Wilo CronoLine IL 250 Series User manual

de Einbau- und Betriebsanleitung
en Installation and operating instructions
fr Notice de montage et de mise en service
nl Inbouw- en bedieningsvoorschriften
GB Installation and operating instructions
RUS ????????????????????????????????
2 140 040-Ed.01 / 2013-09
Wilo-CronoLine IL 250...

Demontage der Gleitringdichtung / Unmounting the mechanical seal /
Démontage de la garniture mécanique / Demontage van de mechani-
sche afdichting
Fig. 1 Fig. 2
2
1
1
1
Fig. 3 Fig. 4
Fig. 5 Fig. 6
4
4
1
2
3
2
1
3

Fig. 7 Fig. 8
Fig. 9 Fig. 10
3
2
1

Montage der Gleitringdichtung / Mounting the mechanical seal /
Montage de la garniture mécanique / Montage van de mechanische
afdichting
Fig. 11 Fig. 12
1
Fig. 13 Fig. 14
1
23
Fig. 15 Fig. 16

Fig. 17 Fig. 18
1
2
1
Fig. 19 Fig. 20
Fig. 21 Fig. 22
1
1
2

Motorwechsel / Exchange of Motor / Remplacement du moteur /
Vervanging van de motor
Fig. 23 Fig. 24
1
8x
Fig. 25 Fig. 26
Fig. 27

de Einbau- und Betriebsanleitung 3
en Installation and operating instructions 25
fr Notice de montage et de mise en service 47
nl Inbouw- en bedieningsvoorschriften 69

English
24 WILO SE 09/2013
1 General ..................................................................................................................................................25
2 Safety ....................................................................................................................................................25
2.1 Indication of instructions in the operating instructions .................................................................................25
2.2 Personnel qualifications ......................................................................................................................................26
2.3 Danger in the event of non-observance of the safety instructions ..............................................................26
2.4 Safety consciousness on the job ........................................................................................................................26
2.5 Safety instructions for the operator .................................................................................................................26
2.6 Safety instructions for installation and maintenance work ...........................................................................26
2.7 Unauthorised modification and manufacture of spare parts ..........................................................................27
2.8 Improper use ........................................................................................................................................................27
3 Transport and interim storage ...........................................................................................................27
3.1 Shipping ................................................................................................................................................................27
3.2 Transport for installation/removal purposes ....................................................................................................27
4 Intended use .........................................................................................................................................29
5 Product information ............................................................................................................................29
5.1 Type key ................................................................................................................................................................29
5.2 Technical data ......................................................................................................................................................30
5.3 Scope of delivery .................................................................................................................................................31
5.4 Accessories ...........................................................................................................................................................31
6 Description and function ....................................................................................................................31
6.1 Description of the product .................................................................................................................................31
6.2 Anticipated noise levels ......................................................................................................................................31
7 Installation and electrical connection ...............................................................................................31
7.1 Installation ............................................................................................................................................................32
7.2 Electrical connection ...........................................................................................................................................34
8 Commissioning .....................................................................................................................................36
8.1 Initial commissioning ...........................................................................................................................................36
8.2 Operation ..............................................................................................................................................................37
9 Maintenance .........................................................................................................................................38
9.1 Air supply ..............................................................................................................................................................39
9.2 Maintenance work ...............................................................................................................................................39
9.3 Motor .....................................................................................................................................................................41
9.4 Screw tightening torques ...................................................................................................................................43
10 Faults, causes and remedies ...............................................................................................................43
10.1 Mechanical faults .................................................................................................................................................44
11 Spare parts ...........................................................................................................................................45
12 Disposal ................................................................................................................................................45

