Wilo Atmos GIGA-N User manual

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Wilo-Atmos GIGA-N
6074707 • Ed.01/2019-04
en Installation and operating instructions

en
Installation and operating instructions Wilo-Atmos GIGA-N 3
Table of contents
1 General information ................................................................................................................................................................. 5
1.1 About these instructions ..................................................................................................................................................................................5
1.2 Copyright ............................................................................................................................................................................................................5
1.3 Subject to change..............................................................................................................................................................................................5
2 Safety......................................................................................................................................................................................... 5
2.1 Identification of safety instructions................................................................................................................................................................5
2.2 Personnel qualifications....................................................................................................................................................................................6
2.3 Electrical work ....................................................................................................................................................................................................7
2.4 Transport.............................................................................................................................................................................................................7
2.5 Installing/dismantling........................................................................................................................................................................................7
2.6 During operation ................................................................................................................................................................................................7
2.7 Maintenance tasks.............................................................................................................................................................................................8
2.8 Drive: IEC standard motor.................................................................................................................................................................................9
2.9 Operator responsibilities...................................................................................................................................................................................9
3 Application/use......................................................................................................................................................................... 9
3.1 Intended use.......................................................................................................................................................................................................9
3.2 Improper use.......................................................................................................................................................................................................9
4 Product description................................................................................................................................................................ 10
4.1 Design............................................................................................................................................................................................................... 10
4.2 Operation with frequency converter............................................................................................................................................................ 10
4.3 Technical data .................................................................................................................................................................................................10
4.4 Type key........................................................................................................................................................................................................... 11
4.5 Scope of delivery............................................................................................................................................................................................. 11
4.6 Accessories ...................................................................................................................................................................................................... 11
4.7 Anticipated noise levels................................................................................................................................................................................. 11
4.8 Permissible forces and torques on the pump flanges................................................................................................................................ 13
5 Transportation and storage................................................................................................................................................... 14
5.1 Delivery............................................................................................................................................................................................................. 14
5.2 Transport.......................................................................................................................................................................................................... 14
5.3 Storage ............................................................................................................................................................................................................. 15
6 Installation and electrical connection .................................................................................................................................. 16
6.1 Personnel qualifications................................................................................................................................................................................. 16
6.2 Operator responsibilities................................................................................................................................................................................ 16
6.3 Preparing the installation............................................................................................................................................................................... 16
6.4 Setting up the pump by itself (variantB, Wilo variant key) ...................................................................................................................... 16
6.5 Installing the pump unit on a base ............................................................................................................................................................... 17
6.6 Pipework........................................................................................................................................................................................................... 18
6.7 Aligning the unit.............................................................................................................................................................................................. 19
6.8 Electrical connection...................................................................................................................................................................................... 23
7 Commissioning........................................................................................................................................................................ 24
7.1 Personnel qualifications................................................................................................................................................................................. 25
7.2 Filling and venting........................................................................................................................................................................................... 25
7.3 Checking the direction of rotation...............................................................................................................................................................25
7.4 Switching on the pump..................................................................................................................................................................................26
7.5 Switching frequency....................................................................................................................................................................................... 26
8 Shutdown................................................................................................................................................................................. 27
8.1 Switching off the pump and temporary shutdown.................................................................................................................................... 27
8.2 Shutdown and storage ................................................................................................................................................................................... 27
9 Maintenance/repair ................................................................................................................................................................ 27
9.1 Personnel qualifications................................................................................................................................................................................. 28
9.2 Operation monitoring..................................................................................................................................................................................... 28
9.3 Maintenance tasks.......................................................................................................................................................................................... 29

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4 WILO SE 2019-04
9.4 Draining and cleaning..................................................................................................................................................................................... 29
9.5 Dismantling...................................................................................................................................................................................................... 29
9.6 Installation ....................................................................................................................................................................................................... 31
10 Faults, causes and remedies .................................................................................................................................................. 34
10.1 Faults ................................................................................................................................................................................................................ 35
10.2 Causes and remedies......................................................................................................................................................................................35
11 Spare parts............................................................................................................................................................................... 37
11.1 Spare parts list.................................................................................................................................................................................................37
12 Disposal.................................................................................................................................................................................... 38
12.1 Oils and lubricants........................................................................................................................................................................................... 38
12.2 Water-glycol mixture..................................................................................................................................................................................... 38
12.3 Protective clothing .........................................................................................................................................................................................38
12.4 Information on the collection of used electrical and electronic products.............................................................................................. 38

