Wilo Cronoline User manual

Installation and operating instructions
Wilo-Cronoline
2 069 148-Ed.02 / 2007-05-11-Kothes!

2Wilo AG 05/2007
English
Overview
Installation and Operating Instructions
1Overview
Troubleshooting guide >page 19
Safety >page 4
Functionality >page 7
Transport and Storage >page 8
Installation >page 8
Maintenance and Repair >page 13
Screw torques >page 18
Technical data >page 5
Electrical connection >page 10
Mechanical Installation >page 8
Ventilate >page 12
Check direction of rotation
>page 12
Connect condensate drain >page 10
Performance regulation >page 7
Attach pump >page 9
Dismantle motor >page 14
Direction of flow >page 7
Safety sticker >page 4

Installation and Operating Instructions Wilo-Cronoline 3
English
Overview
1
2
3
4567
98 1011
12
13
14
17
18
19
20
20
16
15
1Discharge Flange
2Discharge Pressure Gauge Tapping – ¼”
NPT
3Mechanical Seal Air Vent
4Shaft
5Lantern
6Coupling guard
7Coupling
8Motor
9Motor bolt
10 Condensate drain connection (only in some
models)
11 Condensate drain connection
12 Volute Bolt
13 Suction Pressure Gauge Tapping – ¼” NPT
14 Suction Flange
15 Lantern O-ring
16 Stationary seal ring of mechanical seal
17 Mechanical seal
18 Impeller
19 Impeller fastening nut and washer
20 Pump Feet

4Wilo AG 05/2007
English
Safety
2Safety
About these instructions • These instructions must be read in full prior to installation.
Failure to comply with these instructions may lead to serious
injury or damage to the pump.
• Once the pump is installed, give these instructions to the
operator.
• These instructions should be kept in the vicinity of the
pump.They serve as a reference in case of later problems.
• Wilo is not liable for damage arising from non-compliance
with these instructions.
Warning notices Important safety notices are categorized as follows:
Safety sticker Safety stickers are located on the motor giving important
instructions on how to handle the pump.The instructions on the
safety sticker must be strictly obeyed.
Qualifications The pump may only be installed by qualified personnel. The elec-
trical systems may only be connected by qualified electricians.
Additionally, national regulations concerning the Qualifications
of personnel must be obeyed.
Modification, spare parts No technical alterations or modifications may be made to the
pump. Use only original spare parts.
Danger: Indicates life threatening due to electrical cur-
rent.
Warning: Indicates possible life threatening or risk of
injury.
Caution: Indicates possible threats to pump or other
objects.
Note: Highlights tips and information.

Installation and Operating Instructions Wilo-Cronoline 5
English
Technical data
Electrical power supply Working with electrical current could cause serious risk of bodily
injury, therefore:
• Before starting work on the pump, switch off the power and
secure it against reconnection.
• Do not bend or clamp power cable or expose it to heat
sources.
• Do not immerse the pump in water or other liquids or expose
it to spray water or moisture.
Rotating components The pump contains rotating components that are exposed if the
pump housing is open or the coupling guard is missing. Touching
the rotating components can cause serious injury, therefore:
• Before opening the pump housing, switch off the motor and
secure against reconnection.
• Never switch on the motor when the pump housing is open or
the coupling guard is missing.
• Never operate the pump without the coupling guard.
High Deadweight The pump has a very high deadweight, depending on the model.
If the pump is dropped or it falls, there is a risk of death by crush-
ing if pump falls, therefore:
• Exercise caution when lifting or transporting.
• Never walk under suspended loads.
• Always put the pump and pump parts down ensuring they
cannot tip over.
• Only use the transportation methods described in these
operating instructions >Page 8.
• Before loosening screws, secure the pump parts to be
loosened to prevent them from falling.
3 Technical data
3.1 Type plate
IL Series: Inline pump with flange connection
2.5 Nominal diameter of pipe connection (inches)
-50 Maximum pump height (ft)
/260 Maximum capacity (GPM)
-2 Number of poles
115/208-230 Voltage (V)