English
Installation and operating instructions Wilo-CronoLine IL 250... 25
Installation and operating instructions
1 General
About this document The language of the original operating instructions is German. 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 adherence to these instructions is
a precondition for the proper use and correct operation of the prod-
uct.
The installation and operating instructions correspond to the relevant
version of the product and the underlying safety regulations and
standards valid at the time of going to print.
EC declaration of conformity:
A copy of the EC declaration of conformity is a component of these
operating instructions.
If a technical modification is made on the designs named there with-
out our agreement or the declarations made in the installation and
operating instructions on the safety of the product/personnel are not
observed, this declaration loses its validity.
2Safety These operating instructions contain basic information which must
be adhered to during installation, operation and maintenance. For this
reason, these operating instructions must, without fail, be read by the
service technician and the responsible specialist/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 included under the following main
points.
2.1 Indication of instructions in the
operating instructions
Symbols General danger symbol
Danger due to electrical voltage
NOTE
Signal words DANGER!
Acutely dangerous situation.
Non-observance results in death or the most serious of injuries.
WARNING!
The user can suffer (serious) injuries. 'Warning' implies that (seri-
ous) injury to persons is probable if this information is disregarded.
CAUTION!
There is a danger of damaging the product/unit. 'Caution' implies
that damage to the product is likely if this information is disre-
garded.
NOTE:
Useful information on handling the product. It draws attention to
possible problems.

English
26 WILO SE 09/2013
Information applied directly to the product must be strictly complied
with and kept in a fully legible condition. Such information includes:
• Direction of rotation arrow
• Identification for fluid connections
• Rating plate
• Warning sticker
2.2 Personnel qualifications The installation, operating and maintenance personnel must have the
appropriate qualifications 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. If the personnel are
not in possession of the necessary knowledge, they are to be trained
and instructed.
2.3 Danger in the event of non-
observance of the safety
instructions
Non-observance of the safety instructions can result in risk of injury
to persons and damage to the product/unit. Non-observance of the
safety instructions results in the loss of any claims to damages. Non-
observance of the safety instructions can result in the loss of any
claims to damages.
In detail, non-observance can, for example, result in the following
risks:
• Danger to persons from electrical, mechanical and bacteriological
influences
• Damage to the environment due to leakage of hazardous materials
• Property damage
• Failure of important product/unit functions
• Failure of required maintenance and repair procedures.
2.4 Safety consciousness on the job The safety instructions included in these installation and operating
instructions, the existing 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 operator This appliance is not intended for use by persons (including children)
with reduced physical, sensory or mental capabilities, or lack of expe-
rience 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.
• If hot or cold components on the product/the unit lead to hazards,
local measures must be taken to guard them against touching.
• Guards protecting against touching moving components (such as the
coupling) must not be removed whilst the product is in operation.
• Leakages (e.g. from a shaft seal) of hazardous fluids (e.g. 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.
• Danger from electrical current must be eliminated. Local directives or
general directives [e.g. IEC, VDE etc.] and local power supply compa-
nies 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 suffi-
ciently informed from their own detailed study of the operating
instructions.

English
Installation and operating instructions Wilo-CronoLine IL 250... 27
Work to the product/unit must only be carried out when at
a standstill. It is mandatory that the procedure described in the instal-
lation 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 manufac-
turer's declarations regarding safety.
Modifications to the product are only permissible after consultation
with the manufacturer. Original spare parts and accessories author-
ised by the manufacturer ensure safety. The use of other parts will
absolve us of liability for consequential events.
2.8 Improper use The operating reliability of the supplied product is only guaranteed
when used properly in accordance with the section in the operating
instructions titled “Intended use”. The limit values must on no
account fall under or exceed those specified in the catalogue/data
sheet.
3 Transport and interim storage
3.1 Shipping The pump is delivered from the factory packaged in a cardboard box
or secured to a pallet and protected against dust and moisture.
Transport inspection On arrival, inspect the pump immediately for any transport damage.
If damage is found, the necessary procedure involving the forwarding
agent must be taken within the specified period.
Storage Before installation, the pump must be kept dry, frost-free and pro-
tected from mechanical damage.
If available, leave the covers on the pipe connections so that no dirt
and other foreign matter can get into the pump housing.
Rotate the pump shaft once a week to prevent scoring at the bearings
and sticking.
Consult Wilo about which corrosion-proofing measures are to be car-
ried out in the event of a long storage time.
CAUTION! Risk of damage due to incorrect packaging!
If the pump is transported again at a later time, it must be packaged
so that it cannot be damaged during transport.
• Use the original packaging for this, or select equivalent packaging.
3.2 Transport for installation/removal
purposes
WARNING! Danger of personal injury!
Improper transport can lead to personal injury.
• Unload boxes, lathed spaces , pallets or cartons, depending on their
size and construction, with forklifts or with slings.