General information en
Installation and operating instructions Wilo-Atmos GIGA-N 5
1 General information
1.1 About these instructions
These installation and operating instructions are an integral part of the device. Read
these instructions before commencing work and keep them in an accessible place at all
times. Strict adherence to these instructions is a requirement for intended use and cor-
rectly operating the device. All specifications and markings on the device must be ob-
served. These installation and operating instructions correspond to the relevant version
of the device and the underlying safety standards that apply at the time of going to
print.
The language of the original operating instructions is German. All other languages of
these instructions are translations of the original operating instructions.
1.2 Copyright
These installation and operating instructions have been copyrighted by the manufac-
turer. The contents, of whatever type, may not be reproduced or distributed, or used for
purposes of competition and shared with others.
1.3 Subject to change
The manufacturer reserves the right to make technical modifications to the device or
individual components. The illustrations used may differ from the original and are in-
tended as an example representation of the device.
2 Safety
This chapter contains basic information for the individual phases of the life cycle. Fail-
ure to observe this information carries the following risks:
▪Injury to persons from electrical, mechanical and bacteriological factors as well as elec-
tromagnetic fields
▪Environmental damage from discharge of hazardous substances
▪Property damage
▪Failure of important functions of the product
Failure to observe the information contained herein will result in the loss of claims for
damages.
The instructions and safety instructions in the other chapters must also be ob-
served!
2.1 Identification of safety instruc-
tions
These installation and operating instructions set out safety instructions for preventing
personal injury and damage to property. These safety instructions are shown differ-
ently:
▪Safety instructions relating to personal injury start with a signal word, are preceded by
a corresponding symbol and are shaded in grey.
DANGER
Type and source of the danger!
Consequences of the danger and instructions for avoidance.
▪Safety instructions relating to property damage start with a signal word and are dis-
played without a symbol.
CAUTION
Type and source of the danger!
Consequences or information.
Signal words
▪DANGER!
Failure to observe the safety instructions will result in serious injuries or death!

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6 WILO SE 2019-04
▪WARNING!
Failure to follow the instructions can lead to (serious) injuries!
▪CAUTION!
Failure to follow the instructions can lead to property damage and a possible total loss.
▪NOTICE!
Useful information on handling the product
Symbols
These instructions use the following symbols:
Danger – high voltage
General warning symbol
Warning – danger of crushing
Warning – risk of cutting injuries
Warning – hot surfaces
Warning – high pressure
Warning – suspended loads
Personal protective equipment: wear a safety helmet
Personal protective equipment: wear foot protection
Personal protective equipment: wear hand protection
Personal protective equipment: wear mouth protection
Personal protective equipment: wear safety goggles
Useful information
2.2 Personnel qualifications
Personnel must:
▪Be instructed about locally applicable regulations governing accident prevention.
▪Have read and understood the installation and operating instructions.
Personnel must have the following qualifications:
▪Electrical work: A qualified electrician must carry out the electrical work.
▪Installation/dismantling must be carried out by a qualified technician who is trained in
the use of the necessary tools and fixation materials.

Safety en
Installation and operating instructions Wilo-Atmos GIGA-N 7
Definition of “qualified electrician”
A qualified electrician is a person with appropriate technical education, knowledge and
experience who can identify and prevent electrical hazards.
2.3 Electrical work
▪Electrical work must be carried out by a qualified electrician.
▪When connecting to the mains, comply with the locally applicable laws and regulations
of the local energy supply company.
▪Before commencing work, disconnect the device from the mains and secure it against
being switched on again without authorisation.
▪Train personnel on how to make the electrical connection as well as on the methods for
switching off the device.
▪Observe the technical information in these installation and operating instructions as
well as on the rating plate.
▪Earth the device.
▪Observe the manufacturer’s specifications when connecting to electrical switching sys-
tems.
▪Comply with the specifications on electro-magnetic compatibility when using elec-
tronic start-up controllers (e.g. soft starter or frequency converter). If required, take
into account special measures (shielded cables, filters, etc.).
▪Replace defective connection cables. Contact customer service.
2.4 Transport
▪Wear protective equipment:
– Safety gloves for protection against cuts
– Safety shoes
– Sealed safety goggles
– Safety helmet (when using lifting equipment)
▪Only use legally specified and approved lifting gear.
▪Select lifting gear based on the available conditions (weather, attachment point, load,
etc.).
▪Always attach the lifting gear to the designated attachment points (lifting eyes).
▪Position the lifting equipment in a way that ensures stability during use.
▪When using lifting equipment, a second person must be present to coordinate the pro-
cedure if required (e.g. if the operator’s field of vision is blocked).
▪Persons must not stand underneath suspended loads. Do not move suspended loads
over workplaces where people are present.
Please note the following information during transport and prior to installation:
▪Do not reach into suction ports, discharge ports or other openings.
▪Avoid the penetration of foreign objects. To this end, leave the protective covers or
packaging on until they have to be removed for installation.
▪Packaging and covers may be removed from suction or outlet openings for inspection
purposes. They must be put back on afterwards to protect the pump and ensure safety.
2.5 Installing/dismantling
▪Wear the following protective equipment:
– Safety shoes
– Safety gloves for protection against cuts
– Safety helmet (when using lifting equipment)
▪Comply with laws and regulations on work safety and accident prevention in force at
the site of installation.
▪The procedure described in the installation and operating instructions for shutting
down the product/unit must be strictly observed.
▪Disconnect the device from the mains and secure it against being switched on again
without authorisation.
▪All rotating parts must be at a standstill.
▪Close the gate valve in the inlet and in the pressure pipe.
▪Provide adequate aeration in enclosed spaces.
▪Clean the device thoroughly. Disinfect devices that use fluids hazardous to health!
▪Make sure that there is no risk of explosion when carrying out any type of welding work
or work with electrical devices.
2.6 During operation
▪Wear protective equipment:
– Safety shoes
– Safety helmet (when using lifting equipment)

