Wilo CronoNorm-NL Series User manual

Wilo-CronoNorm-NL, NLG
Pioneering for You
2 136 329-Ed.03 / 2013-07-Wilo
en Installation and operating instructions

English
WILO SE 07/2013
1 General ....................................................................................................................................................3
2 Safety ......................................................................................................................................................3
2.1 Indication of instructions in the operating instructions ...................................................................................3
2.2 Personnel qualifications ........................................................................................................................................4
2.3 Danger in the event of non-observance of the safety instructions ................................................................4
2.4 Safety consciousness on the job ..........................................................................................................................4
2.5 Safety instructions for the operator ...................................................................................................................4
2.6 Safety instructions for installation and maintenance work .............................................................................5
2.7 Unauthorised modification and manufacture of spare parts ............................................................................6
2.8 Improper use ..........................................................................................................................................................6
3 Transport and interim storage .............................................................................................................6
3.1 Shipping ..................................................................................................................................................................6
3.2 Transport for installation/dismantling purposes ...............................................................................................7
3.3 Removing/replacing corrosion protection (only NL pumps)..............................................................................8
4 Intended use ...........................................................................................................................................9
5 Product information ..............................................................................................................................9
5.1 Type key ..................................................................................................................................................................9
5.2 Technical data ......................................................................................................................................................10
5.3 Scope of delivery .................................................................................................................................................11
5.4 Accessories ...........................................................................................................................................................11
6 Description and function ....................................................................................................................11
6.1 Description of the product .................................................................................................................................11
6.2 Design set-up .......................................................................................................................................................11
6.3 Anticipated noise levels for standard pumps ...................................................................................................12
6.4 Permissible forces and torques on the pump flanges ......................................................................................13
7 Installation and electrical connection ...............................................................................................15
7.1 Preparation ...........................................................................................................................................................15
7.2 Setting up the pump alone (variant B, according to Wilo variant key) ..........................................................15
7.3 Installation on a base of the pump unit .............................................................................................................16
7.4 Pipework ...............................................................................................................................................................18
7.5 Aligning the unit ..................................................................................................................................................19
7.6 Electrical connection ...........................................................................................................................................22
7.7 Protective devices ...............................................................................................................................................22
8 Commissioning / decommissioning ...................................................................................................22
8.1 Safety ....................................................................................................................................................................22
8.2 Filling and bleeding ..............................................................................................................................................22
8.3 Checking the direction of rotation ....................................................................................................................23
8.4 Switching on the pump .......................................................................................................................................23
8.5 Leak check ............................................................................................................................................................24
8.6 Switch-on frequency ..........................................................................................................................................25
8.7 Switching off the pump and temporary shutdown ..........................................................................................25
8.8 Decommissioning and storage ...........................................................................................................................25
9 Maintenance/repair .............................................................................................................................26
9.1 Safety ....................................................................................................................................................................26
9.2 Operation monitoring ..........................................................................................................................................27
9.3 Maintenance work ...............................................................................................................................................27
9.4 Draining and cleaning ..........................................................................................................................................27
9.5 Dismantling ..........................................................................................................................................................28
9.6 Installation ............................................................................................................................................................33
9.7 Screw tightening torques ...................................................................................................................................37

English
Installation and operating instructions Wilo-CronoNorm-NL, NLG
10 Faults, causes and remedies .............................................................................................................. 38
10.1 Faults ....................................................................................................................................................................38
10.2 Causes and remedies ........................................................................................................................................... 39
11 Spare parts ........................................................................................................................................... 41
11.1 Spare parts lists, Wilo-CronoNorm-NL .............................................................................................................42
11.2 Spare parts lists, Wilo-CronoNorm-NLG .......................................................................................................... 46
12 Disposal ................................................................................................................................................50

English
Installation and operating instructions Wilo-CronoNorm-NL, NLG 3
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 product.
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 product/personnel safety 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
(serious) injury to persons is probable if this note is disregarded.
CAUTION!
There is a risk of damaging the product/unit. “Caution” concerns
possible damage to the product that could occur if this note is dis-
regarded.
NOTE:
Useful information on handling the product. It draws attention to
possible problems.

English
4WILO SE 07/2013
Information that appears directly on the product, such as:
• direction of rotation arrow
• rating plate
• warning sticker
must be strictly complied with and kept in legible condition.
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. This can be accom-
plished if necessary by the manufacturer of the product at the request
of the operator.
2.3 Danger in the event of non-
observance of the safety
instructions
Non-observance of the safety instructions can result in risk of injury
to persons and damage to the environment and the product/unit.
Non-observance of the safety instructions results 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 conveyed 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 energy supply compa-
nies must be adhered to.
• The area near the pump unit must be kept free of contaminants to
eliminate the chance of a fire or an explosion due to contact of con-
taminants with hot unit surfaces.
• The instructions in this manual apply to the standard equipment
design. This book does not discuss all details or frequent deviations.
Additional information is available from the manufacturer.
• If there are any doubts about the function or setting of parts of the
equipment, contact the manufacturer immediately.