6Wilo AG 05/2007
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Technical data
3.2 Data
Description Information Option
Mains voltage 1 ~ 115 / 208-230 V, 60 Hz (≤2HP)
3~208 - 230 / 460V, 60 Hz (≥1 HP)
3~575V, 60 Hz (≥1 HP)
Degree of motor protection ODP
TEFC ●
Protection against overheating Integrated protection PTC / PTO a
a. On-site trip unit required
●
Flange connection Flanges acc. ASME Class 125
Motor flange design acc. NEMA MG1 Type C face Mounting
Special motor design Special voltage/frequency ●
Max. working pressure 175 psi [12 bar]
250 psi [17 bar] ●
Max. permissible liquid temper-
ature range
water only: from 32 °F to 200 °F [-0 °C to +90 °C]
water/glycol up to 50 %:
from -4 °F to 250 °F [-20 °C to +120 °C]
Max. permissible liquid temper-
ature range with high tempera-
ture seal
at 175 psi [12 bar]:
from -4 °F to 250 °F [-20 °C to +120 °C]
at 165 psi [11 bar]:
from -4 °F to 285 °F [-20 °C to +140 °C]
Max. ambient temperature 104 °F [40 °C]
Approved liquids Heating water
Chilled/Cold water
Water/glycol mixtures b
b.Hydraulic corrections necessary depending on liquid's density and viscosity. Only approved additives with
corrosion inhibitors may be used. Observe manufacturer's instructions.
Heat transfer oil ●
Other liquids on request c
c. Contact WILO before using any liquids other than above-listed liquids, different mixture ratios and higher
temperatures.
●
Legend:
●Special design or accessories (at added cost on request)
Note: For additional data, see type plate, product informa-
tion sheet or Wilo catalog.

Installation and Operating Instructions Wilo-Cronoline 7
English
Functionality
3.3 Materials
3.4 Scope of delivery
1Pump complete
2Installation and operating instructions (not displayed)
4 Functionality
4.1 Application
The purpose of the pump is to pump the liquids specified in the
technical data for the building services industry and for industrial
plants.
Pumping different liquids and exceeding the limit values speci-
fied in the technical data may destroy the pump.
4.2 Functions
Design The pump is a single-stage circulating pump with an inline design
It is driven by an electric motor according to the NEMA standard.
Assembly For pumps up to an output of 20 HP, the flanges are designed
such that the pump can be mounted without additional support.
For pumps with an output of over 20 HP, the pump must be
screwed onto the three feet >Page 9.
Performance regulation External pressure sensors and an external control unit can be
connected to the suction side and the discharge side by means of
a pressure gauge tapping for each side.
The motor speed can be controlled using an external frequency
converter.
Direction of flow The arrows on the flanges indicate the direction of flow.
Pump housing and lantern Cast iron ASTM A126 Class B
Impeller Bronze (Standard), Cast Iron Optional
Pump shaft Stainless steel 1.4122
1

8Wilo AG 05/2007
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Transport and Storage
5 Transport and Storage
5.1 Shipping
Shipping The pump is delivered packaged in cardboard or lashed down on
a pallet and is protected against dust and moisture.
Transport inspection Upon receipt, unpack and check pump and all accessories.
Report transit damage immediately.
Storage Until the pump is installed, the pump must be stored in a dry,
frost-free place where it is also protected against mechanical
damage.
5.2 Impacts
To lift the pump using a crane, the pump has to be tied down as
illustrated using suitable straps. Place the pump in the hanger
which will tighten itself due to the pump's deadweight.
6 Installation
6.1 Mechanical Installation
Caution: Damage due to incorrect packaging!
If the pump needs to be transported again at a later date, it must
be securely packaged for transit. Use the original packaging or
equivalent packaging.
Warning: Risk of injury due to high deadweight!
The pump is heavy and can cause considerable injury if dropped
or if it falls.Only transport the pump using a suitable hoist. Wear
work shoes and a helmet. Never stand under hanging loads.
Danger: Risk to life due to electric shock!
Before starting work, make sure that the pump is disconnected
from the power supply.
Warning: Danger due to high deadweight!
The pump itself and pump components may have a very high
deadweight.There is a risk of potentially fatal impact and crush-
ing caused by falling parts.
Always use suitable lifting equipment and secure parts from
falling.