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8 WILO SE 2019-04
▪The work area in which the device is used is not a recreational area. No persons are al-
lowed in the work area during operation.
▪The operator must report any faults or irregularities to a line manager immediately.
▪If hazardous defects occur, the operator must immediately deactivate the device. Haz-
ardous defects include:
– Malfunction of safety and monitoring devices
– Damage to housing parts
– Damage to electrical equipment
▪Open all gate valves in the piping on the suction and pressure side.
▪Only carry out the maintenance tasks described in these installation and operating in-
structions.
▪Only genuine spare parts from the manufacturer may be used for repairs, replacements,
add-ons and modifications. Use of parts other than original parts releases the manufac-
turer from any liability.
▪Collect any leakage of fluids and operating fluids immediately and dispose of it accord-
ing to the locally applicable guidelines.
▪Tools and other objects should only be kept in their designated places.
Thermal hazards
Most drive surfaces can become hot during operation. The areas of the stuffing box and
bearing bracket on the pump can become hot in the event of a malfunction or incorrect
setting.
The surfaces in question also remain hot after switching off the unit. These surfaces
may only be touched with extreme caution. Wear protective gloves if it is essential to
touch hot surfaces.
Make sure that the drained water is not too hot for more intensive contact with skin.
Introduce appropriate equipment to protect components that may become hot against
accidental contact.
Hazard due to articles of clothing or other objects being caught
To avoid the dangers presented by the rotating parts of the device:
▪Do not wear loose or frayed clothing or jewellery.
▪Do not dismantle devices for protecting against accidental contact with moving parts
(e.g. coupling guard).
▪Only put the device into operation once this protection is in place.
▪The devices for protecting against accidental contact with moving parts may only be
removed when the system is at a standstill.
Hazards due to noise
Observe the sound pressure specifications on the motor rating plate. The sound pres-
sure value of the pump is generally about the same value as that of the motor +2dB(A).
Observe the applicable health and safety regulations. If the device is operated under
normal operating conditions, the operator must measure the sound pressure.
Sound pressure levels of 80dB(A) and above must be noted in the work regulations!
The operator must also introduce the following preventative measures:
▪Inform the operating personnel
▪Provide hearing protection
For a sound pressure level of 85dB(A) and above, the operator must:
▪Make it a mandatory requirement to wear hearing protection
▪Demarcate the noisy areas.
▪Take measures to reduce noise (e.g. insulation, noise barriers)
Leakages
Observe local standards and regulations. Avoid pump leakages to protect persons and
the environment against hazardous (explosive, toxic or hot) substances.
Ensure that a dry run of the pump is not possible. A dry run can damage the shaft seal
and thereby cause leakages.
2.7 Maintenance tasks
▪Wear the following protective equipment:
– Sealed safety goggles
– Safety shoes
– Safety gloves for protection against cuts

Application/use en
Installation and operating instructions Wilo-Atmos GIGA-N 9
▪Only carry out the maintenance tasks described in these installation and operating in-
structions.
▪Only original parts from the manufacturer may be used for maintenance and repairs.
Use of parts other than original parts releases the manufacturer from any liability.
▪Collect any leakage of fluid and operating fluid immediately and dispose of it according
to the locally applicable guidelines.
▪Store tools at the designated locations.
▪After completing work, reattach all safety and monitoring devices and check that they
function properly.
2.8 Drive: IEC standard motor
The hydraulics have a standardised connection flange for installing an IEC standard mo-
tor. See the technical data for the performance data (e.g. size, construction, hydraulic
rated power, speed) needed to select a motor.
2.9 Operator responsibilities
The operator must:
▪Provide the installation and operating instructions in a language which the personnel
can understand.
▪Make sure that personnel are suitably trained for the specified work.
▪Ensure that safety and information signs mounted on the device are always legible.
▪Train personnel with regard to the operating principles of the system.
▪Eliminate any risk from electrical current.
▪Equip hazardous components (extremely cold, extremely hot, rotating, etc.) with an on-
site guard.
▪Demarcate and cordon off the hazardous area.
▪Define personnel responsibilities to ensure safe working practice.
Children and persons younger than 16years or with reduced physical, sensory or mental
capacities or limited experience are prohibited from handling the device! Persons under
the age of 18 must be supervised by a technician.
3 Application/use
3.1 Intended use
The glanded pumps in the Wilo-Atmos GIGA-N series are intended for use as circulators
in building services.
The Wilo-Atmos GIGA-N pumps may only be used for:
▪Hot-water heating systems
▪Cooling and cold water circulation systems
▪Drinking water systems (special version)
▪Industrial circulation systems
▪Heat carrier circuits
▪Irrigation
The pumps are only approved for the fluids specified in the “Technical data” section.
3.2 Improper use
WARNING!Misuse of the pump can lead to dangerous situations and damage.
▪Never use with fluids that have not been approved by the manufacturer.
▪Non-permitted substances in the fluid can destroy the pump. Abrasive solids (e.g. sand)
increase pump wear.
▪Highly flammable materials/fluids should always be kept at a safe distance from the
device.
▪Never allow unauthorised persons to carry out work.
▪Never operate the pump beyond the specified limits of use.
▪Never carry out unauthorised conversions.
▪Use authorised accessories and genuine spare parts only.
Typical installation locations are technical rooms within the building with other do-
mestic installations. No provision has been made for direct installation of the pump in
rooms used for other purposes (residential and work rooms).
Outdoor installation requires a corresponding, special version (motor with anti-con-
densation heater).