English
28 WILO SE 09/2013
• Always lift heavy parts of more than 30 kg with hoisting gear that
is in accordance with local regulations. The bearing capacity has to
be adapted to the weight.
• The pump must be transported using approved load-bearing
equipment (e.g. block and tackle, crane, etc.). This must be secured
to the pump flanges and, if necessary, to the outer diameter of the
motor (protection against slipping is required!).
• When lifting machines or parts using eyes, only use load hooks or
shackles that are in accordance with local regulations.
• To lift with the crane, the pump must be supported by suitable
belts as shown in (Fig. 28). Place loops around the pump which
tighten from the pump's own weight.
• The transport eyes on the motor are only for guiding while bearing
the load (Fig. 29).
• The transport eyes on the motor are only for transporting the
motor and are not approved for transporting the complete pump
(Fig. 30).
• If load chains or ropes are put over sharp edges, a guard has to be
used or they have to be put through eyes.
• When using pulley block or other hoisting gear, be sure that the
load is lifted vertically.
• Prevent the suspended load from swinging. This can be done, for
example, by using a second pulley block, whereby the pulling
direction of the two pulley blocks should be less than 30° to verti-
cal.
• Never subject load hooks, eyes or shackles to bending forces –
their load axes have to be in the direction of the tractive forces.
• When lifting, be sure that the load limit of a rope is reduced for
diagonal pulling. The safety and effectiveness of a stranding is best
ensured when all load-bearing elements are loaded in the vertical
direction to the greatest extent possible. If need be, use a lifting
arm which can be attached vertically to the load rope.
• Set up a safety zone in such a way that there is no danger in the
event that the load or a part of the load slips or the hoisting gear
breaks or tears.
• Never leave a load longer than necessary in a suspended position.
Be sure there is no danger to personnel when accelerating and
slowing down during the lifting procedure.
WARNING! Danger of personal injury!
Setting up the pump without securing it can lead to personal injury.
• Do not place the pump unsecured on the pump base. The base with
the threaded holes is only used for attachment. When standing
freely, the pump might not be sufficiently stable.
WARNING! Risk of injury due to high dead weight!
The pump itself and pump parts can be extremely heavy. Falling
parts pose a risk of cuts, crush injuries, bruises or impacts which
may lead to death.
• Always use suitable lifting equipment and secure parts against fall-
ing.
• Never stand underneath a suspended load.
• Make sure the pump is securely positioned and is stable during
storage and transport as well as prior to all installation and other
assembly work.
• Always wear protective clothing, protective gloves and protective
goggles when working.
Fig.28: Fitting load slings
Fig. 29: Transporting the pump
Fig. 30: Transporting the motor

English
Installation and operating instructions Wilo-CronoLine IL 250... 29
4Intendeduse
Purpose The glanded pumps of the IL (Inline) series are meant to be used as cir-
culation pumps in building services.
Fields of application They may be used for:
• Hot water heating systems
• Cooling and cold water circulation systems
• Industrial circulation systems
Restrictions The pumps are exclusively intended for installation and operation in
enclosed rooms. Typical installation locations are technical rooms
within the building with other domestic installations. No provision has
been made for direct installation of the device in rooms used for other
purposes (residential and work rooms). The following is not permit-
ted:
• Outdoor installation and operation outdoors
CAUTION! Risk of damage to property!
Impermissible substances in the fluid can destroy the pump. Abra-
sive solids (e.g. sand) increase pump wear.
Pumps without an Ex certificate are not suitable for use in poten-
tially explosive areas.
• Correct use of the pump/installation also includes following these
instructions.
• Any use over and beyond these is interpreted as incorrect use.
5 Product information
5.1 Type key
The type key consists of the following elements:
Pump rating plate:
Fig. 31, Item 1 shows the arrangement of the pump rating plate.
Fig. 31: Arrangement of the pump rating
plate
1
Example: IL 250/420-110/4
IL Flange-end pump as Inline pump
250 Nominal diameter DN of the pipe connection
420 Nominal impeller diameter [mm]
110 Nominal power of the motor [kW]
4 Number of poles of the motor