Installation and Operating Instructions Wilo-Cronoline 9
English
Installation
Installation site The installation site should be a weather-resistant, frost-free
and dust-free area that has good air circulation. Select an easily
accessible installation site.
Keep a minimum distance of 8 inches [20 cm] between the motor
cover and surrounding surfaces.
1. Insure the pump is installed in a way that no piping stresses
are transferred to the pump.
A straight piece of piping of 3 pipe diameters in length is
required on both sides to insure laminar flow.
Attach pump 2. Install only as shown (Figs. A/B):
- Installation with a horizontal motor (Fig. B) is permissible
only for pumps with an output of up to 20 HP.
- The motor may not point downwards (Fig. C).
- In the case of installation with horizontal motor (B), the air
vent valve must point upwards.
3. If necessary, disassemble the motor and rotate >Page 14.
The electrical terminal box may not point downwards (Fig. C).
4. The feet of the pump are drilled and tapped for floor or wall
mounting. Insure the volute is not stressed by the piping.
Connect flangeconnection 5. Screw flange connection onto suction and discharge piping.
Caution: Dirt causes damage!
Dirt can render the pump inoperative.Before installing the
pump, complete all welding and soldering work and thoroughly
clean the pipe system.
min 3 x O
min 3 x O
1
1
Note: Install an isolation valve (1) on the suction and dis-
charge sides of the pump so that the pump can be replaced
without having to empty the entire piping system.
A B
C
Note: The arrows on the flanges indicate the direction of
flow.
Note: With motor output of 7.5 HP or more, a housekeep-
ing pad is recommended.

10 Wilo AG 05/2007
English
Installation
Connect condensate drain
6. If desired, a condensate drain can be connected.
(1) Condensate drain for vertical installation position of the
motor
(2) Condensate drain for horizontal motor installation
position (only available in some models)
7. Seal up unused condensate drain.
6.2 Electrical connection
Electrical connection 1. Connect the connecting cable with power switched off and
secure against reconnection.
2. Lay the connecting cable such that it doesn't come into
contact with the pump, the pump housing or the piping.
3. Check whether the voltage and amperage in the mains match
the specifications on the type plate of the pump.
4. Open the terminal box.
5. Lay the cable such that no condensation or spray water can
run into the cable screws (Fig. A).
6. Connect grounding cable.
1
2
Caution: Damage due to overheating!
For insulated piping systems, only the pump volute may be
insulated, not the lantern and the motor. These could be
damaged by heat build-up.
Danger: life threatening due to electrical shock!
Touching live parts can be fatal. Work on the electrical connec-
tion may only be performed by a trained electrician. Prior to
connecting, ensure that the connecting line is voltage-free.
Warning: Danger due to a damaged cable!
For pumps that pump hot liquids or that are used in proximity to
hot surfaces with temperatures above 194 °F [90 °C], a heat-
resistant cable must be used.
Note: For the correct cable size, refer to local wiring
restrictions.
Caution: Damage due to incorrect voltage!
Never operate the pump with incorrect voltage. This could
damage the motor.
A B

Installation and Operating Instructions Wilo-Cronoline 11
English
Installation
7. Install motor control, cabling, overload protection, mains
circuit breaker and accessories in accordance with the locally
applicable safety regulations.
8. To protect the motor, overheating protection should also be
installed.
9. Low temperature applications (below normal temperature
ranges) may require external motor and mechanical seal
heaters – contact WILO for additional details.
10. Tighten cable screws
11. Close terminal box and ensure that no spraying water can
enter it.
Caution when connecting to
an automatic pump control
device
Comply with respective installation and operating instructions
when wiring to automatic pump control device (DDC or Building
Management Systems). Be sure the following guidelines are met:
• AC power is within ±10% of rated voltage with rated
frequency (see motor name plate for ratings)
or
• AC power is within ±5% of rated frequency with rated voltage
or
• Combined variation in voltage and frequency of ±10%
(sum of absolute values) of rated values, provided the fre-
quency variation does not exceed ±5% of rated frequency
Note: The connection diagram is located on an exterior
label or inside the terminal box.
Note: Special motors can be supplied with a PTC thermal
sensor that must be connected to the PTC trip relay.