en Product description
10 WILO SE 2019-04
Intended use also includes compliance with this manual. Any other use is regarded as
non-compliant with the intended use.
4 Product description
4.1 Design
The Wilo-Atmos GIGA-N pump is a single-stage back pull-out-centrifugal pump with
spiral housing for horizontal installation. Power and dimensions in accordance with
EN733.
Suitable Wilo control devices (e.g. Comfort control system, CC-HVAC) can control the
power of the pumps continuously. This allows optimisation of the pump output for the
demands of the installation and particularly economically efficient pump operation.
4.1.1 Hydraulics
The pump consists of a radially divided spiral housing (optionally with replaceable neck
rings) and cast-on pump support feet. The impeller is a closed radial impeller. The pump
shaft is supported by grease-lubricated radial ball bearings.
4.1.2 Motor
The system is driven by IEC standard motors in a three-phase current version.
NOTICE
Use a heat-resistant mains connecting cable in systems where fluid temperatures
exceed 90°C!
4.1.3 Seal
The fluid pump is sealed via a mechanical seal in accordance with EN12756.
4.2 Operation with frequency con-
verter
Operation on the frequency converter is permitted. Refer to the documentation from
the motor manufacturer for the relevant requirements and observe its contents.
4.3 Technical data
General
Date of manufacture [MFY] See rating plate
Mains connection [U/f] See motor rating plate
Power consumption [P1]See motor rating plate
Rated power [P2]See motor rating plate
Rated speed [n] See rating plate
Max. delivery head [H] See rating plate
Max. volume flow [Q] See rating plate
Permissible fluid temperature [t] -20°C to +140°C
Permissible ambient temperature
[t]
+40°C
Permissible operating pressure
[Pmax]
16bar
Flanges PN16 in accordance withEN1092-2
Permissible fluids
– Heating water in accordance with VDI2035
– Cooling/cold water
– Water-glycol mixture up to 40% vol.
Protection class IP55
Insulation class [Cl.] F

Product description en
Installation and operating instructions Wilo-Atmos GIGA-N 11
Motor protection See manufacturer’s documentation
Special version or with auxiliary equipment (at additional charge)
Permissible fluids
– Heating water according to VDI2035 Cooling/
cold water
– Water-glycol mixture up to 40% vol.
Special voltages/frequencies Pumps with motors with different voltages or
other frequencies are available on request
Additional information CH
Approved fluids for heating
pumps
– Heating water (in accordance with VDI2035/
VdTÜV Tch 1466/CH: in accordance with
SWKIBT102-01)
– No oxygen binding agents, no chemical sealant.
– Ensure enclosed system from corrosion per-
spective. In accordance with VDI2035 (CH:
SWKIBT102-01); fix leaky spots.
Statement of date of manufacture
The date of manufacture is stated in accordance with ISO8601: JJJJWww
▪JJJJ = year
▪W = abbreviation for week
▪ww = calendar week
4.4 Type key
Example: Wilo-Atmos GIGA-N 040/200-11/2
Atmos Product family
GIGA Series
NConstruction
040 Nominal diameter DN of pressure port
200 Nominal diameter of the impeller in mm
11 Rated motor power P2 in kW
2Number of poles
4.5 Scope of delivery
Complete unit
▪Atmos GIGA-N pump
▪Baseplate
▪Coupling and coupling guard
▪With or without electric motor
▪Installation and operating instructions
Pump by itself:
▪Atmos GIGA-N pump
▪Bearing bracket without baseplate
▪Installation and operating instructions
4.6 Accessories
Accessories have to be ordered separately. For a detailed list, consult the catalogue and
spare parts documentation.
4.7 Anticipated noise levels
4.7.1 Pump with three-phase motor,
50Hz without speed control
Motor power PN [kW] Measuring surface sound-pressure level Lp, A [dB(A)] 1)
2-pin (2900rpm) 4-pin (1450rpm)
0.37 – 45
0.55 58 46