English
30 WILO SE 09/2013
5.2 Technical data
When ordering spare parts be sure to state all the information given
on the pump and motor rating plates.
Fluids If water/glycol mixtures with up to 40% glycol (or fluids with
a different viscosity to pure water) are used:
• the pump data must be corrected...
• to match the higher viscosity
• depending on the percentage mixing ratio
• depending on the fluid's temperature
• Adjust the motor power if need be
Only use brand-name goods with corrosion inhibitors. The respective
manufacturer's instructions are to be observed.
• The fluid must be sediment-free.
• Wilo's approval must be obtained for use of other media.
• Mixtures with a proportion of glycol of > 10 % influence the Δp-v
pump curve and the flow calculation.
NOTE
Always read and follow the material safety data sheet for the fluid
being pumped.
Property Value Remarks
Speed 50 Hz version: 1450 rpm
60 Hz version: 1740 rpm
Compare pump rating plate
Fig. 31 Item 2.
Nominal diameters DN 250
Pipe connections Flanges PN 16 EN 1092-2
Permissible min./max. fluid temperature -20°C to +140°C
Max. permitted ambient temperature: 40°C
Max. permitted operating pressure 16 bar
Insulation class F
Protection class IP 55
Pipe and pressure measurement connections PN 16 flange in accordance with
EN 1092-2
With pressure measurement connec-
tions Rp 1/8
In accordance with DIN 3858
Approved fluids • Heating water in acc. with VDI 2035
• Industrial water
• Cooling/cold water
• Water/glycol mixtures up to 40% vol.
glycol at max 40°C
• Other media upon request
•Standardversion
•Standardversion
•Standardversion
•Standardversion
• Special version or auxiliary
equipment1)
Electrical connection • 3~400 V, 50 Hz
• 3~380 V, 60 Hz
• Other voltages on request
•Standardversion
• Special version or auxiliary
equipment1)
• Special version or auxiliary
equipment1)
PTC thermistor sensor •Standardversion
Speed switch over, speed control • Control devices (Wilo CC system)
• Pole switchover
•Standardversion
• Special version or auxiliary
equipment1)
Motor special version
(on request)
• Special voltage/frequency • Special version or auxiliary
equipment1)
1) for a surcharge

English
Installation and operating instructions Wilo-CronoLine IL 250... 31
5.3 Scope of delivery • Pump IL including mounting foot for installation and foundation fixa-
tion
• Installation and operating instructions
5.4 Accessories Accessories must be ordered separately:
•PTCthermistortripping unit for switch cabinet installation
See catalogue for detailed list.
6Descriptionandfunction
6.1 Description of the product All the pumps described are single-stage low-pressure centrifugal
pumps in a compact construction with a coupled motor. The mechan-
ical seal is maintenance free. The pumps have to be sufficiently
anchored and placed on a foundation base.
In conjunction with a control device (Wilo-CC system), the power of
the pumps can also be continuously controlled. This allows optimisa-
tion of the pump output for the demands of the installation and eco-
nomically efficient pump operation.
6.2 Anticipated noise levels Anticipated noise levels for orientation:
1) Spatial mean value of sound-pressure levels on a square measuring surface at a distance of 1 m from the sur-
face of the motor.
7 Installation and electrical
connection
Safety DANGER! Danger of death!
Incorrect installation and inexpert electrical connection can pose
a risk of fatal injury.
• Have the electrical connections established by approved electri-
cians only, in compliance with the applicable regulations.
• Accident prevention regulations must be observed!
DANGER! Danger of death!
Failure to install safety devices on the terminal box or near the
coupling can cause electrical shock or contact with rotating parts,
potentially resulting in life-threatening injuries.
• Before commissioning, all safety devices (such as terminal box
covers or coupling covers) that were removed must be reinstalled.
CAUTION! Risk of damage to property!
Danger of damage due to incorrect handling.
• Have the pump installed by qualified personnel only.
Motor power PN[kW] Sound-pressure level Lp (A)
[dB(A)] 1)
(Pump with motor 1450 rpm)
75 72
90 70
110 72
132 72
160 72
200 73