12 Wilo AG 05/2007
English
Installation
6.3 Fill and ventilate
Ventilate
1. Open air vent valve (1) 1/2 turn, do not remove.
2. Completely open suction side and discharge side isolation
valves.
3. Wait until the liquid has exited the ventilation opening and
until bubbles no longer form.
4. Tightly close the ventilation opening.
Avoid cavitation 5. Ensure that the minimum pressure stipulated in the product
catalog is present on the suction side.
Check direction of rotation 6. Check the motor's direction of rotation by briefly turning it
on. The direction of rotation is correct if the fan or other
visibly rotating parts of the pump are rotating in the direction
of the arrow (2).
On three phase only, if the direction of rotation is incorrect,
have an electrician correct it by swapping two phases.
For single phase applications, to change direction of the
motor please follow the directions supplied with the motor.
If there is not arrow on the motor run the pump, note pres-
sure, reverse rotation and recheck pressure. The rotation that
produces a higher pressure is the correct rotation (for clarifi-
cation contact WILO).
7. Turn on the pump for test operation and observe whether it
is pumping correctly. If necessary, ventilate again until a
sufficient pumping result is achieved.
Caution: Damage due to dry running!
The pump may never be allowed to run dry. Dry running destroys
the mechanical seal.
1
2
Warning: Danger due to hot liquid under pressure!
Extreme caution must be used when venting systems that have
elevated temperatures and/or dangerous fluids. Maintain suffi-
cient distance from the air vent opening, wear suitable clothing
including protective glasses/facial protection and gloves.
Caution: Damage due to cavitation!
Failing to maintain minimum pressure on the suction side can to
lead to cavitation accompanied by noise.This can damage the
pump. This minimum inlet pressure depends on the operating
conditions and the duty point of the pump and must be calcu-
lated accordingly. Please contact WILO or your WILO distributor
if this further information is required.

Installation and Operating Instructions Wilo-Cronoline 13
English
Operation
7Operation
8 Maintenance and Repair
Warning: Risk of burning or freezing on if the pump is
touched!
Depending on the operating conditions of the pump or installa-
tion (liquid temperature), the entire pump can become very hot
or very cold. Keep your distance during pump operation!
Caution: Damage to the pump through overheating!
The pump may not be operated longer than 1 minute without
flow. An accumulation of energy creates heat that can damage
the pump shaft, impeller and mechanical seal.
A minimum flow rate of approx. 10% of maximum flow rate
must always be guaranteed.
Danger: life threatening due to electrical shock!
Touching live components can be fatal. Only qualified electri-
cians may work on the electrical system. Prior to any mainte-
nance work, disconnect the pump from the power supply and
secure against reconnection.
Warning: Damage due to incorrectly tightened screws!
Overtightened screws can break off. Subsequently, separate
parts and fragments may chip off and / or the hot liquid may
spray.
Observe screw tightening torque specifications >Page 18.
Warning: Danger due to hot liquid under pressure!
During dismantling of motor or pump, hot liquids may escape
under high pressure. Allow the pump to cool down first.
Close isolation valve prior to dismantling pump.
Caution: Damage due to incorrectly performed
maintenance!
Incorrectly performed maintenance work can damage the
pump. The maintenance work described below may therefore
only be performed by trained personnel.