en Product description
12 WILO SE 2019-04
Motor power PN [kW] Measuring surface sound-pressure level Lp, A [dB(A)] 1)
2-pin (2900rpm) 4-pin (1450rpm)
0.75 61 46
1.1 61 51
1.5 64 51
2.2 64 55
369 55
466 58
5.5 64 58
7.5 72 63
972 65
11 72 65
15 72 65
18.5 72 70
22 77 70
30 80 71
37 80 72
45 77 72
55 76 66
75 79 71
90 79 71
110 79 73
132 – 73
160 – 73
200 – 75
1) Spatial mean value of sound-pressure levels within a cube-shaped measuring area at
a distance of 1m from the surface of the motor
Table1: Anticipated noise levels for standard pump (50Hz)
4.7.2 Pump with three-phase motor,
60Hz without speed control
Motor power PN [kW] Measuring surface sound-pressure level Lp, A [dB(A)] 1)
2-pin (2900rpm) 4-pin (1450rpm)
0.37 – 49
0.55 62 50
0.75 62 53
1.1 64 53
1.5 64 53
2.2 70 56
370 58
3.7 73 58
4.5 71 58
5.5 71 60
7.5 74 60
9.2 74 60
11 74 66
15 74 66
18.5 74 66

Product description en
Installation and operating instructions Wilo-Atmos GIGA-N 13
Motor power PN [kW] Measuring surface sound-pressure level Lp, A [dB(A)] 1)
2-pin (2900rpm) 4-pin (1450rpm)
22 74 66
30 78 68
37 78 68
45 81 69
55 81 70
75 81 75
90 83 75
110 83 75
132 83 77
150 83 77
185 83 80
200 86 80
220 86 80
260 86 80
300 86 80
330 86 80
370 – 80
1) Spatial mean value of sound-pressure levels within a cube-shaped measuring area at
a distance of 1m from the surface of the motor
Table2: Anticipated noise levels for standard pump (60Hz)
4.8 Permissible forces and torques on
the pump flanges
Z
Y
X
Y
X
Z
Fig.1: Permissible forces and torques on the
pump flanges–pump made of grey cast iron
DN Forces F [N] Torques M [Nm]
FXFYFZΣ Forces F MXMYMZΣ Torques M
Pressure port
32 315 298 368 578 385 263 298 560
40 385 350 438 683 455 315 368 665
50 525 473 578 910 490 350 403 718
65 648 595 735 1155 525 385 420 770
80 788 718 875 1383 560 403 455 823
100 1050 945 1173 1838 613 438 508 910
125 1243 1120 1383 2170 735 525 665 1068
150 1575 1418 1750 2748 875 613 718 1278
Suction port
50 578 525 473 910 490 350 403 718
65 735 648 595 1155 525 385 420 770
80 875 788 718 1383 560 403 455 823
100 1173 1050 945 1838 613 738 508 9100
125 1383 1243 1120 2170 735 525 665 1068
150 1750 1575 1418 2748 875 613 718 1278
200 2345 2100 1890 3658 1138 805 928 1680
Values in acc. with ISO/DIN5199–class II (2002)–AppendixB, Family no. 1A.
Table3: Permissible forces and torques on the pump flanges

en Transportation and storage
14 WILO SE 2019-04
If not all working loads reach the maximum permitted values, one of these loads may
exceed the normal limit value. This is under the condition that the following additional
conditions are fulfilled:
▪All force and torque components are limited to 1.4times the maximum permitted value.
▪The forces and torques acting on each flange meet the requirements of the compensa-
tion equation.
Fig.2: Compensation equation
Σ Feffective and Σ Meffective are the arithmetic sums of the effective values of both pump
flanges (inlet and outlet). Σ Fmax. permitted and Σ Mmax. permitted are the arithmetic sums of the
maximum permitted values of both pump flanges (inlet and outlet). The algebraic signs
of Σ F and Σ M are not taken into consideration in the compensation equation.
5 Transportation and storage
5.1 Delivery
The pump is secured to a pallet ex works and is protected against dirt and moisture.
Check the shipment immediately on receipt for defects (damage, completeness). De-
fects must be noted on the freight documentation. Any defects must be notified to the
transport company or the manufacturer immediately on the day of receipt of shipment.
Subsequently notified defects can no longer be asserted.
5.2 Transport
DANGER
Risk of fatal injury due to suspended loads!
Never allow anyone to stand under suspended loads! Danger of (serious) injuries
caused by falling parts. Loads may not be carried over work places where people are
present!
The safety zone must be marked so that there is no danger when the load (or part of
it) slips away or if the lifting device snaps or is ripped off.
Loads must never be suspended for longer than necessary.
Accelerations and braking during the lifting operation must be performed in a way
that rules out any danger to people.
WARNING
Hand and foot injuries due to lack of protective equipment!
Danger of (serious) injuries during work. Wear the following protective equipment:
• Safety shoes
• Safety gloves for protection against cuts
• Sealed safety goggles
• Safety helmet must be worn if lifting equipment is used!
NOTICE
Use only properly functioning lifting equipment!
Use only properly functioning lifting equipment to lift and lower the pump. Ensure
that the pump does not become jammed during lifting and lowering. Do not exceed
the maximum bearing capacity of the lifting equipment! Check that lifting equip-
ment is functioning properly before use!