English
32 WILO SE 09/2013
CAUTION! Damage to the pump due to overheating!
The pump must not be allowed to operate dry for more than
1 minute. Dry running causes a build-up of energy in the pump,
which can damage the shaft, impeller, and mechanical seal.
• Make sure that the volume flow does not go below the minimum
value Qmin.
Calculation of Qmin:
7.1 Installation
Preparation • The pump has to be checked for compliance with the specifications
on the delivery receipt; Wilo has to be informed of any damage or
missing parts. Check slat crates/cartons/wrappings for spare parts or
accessory components which could be included with the pump.
Installation location • The pumps must be protected from the weather and installed in
a frost/dust-free, well-ventilated and vibration-insulated environ-
ment which is not potentially explosive. The pump must not be
installed outdoors.
• Install the pump in a place that is easy to access so that subsequent
inspections, maintenance (e.g. mechanical seal) or replacement is
easily possible.
• The suction line is to be kept as short as possible.
Foundation • For a vibration-insulated installation, a simultaneous isolation of the
base block itself from the building structure by an elastic intermediate
layer (e.g. cork or Mafund pad) is required.
CAUTION! Risk of damage to property!
Danger of damage due to incorrect handling.
• A missing foundation or an incorrect installation of the unit on the
foundation can lead to a malfunction of the pump; this is not cov-
ered by the warranty.
• Anchor bolts (M20) for the base plate drilled holes are necessary for
anchoring.
• The concrete foundation has to be hardened before the unit is put on.
Its surface has to be horizontal.
Positioning/alignment • The pump should only be installed after completion of all welding and
soldering work and, if necessary, flushing of the pipe system. Dirt can
cause pump failure.
Qmin = 10% x Qmax pump xActual speed
Max. speed

English
Installation and operating instructions Wilo-CronoLine IL 250... 33
• Only lift the pump using permitted load-bearing equipment
(see chapter 3 “Transport and interim storage” on page 27).
NOTE
Shut-off devices shall be installed in front of and behind the pump in
all cases in order to avoid having to drain the entire system when
checking, servicing or replacing the pump. If need be, the necessary
non-return valves are to be provided.
• The pipes and pump must be free of mechanical stress when installed.
The pipes must be fastened in such a way that the pump does not
bear the weight of the pipes.
• Installation position: Only vertical installation is permitted
(see Fig. 32).
CAUTION! Risk of damage to property!
Danger of damage due to incorrect handling.
• When pumping out a tank, ensure that the fluid level is always high
enough above the suction port of the pump so that the pump never
runs dry. The minimum inlet pressure must be maintained.
NOTE
In the case of insulated systems, only the pump housing may be insu-
lated, not the lantern or drive.
Example for a foundation screwed connection (Fig. 33):
• Align the whole unit when installing on the foundation with the help
of the spirit level (at the shaft/pressure port).
• Always put the washers (B) to the left and right directly at the fixation
material (e.g. stone bolts (A)) between the baseplate (E) and founda-
tion (D).
• Evenly and firmly tighten the fixation material.
Connection of the piping CAUTION! Risk of damage to property!
Danger of damage due to incorrect handling.
• Under no circumstances may the pump be used as a fixed point for
the pipe.
• The present NPSH of the system always has to be greater than the
required NPSH of the pump.
•Theforcesandtorques being exerted by the pipe system on the pump
flange (e.g., by warping, thermal expansion) may not exceed the per-
mitted forces and torques.
• Intercept the pipes direct before the pump and connect them without
tension. Their weight must not put a strain on the pump.
• The suction line is to be kept as short as possible. Lay the suction line
to the pump so that it continuously rises while the intake falls. Possi-
ble air entry points are to be avoided.
• If a dirt trap in the suction line is required, then its free cross-section
has to be 3-4 times the cross-section of the piping.
• For short pipes, the nominal diameters should be at least that of the
pump connections. The long pipes, the most economical nominal
diameter is to be determined on a case-by-case basis.
Fig. 32: Permitted/impermissible installa-
tion positions
Fig. 33: Example of a foundation screwed
connection
DC E AB

