The language of the original operating instructions is English. All other languages of
these instructions are translations of the original operating instructions.
These installation and operating instructions are an integral part of the product. They
must be kept readily available at the place where the product is installed. Strict adher-
ence to these instructions is a precondition for the proper use and correct operation of
the product.
These installation and operating instructions correspond to the relevant version of the
product and the underlying safety standards valid at the time of going to print.
2 Safety These operating instructions contain basic information which must be adhered to dur-
ing installation, operation and maintenance. For this reason, these operating instruc-
tions must, without fail, be read by the service technician and the responsible special-
ist/operator before installation and commissioning.
It is not only the general safety instructions listed under the main point “safety” that
must be adhered to but also the special safety instructions with danger symbols in-
cluded under the following main points.
ƒInjuries due to electrical, mechanical and bacteriological factors and electromag-
netic fields.
ƒDamage to the environment due to leakage of hazardous materials.
ƒDamage to the installation.
ƒFailure of important product functions.
2.1 Symbols and signal words in the
operating instructions Symbols:
WARNING
General safety symbol
WARNING
Electrical risks
NOTICE
Notes

en Safety
12 WILO SE 02/2022
Signal words
DANGER
Imminent danger.
May result in death or severe injuries if the hazard is not prevented.
WARNING
Non-observance may result in (very) severe injury.
CAUTION
The product risks becoming damaged. “Caution” is used when there is a risk to the
product if the user does not observe procedures.
NOTICE
Note containing useful information for the user about the product. It assists the user
in the case of an issue;
2.2 Personnel qualification The installation, operating and maintenance personnel must have the appropriate qual-
ifications for this work. Area of responsibility, terms of reference and monitoring of the
personnel are to be ensured by the operator. If the personnel are not in possession of
the necessary knowledge, they are to be trained and instructed. This can be accom-
plished if necessary by the manufacturer of the product at the request of the operator.
2.3 Danger in the event of non-ob-
servance of the safety instruc-
tions
Non-observance of the safety instructions can result in risk of injury to persons and
damage to the environment and the product/unit. Nonobservance of the safety in-
structions results in the loss for any claims to damages. In particular, non-observance
can, for example, result in the following risks:
ƒDanger to persons due to electrical, mechanical and bacteriological factors
ƒDamage to the environment due to leakage of hazardous materials
ƒProperty damage
ƒFailure of important product/unit functions
ƒFailure of required maintenance and repair procedures
2.4 Safety consciousness on the job The safety instructions included in these installation and operating instructions, the ex-
isting national regulations for accident prevention together with any internal working,
operating and safety regulations of the operator are to be complied with.
2.5 Safety instructions for the user This appliance is not intended for use by persons (including children) with reduced
physical, sensory or mental capabilities, or lack of experience and knowledge, unless
they have been given supervision or instruction concerning use of the appliance by a
person responsible for their safety. Children should be supervised to ensure that they
do not play with the appliance.
ƒIf hot or cold components on the product/unit lead to hazards, local measures must
be taken to guard them against touching.
ƒGuards which protect personnel from coming into contact with moving compon-
ents (e.g. the coupling) must not be removed while the product is in operation.
ƒLeakages (e.g. from the shaft seals) of hazardous fluids (which are explosive, toxic
or hot) must be led away so that no danger to persons or to the environment arises.
National statutory provisions are to be complied with.
ƒHighly flammable materials are always to be kept at a safe distance from the
product.
ƒDanger from electrical current must be eliminated. Local directives or general dir-
ectives [e.g. IEC, VDE etc.] and local power supply companies must be adhered to.
2.6 Safety instructions for installation
and maintenance work The operator must ensure that all installation and maintenance work is carried out by
authorised and qualified personnel, who are sufficiently informed from their own de-
tailed study of the operating instructions