Transportation and storage en
Installation and operating instructions Wilo-Atmos GIGA-N 15
CAUTION
Property damage due to incorrect transport
To ensure proper alignment, all equipment is pre-assembled. If dropped or if im-
properly handled, there is a risk of misalignment or deficient performance due to de-
formations. The pipes and valves will not withstand loads and should not be used to
secure loads in transit.
• Only use permitted lifting gear for transport. Ensure the stability of the load since,
with this particular pump design, the centre of gravity is shifted to the top (top-
heavy).
•Never attach lifting gear to shafts in order to lift the unit.
• Do not use the transport lugs on the pump or motor to lift the entire unit. They are
only meant for transporting the individual components during installation or dis-
mantling.
Only remove the outer packaging at the place of utilisation to ensure that the pump is
not damaged during transport.
CAUTION
Risk of damage due to incorrect packaging.
If the pump is transported again at a later date, it must be packaged so that it cannot
be damaged during transport. Use the original packaging for this, or choose equival-
ent packaging.
5.2.1 Attaching the pump
Fig.3: Attaching the pump
▪Comply with applicable national safety regulations.
▪Use legally specified and approved lifting gear.
▪Select the lifting gear based on the prevailing conditions (weather, attachment point,
load, etc.).
▪Only attach the lifting gear to the attachment point. Fix in place with a shackle.
▪Never feed the lifting gear over or through transport lugs without protection.
▪Never feed the lifting gear over sharp edges without protection.
▪Use lifting equipment with sufficient bearing capacity.
▪The stability of the lifting equipment must be ensured during operation.
▪When using lifting equipment, ensure a second person is present to coordinate the pro-
cedure if required (e.g. if the operator’s field of vision is blocked).
▪When lifting, make sure that the load limit of the lifting gear is reduced when pulling at
an angle. The safety and efficiency of the lifting gear is best guaranteed when all load-
bearing elements are loaded vertically. If necessary, use a lifting arm, to which the lift-
ing gear can be vertically attached.
▪Ensure the load is lifted vertically!
▪Prevent the suspended load from swinging!
5.2.2 Attaching the unit
Fig.4: Attaching the unit
▪Comply with applicable national safety regulations.
▪Use legally specified and approved lifting gear.
▪Select the lifting gear based on the prevailing conditions (weather, attachment point,
load, etc.).
▪Only attach the lifting gear to the attachment point. Fix in place with a shackle.
▪Never feed the lifting gear over or through transport lugs without protection.
▪Never feed the lifting gear over sharp edges without protection.
▪Use lifting equipment with sufficient bearing capacity.
▪The stability of the lifting equipment must be ensured during operation.
▪When using lifting equipment, ensure a second person is present to coordinate the pro-
cedure if required (e.g. if the operator’s field of vision is blocked).
▪When lifting, make sure that the load limit of the lifting gear is reduced when pulling at
an angle. The safety and efficiency of the lifting gear is best guaranteed when all load-
bearing elements are loaded vertically. If necessary, use a lifting arm, to which the lift-
ing gear can be vertically attached.
▪Ensure the load is lifted vertically!
▪Prevent the suspended load from swinging!

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16 WILO SE 2019-04
5.3 Storage
NOTICE
Improper storage can lead to damage to the equipment.
Damage caused by improper storage is not covered by the guarantee or warranty.
▪Requirements at the storage location:
– dry
– clean
– well-ventilated
– free from vibrations
– free from humidity
– free from rapid or extreme changes in temperature
▪Store the product somewhere safe against mechanical damage.
▪Protect the bearings and couplings from sand, gravel and other foreign objects.
▪Lubricate the unit to prevent rust and bearing seizing.
▪Manually rotate the drive shaft several times once a week.
Storage for more than three months
Additional precautionary measures:
▪All rotating parts must be coated with a suitable protective medium to protect them
from rust.
▪If the pump is to be stored for more than a year, consult the manufacturer.
6 Installation and electrical con-
nection
6.1 Personnel qualifications
▪Electrical work: A qualified electrician must carry out the electrical work.
6.2 Operator responsibilities
▪Observe locally applicable accident prevention and safety regulations of professional
and trade associations.
▪Observe all regulations for working with heavy loads and under suspended loads.
▪Provide protective equipment and ensure that the protective equipment is worn by
personnel.
▪Avoid pressure surges!
Pressure surges can occur in long pressure pipes. These pressure surges can lead to the
destruction of the pump!
▪Structural components and foundations must be of sufficient stability in order to allow
the device to be fixed in a secure and functional manner. The operator is responsible for
the provision and suitability of the building/foundation!
▪Check that the available consulting documents (installation plans, design of the operat-
ing space, inflow conditions) are complete and correct.
6.3 Preparing the installation
WARNING
Risk of personal injury and property damage due to improper handling!
• Never set up the pump unit on unfortified surfaces or surfaces that cannot bear
loads.
• The pump should only be installed after completion of all welding and soldering
work.
• Flush the pipe system if required. Dirt can cause the pump to fail.
▪The pumps (in the standard version) must be protected from the weather and installed
in a frost/dust-free, well-ventilated environment that is not potentially explosive.
▪Mount the pump in a readily accessible place. This makes it easier to complete inspec-
tions, maintenance (e.g. mechanical seal change) or replacement in the future.
▪A travelling crane or a device for attaching hoisting gear should be installed above the
set-up site of large pumps.