English
34 WILO SE 09/2013
• Adapters for larger nominal diameters should be made with an flaring
angle of about 8° to prevent greater pressure losses.
NOTE
Shut-off devices shall be installed in front of and behind the pump in
all cases, in order to avoid having to drain the entire system when
checking, servicing or replacing the pump. If need be, the necessary
non-return valves are to be provided.
NOTE
A settling section must be provided before and after the pump, in the
form of a straight pipe. The length of this settling section should be at
least 5 x DN of the pump flange (Fig. 34). This measure serves to avoid
flow cavitation.
• Only connect the pipes after the conclusion of all welding and solder-
ing work as well as the cleaning/flushing of the system.
• Remove the flange covers at the suction and pressure ports of the
pump before attaching the piping.
Final check Check the alignment of the unit again as described in chapter 7.1
“Installation” on page 32.
• Tighten the foundation bolts if necessary.
• Check all connections for correctness and function.
• It must be possible to turn the coupling/shaft by hand.
Do not allow the coupling/shaft to turn:
• Release the coupling and re-tighten.
In case this measure is not successful:
• Remove the motor (see chapter 9.3 “Motor” on page 41).
• Clean the motor centring and flange
• Reinstall the motor.
7.2 Electrical connection
Safety DANGER! Danger of death!
A fatal shock may occur if the electrical connection is not made
correctly.
• Only allow the electrical connection to be made by an electrician
approved by the local electricity supplier and in accordance with
the local regulations in force.
• Observe the installation and operating instructions for the acces-
sories.
WARNING! Risk of mains overload!
An inadequate mains design can lead to system failures and even to
cable fires due to mains overload.
• When designing the mains, with regard to the cable cross-sections
and fuses, give special consideration to the fact that short-term
simultaneous operation of all pumps is possible in multi-pump
operation.
Preparation/Notes • The electrical connection must be done in accordance with EN 50178,
EN 60204-1/ IEC 60204-1, IEC 60364 via a fixed connected load.
• To ensure protection from drips and strain relief of the PG screwed
connection, a connected load is to be used with sufficient outer
diameter. By positioning the PG screwed connection or by laying the
cables accordingly, ensure that no drips can enter the terminal box.
• When pumps are used in systems with water temperatures above
90°C, a suitably heat-resistant connection line must be used.
• The connection line is to be placed in such a way that it can under no
circumstances come into contact with the pipe and/or the pump and
motor housing.
Fig. 34: Settling section before and after
the pump
r
5 x DN
d s
r ⬇2,5 · (d · 2s)