Transport and interim storage en
Installation and operating instructions Wilo-Helix V, FIRST V, 2.0-VE 22-36-52 13
Work on the product/unit must only be carried out when at a standstill. It is mandatory
that the procedure described in the installation and operating instructions for shutting
down the product/unit be complied with.
Immediately on conclusion of the work, all safety and protective devices must be put
back in position and/or recommissioned.
2.7 Unauthorised modification and
manufacture of spare parts Unauthorised modification and manufacture of spare parts will impair the safety of the
product/ personnel and will make void the manufacturer’s declarations regarding safety.
Modifications to the product are only permissible after consultation with the manufac-
turer. Original spare parts and accessories authorised by the manufacturer ensure
safety. The use of other parts will absolve us of liability for consequential events.
2.8 Improper use The operating safety of the supplied product is only guaranteed for conventional use in
accordance with Section 4 of the operating instructions. The limit values must on no
account fall under or exceed those values specified in the catalogue/data sheet.
3 Transport and interim storage When receiving the material, check that there has been no damage during the trans-
port. If shipping damage has occurred, take all necessary steps with the carrier within
the allowed time.
CAUTION
Outside influences may cause damages. 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
(humidity, frost etc.).
The product should be cleaned thoroughly before it is put into temporary storage.
The product can be stored for at least one year.
Handle the pump carefully so as not to damage the unit prior to installation.
4 Application This pump’s basic function is to pump hot or cold water, water with glycol or other low
viscosity fluids that contain no mineral oil, solid or abrasive substances, or materials
having long fibres. The manufacturer’s approval is required for use to pump corrosive
chemicals.
WARNING
Risk of explosion
Do not use this pump to handle flammable or explosive liquids.
4.1 Applications areas ƒwater distribution and pressure boosting
ƒindustrial circulation systems
ƒprocess fluids
ƒcooling-water circuits
ƒfirefighting and washing stations
ƒirrigation systems, etc.

en Technical data
14 WILO SE 02/2022
5 Technical data
5.1 Type key
Example: Helix V2205 or Helix2.0-VE2205/2-1/16/E/KS/400-50xxxx
Helix V(F)
Helix FIRST V(F)
Helix2.0-VE
Vertical high-pressure multistage centrifugal pump in in-line design
(F) = VdS certified pump version
With frequency converter
22 Nominal volume flow in m³/h
05 Number of impellers
2 Number of trimmed impellers (if any)
1 Pump material code
1 = Pump housing stainless steel 1.4301 (AISI 304) + hydraulics 1.4307 (AISI 304)
2 = Modular pump housing stainless steel 1.4404 (AISI 316L) + hydraulics 1.4404 (AISI
316L)
4 = Monobloc pump housing cast iron EN-GJL-250 (ACS and WRAS approved coating) +
Hydraulics 1.4307 (AISI 304)
5 = Pump housing cast Iron EN-GJL-250 (standard coating) + hydraulics 1.4307 (AISI 304)
16 Pipe connection
16 = oval flanges PN16
25 = round flanges PN25
30 = round flanges PN40
E Seal type code
E = EPDM
V = FKM
KS K = Cartridge seal, versions without “K” are equipped with simple mechanical seal
S = Lantern orientation align with suction pipe
X = X-Care version
1 1 = Single-phase motor - None or 3 = Triphase motor
(With motor)
400 - 460
Motor electrical voltage (V)
50 - 60 = Motor frequency (Hz)
(Without motor)
Bare-shaft pump
-38FF265 = Ø motor shaft – lantern size
XXXX Option code (if any)
5.2 Data table
Maximum operating pressure
Pump casing 16, 25 or 30 bars depend on the model
Maximum suction pressure 10 bars
Note : real inlet pressure (Pinlet)+ pressure at 0 flow delivered by the pump must
be below the maximum operating pressure of the pump. In case of exceeding
maximum operating pressure, the ball bearing and the mechanical seal could be
damaged or lifetime could decrease.
P Inlet + P at 0 flow ≤ Pmax pump
See pump rating plate to know the maximum operating pressure: Pmax
Temperature range
Liquid temperatures -20°C to +120°C
-30°C to +120°C (if full stainless steel)
-15°C to + 90°C (Viton version for O’ring and mechanical seal)
Ambient tempereature -15° to +50°C (other temperature on request)
Electrical data
Motor efficiency Motor according to IEC 60034-30