14 Wilo AG 05/2007
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Maintenance and Repair
8.1 Cleaning
Clean the exterior of the pump using only a lightly dampened
cloth without detergents.
8.2 Checks
Under normal operating conditions, the pump does not require
regular maintenance work.
The following points, however, must be checked at regular
intervals.
8.3 Disassemble pump
Dismantle motor 1. Disconnect pump from power supply and secure against
reconnection.
2. Close shut-off device to front and rear of pump.
3. If the connection cable is too short for disassembly, have an
electrician disconnect it.
4. Remove all other connections (e.g. condensate drain).
5. If motor is in horizontal installation position, support the
motor or secure it from falling with a crane and a suitable
hoist.
6. Remove screws (1) and remove coupling guard (2) on both
sides.
7. Loosen all coupling screws by a few turns. Do not, however,
remove the screws entirely.
8. Remove other screws on motor flange.
9. Pull out the motor (3) using a suitable hoist and remove.
Check Solution
Leakages If the leakage rate increases (> 5 ml/h [0.2 oz/hr]), replace the
mechanical seal >Page 15.
Motor noise and vibrations Check whether the pump is being operated within the permit-
ted characteristic curve range (see product catalog).
If level of noise increases due to motor mounting or increased
vibrations, replace motor>Page 14, or replace the motor
mounting (see instructions from motor manufacturer).
1
1
2
3

Installation and Operating Instructions Wilo-Cronoline 15
English
Maintenance and Repair
Dismantle lanterns 10. If motor is in horizontal installation position, support lanterns
or secure against falling using a crane or a suitable hoist.
11. Remove screws on lantern flange.
12. Screw in the screws into threadedextraction holes (1) next to
drill holes on lantern flange in order to press lantern out from
pump housing.
13. Take out lantern unit (2) with coupling, shaft, mechanical seal
and impeller using suitable lifting equipment and remove
from pump housing.
Remove impeller 14. Loosen impeller fastening nut (1) counter-clockwise.
15. Loosen impeller (2) from pump shaft using an extractor. In
doing so, place extractor hook under impeller near blade.
16. Remove nut and impeller from shaft.
17. Remove mechanical seal (3) from shaft (4).
Remove shaft 18. Pull coupling (2) and shaft (1) out of lantern.
19. Carefully clean surfaces. If shaft is damaged, it must be
replaced.
Remove seals 20. Remove stationary seal and seal elastomer (1).
21. Remove O-ring (2).
1
2
1
2
34
12
1
2

16 Wilo AG 05/2007
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Maintenance and Repair
8.4 Assemble pump
Assemble coupling and shaft 1. Check machined surfaces and clean if necessary.
2. Place shaft (1) in a coupling shell (2).
3. Insert two spacer disks in opposition (3). The shaft must not
slip through.
4. Place second coupling shell (4) on top, then screw hand-
tight.
Assemble seals 5. Carefully clean seal locations. They must not be damaged.
6. Press new mechanical seal with sealing collar into seal
location (1). Water with commercial dishwashing detergent
can be used as a lubricant.
7. Insert a new O-ring (2) in lantern groove
8. Carefully insert pre-assembled unit consisting of coupling
and shaft (2) into lantern (1).
9. Hold coupling and shaft in place (2) in lantern.
10. Press a new mechanical seal (3) onto shaft.
Water with commercial dishwashing detergent can be used
as a lubricant.
Assemble impeller 11. Check machined surfaces and clean if necessary.
12. Place impeller (1) onto shaft.
13. Slide on washer (2) then screw on impeller fastening nut (3).
14. Fit impeller with strap wrench to secure (4).
15. Screw nut tightly using a torque wrench (5). Torque
>Page 18
43
2
1
1
2
1
3
2
1
2
3
4
5
Caution: Damage to mechanical seal!
Too much pressure and twisting can damage the mechanical
seal. Proceed with caution.