English
Installation and operating instructions Wilo-CronoLine IL 250... 35
• Check the current type and voltage of the mains connection.
• Observe the type plate information for the pump. The current type
and voltage of the mains connection must correspond to the specifi-
cations on the name plate.
• Mains-side fuse protection: dependent on nominal motor current.
• Observe earthing.
• The connection diagram for the electrical connection is in the termi-
nal box (also see Fig. 35/36).
• Secure the motor against overloading with a motor-protective cir-
cuit-breaker or by the PTC thermistor tripping unit. The use of
a motor-protective circuit-breaker is recommended.
Setting the motor-protective circuit-breaker:
•Y-Δstart: If the motor protection switch is switched in the supply line
to a Y-Δcontactor combination, set the switch as for direct starting
(setting to the motor nominal current of the motor rating plate).
If the motor protection switch is switched in a thread of the motor
supply line (U1/V1/W1 or U2/V2/W2), set the motor protection switch
to 0.58 x nominal motor current.
• The special motor design is equipped with PTC thermistor sensors.
Connect the PTC thermistor sensors to the PTC thermistor tripping
unit.
CAUTION! Risk of damage to property!
Danger of damage due to incorrect handling.
• Only a maximum voltage of 7.5 V DC may be applied to the termi-
nal. a higher voltage will destroy the PTC thermistor sensor.
The mains connection to the terminal board is dependent on the rated
power PN, the mains voltage and the start-up type.
Required connection of the connecting bridges in the terminal box:
• When connecting automatic switchgears, observe the relevant instal-
lation and operating instructions.
• For three phase motors with Y-Δconnection, be sure that the switch-
over points between star and triangle are very close together in time.
Longer switch-over times can lead to pump damage.
Recommendation for setting the times for Y-Δactivation:
CAUTION! Risk of damage to property!
Danger of damage due to incorrect handling.
• Only carry out the rotation direction monitoring after the system is
filled. Even brief dry running will destroy the mechanical seal.
Fig. 35: Y-Δ-start (standard)
L1 L2 L3
W2 U2 V2
U1 V1 W1
PTC
Fig. 36: Δconnection
W2 U2 V2
U1 V1 W1
PTC
Activation type Mains voltage 3~400 V
Y-Δstart
(default)
Remove connecting bridges
(Fig. 35)
Start via
Soft starter
Δconnection (Fig. 36)
Motor power Y time to be set
> 30 kW < 5 seconds

English
36 WILO SE 09/2013
8 Commissioning
Safety DANGER! Danger of death!
Failure to install safety devices on the terminal box or near the
coupling can cause electrical shock or contact with rotating parts,
potentially resulting in life-threatening injuries.
• Before commissioning, all safety devices (such as terminal box
covers or coupling covers) that were removed must be reinstalled.
• Keep a safe distance during commissioning!
WARNING! Risk of injury!
If the pump/system is installed improperly, liquid may be ejected
during commissioning. Individual components may also become
loose.
• Keep a safe distance from the pump during commissioning.
• Wear protective clothing, protective gloves and protective gog-
gles.
NOTE:
It is recommended to have the pump serviced and checked by Wilo-
Customer Service.
Preparation The pump has to reach ambient temperature before commissioning.
8.1 Initial commissioning • Check whether the shaft can be rotated without any grinding. In case
the impeller is blocked or grinds, loosen the coupling screws and
tighten them with the specified torque.
• Fill and bleed the system as required.
WARNING! Danger due to extremely hot or extremely cold pressu-
rised fluid!
Depending on the temperature of the fluid and the system pres-
sure, when the vent screw is opened completely, extremely hot or
extremely cold fluid in liquid or vapour may escape or shoot out at
high pressure.
• Always exercise caution when opening the vent screw.
CAUTION! Risk of damage to property!
Dry running will destroy the mechanical seal.
• Make sure that the pump does not run dry.
• To avoid cavitation noise and damage, a minimum intake pressure
must be guaranteed at the suction port of the pump. This minimum
intake pressure depends on the operating situation and the duty point
of the pump, and must be defined accordingly.
The main parameters for defining the minimum intake pressure are
the NPSH of the pump at its duty point and the vapour pressure of the
fluid.
• By briefly switching on, check whether the direction of rotation
agrees with the arrow on the fan cover (see Fig. 37, Item 2). If the
direction of rotation is incorrect, proceed as follows:
• For Y-Δstart, swap the winding start and winding end of 2 windings
on the motor terminal board (e.g. V1 for V2 and W1 for W2).
Fig. 37: Checking the direction of rotation
2