Installation and electrical connection en
Installation and operating instructions Wilo-Atmos GIGA-N 17
6.4 Setting up the pump by itself
(variantB, Wilo variant key)
When installing a pump by itself, the required coupling guard and baseplate of the
pump manufacturer should be used. In any case, all components must meet the CEreg-
ulations. The coupling guard must be compatible with EN953.
6.4.1 Selecting the motor
Select a motor with sufficient power.
Shaft power <4kW 4kW <P2
<10kW
10kW <P2
<40kW
40kW <P2
Limit value P2
for the motor
25% 20% 15% 10%
Table4: Motor/shaft power
Example:
▪Duty point water: Q=100m3/h; H=35m
▪Efficiency: 78%
▪Hydraulic power: 12.5kW
▪Plank the base and baseplate.
The required limit value for this duty point lies at 12.5kWx1.15=14.3kW. A motor
with a power of 15kW would be the correct choice.
Wilo recommends using a B3motor (IM1001) with base installation, which is compatible
with IEC34-1.
6.4.2 Selecting the coupling
▪To establish the connection between the pump with bearing bracket and motor, use a
flexible coupling.
▪Select the coupling size according to the recommendations of the coupling manufac-
turer.
▪Follow the instructions of the coupling manufacturer.
▪After installation on the base and connecting the pipes, check the coupling alignment
and correct it if necessary. The procedure is described in the chapter “Coupling align-
ment”.
▪After reaching the operating temperature, the coupling alignment must be checked
again.
▪Avoid accidental contact during operation. The coupling must be protected in accord-
ance with EN953.
6.5 Installing the pump unit on a base
CAUTION
Danger of property and material damage!
A missing foundation or incorrect installation of the unit on the base can lead to a
malfunction of the pump. Incorrect installation is not covered by the warranty.
• Only have the pump unit installed by qualified personnel.
• A professional from the concrete sector must be hired for all base work.
6.5.1 Base
Fig.5: Installing the unit on a base
The base must be able to support the unit installed on the baseplate indefinitely. The
base must be level to ensure there is no tension on the baseplate or unit. Wilo recom-
mends using premium, non-shrink concrete of an adequate thickness for manufactur-
ing. This would prevent vibrations from being transmitted.
The base must be able to accommodate the forces, vibrations and impact that occur.
Guidance values for dimensioning the base:
▪Approx. 1.5to 2x heavier than the unit.
▪The width and length should each be about 200mm greater than the baseplate.
The baseplate must not be strained or pulled down on the surface of the base. It must
be supported so that the original alignment is not changed.

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18 WILO SE 2019-04
Prepare drilled holes for the anchor bolts. Position pipe sleeves vertically in the base at
the corresponding points. Diameter of the pipe sleeves: Around 2½x the diameter of
the screws. This allows the screws to be moved in order to achieve their final positions.
Wilo recommends initially pouring the base up to about 25mm below the planned
height. The surface of the concrete base must be well contoured before curing. Remove
the pipe sleeves after the concrete cures.
When the baseplate is poured out, insert steel rods vertically into the base at regular in-
tervals. The required number of steel rods is dependent on the size of the baseplate.
The rods must project into the baseplate by up to 2/3.
6.5.2 Preparing the baseplate for an-
choring
Fig.6: Shims on the base surface
Fig.7: Levelling screws on the base surface
▪Thoroughly clean the base surface.
▪Place shims (approx. 20–25mm thick) on every screw hole on the base surface.
Alternatively, levelling screws can also be used.
▪For a length spacing of the fixation bores ≥800mm, shims should be additionally
placed in the middle of the baseplate.
▪Apply the baseplate and level in both directions with additional shims.
▪Align the unit when installing on the base using a spirit level (at the shaft/pressure
port).
The baseplate must be horizontal; tolerance: 0.5mm per metre.
▪Fit anchor bolts in the provided drilled holes.
NOTICE
The anchor bolts must fit in the fastening bores of the baseplate.
They must meet the relevant standards and be sufficiently long, so that a firm fit in
the base is guaranteed.
Fig.8: Levelling and aligning the baseplate
Fig.9: Anchor bolt
▪Pour in anchor bolts with concrete. After the concrete has set, tighten the anchor bolts
evenly and firmly.
▪Align the unit so that the pipes can be connected to the pump stress-free.
6.5.3 Pouring out the baseplate
The baseplate can be poured out after fixing. The process of pouring out reduces vibra-
tions to a minimum.
▪Wet the base surface before pouring out the concrete.
▪Use a suitable, non-shrink mortar for pouring out.
▪Pour the mortar through the openings in the baseplate. Be sure to avoid hollow spaces.
▪Plank the base and baseplate.
▪After curing, check the anchor bolts for a tight fit.
▪Coat the unprotected surfaces of the base to protect from moisture.