Technical data en
Installation and operating instructions Wilo-Helix V, FIRST V, 2.0-VE 22-36-52 15
Motor Protection index IP55
Insulation class 155 (F)
Frequency See pump rating plate
Electrical voltage
Capacitor value (μF) in single-phase
version
Other data
Humidity < 90% without condensation
Altitude < 1000 m (> 1000m on request)
Maximum suction head According to pump’s NPSH
Sound pressure level dB(A) 0/+3 dB(A)
Power (kW)
0.37 0.55 0.75 1.1 1.5 2.2 3 4 5.5 7.5 11 15 18.5 22 30 37 45
50H
z
56 57 57 58 58 62 64 68 69 69 71 71 74 74 76 76 76
60H
z
60 61 61 63 63 67 71 72 74 74 78 78 81 81 84 84 84
5.3 Scope of delivery Complete unit
ƒMultistage pump
ƒInstallation and operating instructions
ƒInstallation and operating instructions for drive
5.4 Accessories Original accessories are available for HELIX range:
Designation Article n°
2x round counterflanges in stainless steel 1.4404 PN16 – DN50 4038587
2x round counterflanges in stainless steel 1.4404 PN25 – DN50 4038589
2x round counterflanges in steel PN16 – DN50 4038585
2x round counterflanges in steel PN25 – DN50 4038588
2x round counterflanges in stainless steel 1.4404 PN16 – DN65 4038592
2x round counterflanges in stainless steel 1.4404 PN25 – DN65 4038594
2x round counterflanges in steel PN16 – DN65 4038591
2x round counterflanges in steel PN25 – DN65 4038593
2x round counterflanges in stainless steel 1.4404 PN16 – DN80 4073797
2x round counterflanges in stainless steel 1.4404 PN25 – DN80 4073799
2x round counterflanges in steel PN16 – DN80 4072534
2x round counterflanges in steel PN25 – DN80 4072536
Bypass kit 25 bar 4124994
Bypass kit (with pressure gauge 25 bar) 4124995
Baseplate with dampers for pumps up to 5.5 kW 4157154
The use of new accessories is recommended.
Please contact your Wilo sales office for full accessories list.

en Description and function
16 WILO SE 02/2022
6 Description and function
6.1 Product description Fig. 1
1. Motor connection bolt
2. Coupling gard
3. Mechanical seal
4. Hydraulic stage casing
5. Impeller
6. Pump shaft
7. Motor
8. Coupling
9. Lantern
10. Tuble liner
11. Flange
12. Pump housing
13. Base plate
Fig. 2, 3
1. Strainer
2. Pump suction valve
3. Pump discharge valve
4. Check valve
5. Drain + priming plug
6. Air bleed screw + Filling plug
7. Tank
8. Foundation block
9. In option: pressure plugs (a-suction, b-discharge)
10. Lifting hook
6.2 Design of product ƒHelix pumps are vertical high pressure non-self priming pumps with inline connec-
tion based on multistage design.
ƒHelix pumps combine use of both high efficiency hydraulics and motors (if any).
ƒAll metallic parts in contact with water are made of stainless steel or grey cast iron.
ƒFor aggressive fluid, special versions exist with stainless steel only for all wetted
components.
ƒHelix pumps are equipped with a simple mechanical seal or with a cartridge seal to
facilitate maintenance.
ƒIn addition, for heaviest motor, a specific coupling allows to change this seal
without removing the motor.
ƒDepending on the model, the pump casing is equipped with additional connections
for connecting accessories (Fig. 10).
ƒHelix lantern design integrates an additional ball bearing that withstand hydraulic
axial forces: this allows the pump to use a fully standard motor.
ƒSpecial handling devices are integrated in order to facilitate pump installation (Fig.
8).
7 Installation and electrical con-
nection
Installation and electrical work in compliance with any local codes and by qualified
personnel only.
WARNING
Bodily injury!
Existing regulations for the prevention of accidents must be observed.