Installation and Operating Instructions Wilo-Cronoline 17
English
Maintenance and Repair
Assemble lantern unit 16. Place tool (1) on pump shaft and let it snap in. It serves as a
bar spacer between coupling and lantern (2).
17. Hold shaft unit firm (3) to avoid damage to the mechanical
seal.
18. Insert pre-assembled lantern unit (2) carefully into pump
housing using suitable lifting equipment. Tighten screws on
lantern flange using a torque wrench. Torque >Page 18.
Assemble motor 19. Slightly loosen the coupling screws, and open the pre-
assembled coupling slightly.
20. Insert key into motor shaft.
21. Instal motor (1) using a suitable hoist.
22. Tighten both opposing screws (2) equally crosswise.
23. Tighten coupling screws slightly at first, until half coupling
shells are lying on spacer disks.
24. Then screw coupling together equally.
Torque >Page 18.
Specified distance of 0.197 inches [5 mm] between lantern
and coupling is correctly set if tool (5) sits between lantern
and coupling free of play.
25. Remove tool (5).
26. Insert coupling guard (3) on both sides and screw in both
motor fastening screws (4).
27. Tighten all screws on motor flange (2 and 4) using torque
wrench. Torque >Page 18.
28. Prior to turning on the power, check whether shaft unit is
easy to rotate and doesn't grind. If necessary, dismantle
components again, check fits and repeat assembly process.
1
2
3
Caution: Damage to mechanical seal!
Twisting shaft unit (3) can damage the mechanical seal. Proceed
with caution.
2
4
3
1
55 mm
Caution: Damage to the pump!
Never operate a pump that is not correctly assembled. This can
damage the pump.

18 Wilo AG 05/2007
English
Spare parts
8.5 Screw torques
9 Spare parts
In order to avoid returns and incorrect orders, please specify the
name plate data for all orders.
Torque (± 10%)
Location
Material/SAE Grade Diameter (inches) ft lb Nm
Impeller-Shaft
Stainless steel
3/8 22 30
1/2 44 60
5/8 74 100
Pump housing - lantern
SAE Grade 5
5/8 75 100
Adapter flange - lantern
SAE Grade 5
5/16 18 25
1/2 44 60
Lantern - motor
SAE Grade 5
3/8 26 35
1/2 44 60
5/8 74 100
Coupling
SAE Grade 8
1/4 9 12
5/16 22 30
3/8 44 60
1/2 74 100
Pressure taps - plug screw 1/4-18 NPT 15 20
Caution: Damage due to incorrect spare parts!
Only original Wilo spare parts are to be used to insure fault-free
pump operation.

Installation and Operating Instructions Wilo-Cronoline 19
English
Troubleshooting guide
10 Troubleshooting guide
Faults Possible cause Remedy
Pump does not
start or fails to
run
Pump seized Switch off power supply, take off pump
head, remove obstruction; if motor
blocked, overhaul/exchange motor/pump
head
Loose terminals tighten all terminals
Blown fuses/breakers Check fuses, replace/reset as necessary
Faulty motor Call service
Tripped overload relay
(excessive amp draw)
throttle hydraulic flow rate down to
nominal on discharge side of pump
Incorrectly set trip relay
(heaters)
Reset thermal overloads to full load
current value specified on name plate
Thermal overload is influenced
by excessive ambient
temperature
Prevent overloads caused by high ambient
temperatures
Tripped PTC relay Check motor and fan cover for dirt/dust
accumulation and clean if necessary;
Check ambient temperature and if neces-
sary, ensure an ambient temperature
≤105 °F [40 °C] by forced ventilation.
Pump runs at
reduced capacity
Incorrect rotation Check direction of rotation, reverse if
necessary
Discharge valve throttled too
far
Slowly open isolating valve
Speed too low Adjust incorrect terminal bridging
(Y in lieu ∆)
Air in suction pipe Check and correct all possible suction
leaks
Pump makes
noise
Insufficient inlet pressure Raise inlet pressure, ensure minimum
required inlet pressure at suction port,
check and if necessary clean suction-side
isolating valve and strainer
Faulty motor bearings Arrange for pump to be inspected and, if
necessary, to be repaired by Wilo or other
authorized service.
Impeller rubs on volute Test the gap between lantern and pump
housing. Clean it, if necessary.
Check that distance from coupling to
lantern is 5 mm >Page 17.
Note: If you cannot fix the problem, contact service engi-
neer or a Wilo branch office.

WILO USA LLC
1290 North 25th Ave
Melrose Park, IL 60160
USA
Phone: [phone] (WILO USA)
FAX: [phone]
Wilo Canada Inc.
Bay 7 – 2915
10th Ave. N.E.
Calgary, Alberta, T2A 5L4
CANADA
Phone: [phone] (WILO CDN)
FAX: [phone]