Installation and electrical connection en
Installation and operating instructions Wilo-Atmos GIGA-N 19
6.6 Pipework
The pipe connections of the pump are fitted with dust caps so that no foreign objects
can penetrate during transport and installation.
▪These caps must be removed before connecting pipes.
r
5 x DN
d s
r ≈ 2,5 · (d - 2s)
Fig.10: Connecting the pump without tension,
settling section upstream and downstream of
the pump
CAUTION
Improper pipework/installation can lead to property damage! Welding
beads, cinder and other contaminants can damage the pump!
• The pipes must be sufficiently dimensioned, taking the pump inlet pressure into
account.
• Connect the pump and pipes using suitable gaskets. Take the pressure, temper-
ature and fluid into account. Check the gaskets for proper fitting.
• The pipes must not transfer any forces to the pump. Brace the pipes directly before
the pump and connect them without tension.
• Observe the permissible forces and torques on the pump connecting pieces!
• The expansion of the pipes in the event of a temperature rise is to be compensated
by suitable means.
• Avoid air pockets in piping by means of appropriate installations.
NOTICE
Simplify subsequent work on the unit!
• To ensure the entire unit does not have to be emptied, install a non-return valve
and shut-off devices before and after the pump.
NOTICE
Avoid flow cavitation!
• A settling section must be provided upstream and downstream of the pump in the
form of a straight pipe. The length of the settling section must be at least 5times
the nominal diameter of the pump flange.
▪The pipes and pump must be free of mechanical stress when installed.
▪The pipes must be fixed in such a way that the pump does not have to support the
weight of the pipes.
▪Clean, flush and purge the unit before connecting the pipes.
▪Remove the covers from the suction and discharge ports.
▪If required, install a dirt filter upstream of the pump in the pipe on the suction side.
▪Then connect the pipes to the pump connecting pieces.
6.7 Aligning the unit
CAUTION
Incorrect alignment can result in property damage!
The transport and installation of the pump can affect the alignment. The motor must
be aligned to the pump (not vice versa).
• Check the alignment before the first start.
CAUTION
Changes to the alignment during operation can result in property dam-
age.
The pump and motor are usually aligned at ambient temperature. Thermal expansion
at operating temperature can change the alignment, particularly in the case of very

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20 WILO SE 2019-04
hot fluids.
Adjustment may be required if the pump is required to pump very hot fluids:
• Allow the pump to run at the actual operating temperature.
• Switch off the pump then immediately check the alignment.
Precondition for reliable, smooth and efficient operation of a pump unit is proper align-
ment of the pump and the drive shaft.
Misalignments can be the cause of:
▪excessive noise development during pump operation
▪vibrations
▪premature wear
▪excessive coupling wear
6.7.1 Coupling alignment
∆Ka
)3)2)1
∆Kw
∆Kr
S
max.
Smin. Smin.
S
max.
Fig.11: Coupling alignment without spacer
∆Ka
∆Kw
∆Kr
S2
max.
S2min.
S2
max.
S2min.
)3)2)1
Fig.12: Coupling alignment with spacer
1. Axial displacement (ΔKa) ▪Adjust the gap ΔKa within the permissible range of deviation.
Permissible deviations for dimensions S and S2, see table “Permissible gaps S and S2”
2. Angular displacement (ΔKw) The angular displacement ΔKw can be measured as the difference between the gaps:
ΔS = Smax. – Smin. and/or ΔS2 = S2max. – S2min.
The following condition must be met:
ΔS and/or ΔS2 ≤ ΔSperm. (perm. = permissible; ΔSperm. is dependent on the speed)
If required, the permissible angular displacement ΔKw can be calculated as follows:
ΔKWperm. in RAD = ΔSperm. /DA
ΔKWperm. in GRD = (ΔSperm. /DA) x (180/π)
(with ΔSperm. in mm, DA in mm)
3. Radial displacement (ΔKr) The permissible radial displacement ΔKrperm. can be taken from the table “Maximum per-
missible shaft displacement”. Radial displacement is dependent on the speed. The nu-
merical values in the table and their interim values can be calculated as follows:
ΔKrperm. = ΔSperm. = (0.1+DA/1000) x 40/√n
(with speed n in rpm, DA in mm, radial displacement ΔKrperm. in mm)
Coupling size DA [mm] S [mm] S2 [mm]
68 68 2 ... 4 5
80 80 2 ... 4 5
95 95 2 ... 4 5
110 110 2 ... 4 5
125 125 2 ... 4 5
140 140 2 ... 4 5
160 160 2 ... 6 6
180 180 2 ... 6 6