Installation and electrical connection en
Installation and operating instructions Wilo-Helix V, FIRST V, 2.0-VE 22-36-52 17
WARNING
Electrical shock hazard
Dangers caused by electrical energy must be excluded.
7.1 Commissioning Unpack the pump and dispose of the packaging in an environmentally-responsible
manner.
7.2 Installation The pump must be installed in a dry, well-ventilated and frost-free place.
CAUTION
Possible damage of the pump!
Dirt and solder drops in to the pump body can effect the pump operation.
• It is recommended that any welding and soldering work be done before installing
the pump.
• Thoroughly flush the system out before installing the pump.
ƒThe pump must be installed in an easily accessible position to facilitate inspection
or replacement.
ƒFor heavy pumps, install a lifting hook (Fig. 2, item 10) above the pump in order to
ease its disassembly.
WARNING
Risk of accident by hot surfaces!
The pump must be positioned so that someone cannot come into contact with the
hot pump surfaces while operation.
ƒInstall the pump in a dry place protected from frost, on a flat concrete block using
appropriate accessories. If possible, use an insulating material under the concrete
block (cork or reinforced rubber) to avoid any noise and vibration transmission into
the installation.
WARNING
Risk of fall!
The pump must be correctly screwed to the ground.
WARNING
Risk of fall!
It is forbidden to remove the 4 screws securing the base plate (Fig.1, item 13) to the
pump housing (Fig.1, item 12) for pump versions with the material code 2 = Modular
pump housing Stainless steel 1.4409 (AISI 316L) .
ƒPlace the pump where it will be easy to reach, to facilitate inspection and removal
work. The pump must always be installed perfectly upright on a sufficiently heavy
concrete base.
WARNING
Risk of parts inside the pump!
Take care to remove closure members of the pump housing before installation.

en Installation and electrical connection
18 WILO SE 02/2022
NOTICE
Each pumps could be tested regarding hydraulic features in factory, some water may
remain in them. It is recommended for hygienic purposes, to carry out a rinsing of
the pump before any using with potable water supply.
ƒThe installation and connection dimensions are given Fig. 4.
ƒLift the pump carefully by using the integrated hooks rings, if necessary with a
hoist and suitable slings according to the current hoist guidelines.
WARNING
Risk of fall!
Take care to pump fixations especially for the highest pumps whose centre of grav-
ity may lead to risk during pump handling.
WARNING
Risk of fall!
Use integrated rings only if they are not damaged (no corrosion ...). Replace them if
needed.
WARNING
Risk of fall!
The pump must be never carried by using motor hooks: these are only designed to
lift the motor alone.
7.3 Pipe connection ƒConnect the pump to the pipes by using appropriate counterflanges, bolts, nuts
and gaskets.
CAUTION
Tightening of screws or bolts must not exceed 80 N.m.
Use of impact wrench is prohibited.
ƒThe circulation sense of the fluid is indicated on the identification label of the
pump.
ƒPump must be installed in such a way that it is not stressed by the pipework. The
pipes must be attached so that the pump does not bear their weight.
ƒIt is recommended that isolation valves be installed on the suction and discharge
side of the pump.
ƒUse of expansion joints may mitigate noise and vibration of the pump.
ƒAs regards the nominal cross-section of the suction pipe, we recommend a cross-
section at least as large as that of the pump connection.
ƒA check valve could be placed on the discharge pipe in order to protect the pump
against hammer shock.
ƒFor direct connection to a public drinking water system, the suction pipe must also
have a check valve and a guard valve.
ƒFor indirect connection via a tank, the suction pipe must have a strainer to keep
any impurities out of the pump and a check valve.
ƒFor indirect connection via a tank, the suction pipe must have a strainer to keep
any impurities out of the pump and a check valve.
ƒIn case of half flanges pump design, it is recommended to connect the hydraulic
network and then keep out the plastic fixation links to prevent any leakage risk.
7.4 Motor connection for bare-shaft
pump (without motor)
ƒRemove coupling guards.

Commissioning en
Installation and operating instructions Wilo-Helix V, FIRST V, 2.0-VE 22-36-52 19
NOTICE
Helix pumps are equipped with captive screws as required in the Machinery Direct-
ive.
ƒInstall the motor on the pump by using screws (FT lantern size – see product des-
ignation) or bolts, nuts and handling devices (FF lantern size – see product desig-
nation) provided with the pump : check motor power and dimension in Wilo cata-
logue.
NOTICE
Depending on fluid characteristics, motor power could be modified. Contact The
Wilo Customer Services if necessary.
ƒClose the coupling guards by screwing all screws provided with the pump.
7.5 Electrical connection
WARNING
Electrical shock hazard!
Dangers caused by electrical energy must be excluded.
• Electrical work by a qualified electrician only!
• All electrical connections must be performed after the electrical supply has been
switched off and secured against unauthorized switching.
• For safe installation and operation a proper grounding of the pump to the power
supply’s grounding terminals is required.
ƒCheck that operating current, voltage and frequency used comply with motor plat-
ing data.
ƒThe pump must be connected to the power supply by a solid cable equipped with a
grounded plug-connection or a main power switch.
ƒThree-Phase motors must be connected to an approved safety switch. The set
nominal current must correspond to the electrical data on the motor name plate.
ƒThe supply cable must be laid so that it never touches the pipework and/or the
pump and motor casing.
ƒThe pump/installation should be grounded in compliance with local regulations. A
ground fault interrupter can be used as extra protection.
ƒThe mains connection must be in accordance with the connection plan (Fig. 5).
ƒThree-phase motors should be protected by a circuit-breaker for the IE class of the
motors. Current setting should be adapted to the pump usage, without exceeding
the value Imax written on the motor nameplate.
7.6 Operation with frequency con-
verter
ƒMotors used can be connected to a frequency converter in order to adapt pump
performance to duty point.
ƒThe converter must not generate voltage peaks at motor terminals higher than
850V and dU/dt slope higher than 2500 V/μs.
ƒIn case of higher value, an appropriate filter must be used: contact converter man-
ufacturer for this filter definition and selection.
ƒStrictly follow instructions provided by the converter manufacturer data sheet for
installation.
ƒMinimum variable speed should not be set below 40% of pump nominal speed.
8 Commissioning Unpack the pump and dispose of the packaging in an environmentally-responsible
manner.
8.1 System filling - Venting
CAUTION
Possible damage of the pump!
Never operate the pump dry.
The system must be filled before starting the pump.

en Commissioning
20 WILO SE 02/2022
Air evacuation process – Pump with sufficient supply pressure (Fig. 3)
ƒClose the two guard valves (2, 3).
ƒUnscrew the venting screw from filling plug (6a).
ƒSlowly open the guard valve on the suction side (2).
ƒRetighten the venting screw when air escapes at the venting screw and the
pumped liquid flows (6a).
WARNING
Risk of scalding!
When the pumped liquid is hot and the pressure high, the stream escaping at the
venting screw may cause burns or other injuries.
ƒOpen the guard valve on the suction side completely (2).
ƒStart the pump and check if direction of rotation matches the one printed on pump
plating. If this is not the case, interchange two phases in the terminal box.
CAUTION
Possible damage of the pump
A wrong direction of rotation will cause bad pump performances and possibly coup-
ling damage.
ƒOpen the guard valve on the discharge side (3).
Air evacuation process – Pump in suction (Fig. 2)
ƒClose the guard valve on the discharge side (3).
Open the guard valve on the suction side (2).
ƒRemove the filling plug (6b).
ƒOpen the drain-priming plug not completely (5b).
ƒFill the pump and the suction pipe with water.
ƒMake sure that there is no air in the pump and in the suction pipe : refilling until
complete removal of air is required.
ƒClose the filling plug with air bleed screw (6b).
ƒStart the pump and check if direction of rotation matches the one printed on pump
plating. If this is not the case, interchange two phases in the terminal box.
CAUTION
Possible damage of the pump
A wrong direction of rotation will cause bad pump performances and possibly coup-
ling damage.
ƒOpen the guard valve on the discharge side a little (3).
ƒUnscrew the air bleed screw from filling plug for air venting (6a).
ƒRetighten the air-bleed screw when air escapes at the air bleed screw and the
pumped liquid flows.
WARNING
Risk of scalding
When the pumped liquid is hot and the pressure high, the stream escaping at the air
bleed screw may cause burns or other injuries.
ƒOpen the guard valve on the discharge side completely (3).
ƒClose the drain-priming plug (5a).
8.2 Starting up
CAUTION
Possible damage of the pump
The pump must not operate at zero flow (closed discharge valve).