English
Installation and operating instructions Wilo-CronoNorm-NL, NLG 5
Shearing hazards Never put fingers, hands, arms, etc. in the suction or outlet openings
or another opening (such as the hole of the venting screw). To avoid
the penetration of foreign objects, leave the protective covers or
packaging on until they have to be removed for installation. If the
packaging or covers of suction or outlet openings are removed for
inspection purposes, they must be put back on afterwards to protect
the pump and ensure safety.
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 ques-
tion also remain hot after switching off the unit. These surfaces may
only be touched with caution. If required, wear protective gloves if
these surfaces must be touched while they are hot.
If the packing is too tightly sealed, the water coming out of the stuff-
ing box can be so hot that there is a danger of scalding. Make sure that
the drained water is not too hot for more intensive contact with skin.
Components which are subject to temperature fluctuations, so that
touching them can therefore be dangerous, must be protected by
suitable devices.
Hazard due to articles of clothing
being caught, etc. Do not wear loose or frayed clothing or jewellery which could be caught by the product.The devices for protecting against accidental
contact with moving parts (e.g. coupling protection) may only be dis-
mantled when the system is at a standstill.The pump must never be
put into operation without these protective devices.
Hazards due to noise If the noise level of the pump exceeds 80 dB(A), the valid health pro-
tection and safety regulations must be complied so that operating
personnel of the system aren't exposed to excessive noise. The sound
pressure specifications on the rating plate of the motor must be
observed. The sound pressure value of the pump is generally about
the same value as that of the motor +2 dB(A).
Leakage Leakage of dangerous (explosive, toxic, hot) substances which come
from the pump (e.g. shaft seal) must be avoided to protect people and
the environment, under the observation of local standards and regu-
lations.
The pump must never be operated without fluid. Otherwise, this can
cause the shaft seal to be destroyed, thereby endangering people and
the environment.
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.
Work to the product/unit must only be carried out when at a standstill.
It is mandatory that the procedure described in the installation and
operating instructions for shutting down the product/unit be com-
plied with.
Immediately on conclusion of the work, all safety and protective
devices must be put back in position and/or recommissioned.
Pumps which pump hazardous fluids must be decontaminated.

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6WILO SE 07/2013
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 safety of the supplied product is only guaranteed for
conventional use in accordance with Section 4 of the operating
instructions. The limit values must on no account fall under or exceed
those specified in the catalogue/data sheet.
3 Transport and interim storage
3.1 Shipping The pump is lashed to a pallet ex works and is protected against dirt
and moisture.
Transport inspection On arrival, inspect the pump immediately for any transport damage. If
damage is found, the necessary procedures 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.
NOTE:
Improper storage can lead to damage to the equipment, which is
excluded from the guarantee and warranty.
Short-term storage (less than three months):
If it is required to store a pump before its installation for a short time,
keep it in a dry, clean and ventilated place, which is free of vibrations,
moisture and fast/extreme temperature differences. Protect the
bearings and couplings from sand, gravel and other foreign objects.
To prevent rust and bearing seizing, lubricate the unit and turn the
rotor by hand by several rotations at least once a week.
Long-term storage (more than three months):
If it is planned to store the pump over a longer period of time, addi-
tional precautionary measures must be taken. All rotating parts must
be coated with a suitable protective medium to protect them from
rust.If the pump should be stored for more than a year, consult the
manufacturer.
CAUTION! Risk of damage due to incorrect packaging!
Ifthepumpistransportedagainatalatertime,itmustbepackaged
so that it cannot be damaged during transport.
• Usetheoriginalpackagingforthis,orchooseequivalent packaging.

English
Installation and operating instructions Wilo-CronoNorm-NL, NLG 7
3.2 Transport for installation/
dismantling purposes
General safety instructions WARNING! Danger of bodily injury!
Improper transport can lead to personal injury (e.g. crushing inju-
ries).
• Only have work for lifting or moving the unit done by professionals.
• To lift the unit, never attach hooks or slings to shafts.
• Never lift the pump via the lug in the bearing bracket.
• When manually lifting components,work with proper lifting tech-
niques.
• Never stand beneath a suspended load.
• The existing accident prevention regulations must be complied
with.
• Alwayswear protectiveclothing,protectiveglovesand protective
goggles when working.
Containers, boxes, pallets, and boxes made of wood can be unloaded
with a forklift or by using lifting belts, depending on the size and con-
struction.
Attaching the transport ropes CAUTION! Risk of damaging the pump!
To ensure proper alignment, all equipment is pre-installed. If
dropped or if improperly handled, there is a risk of misalignment or
deficient performance.
• The bearing capacity of the hoisting gear must be appropriate for
the weight of the pump. The pump weight can be found in the cat-
alogue or the data sheet of the pump.
• To avoid deformations, lift up the pump accordingly (Fig. 1) or
(Fig. 2).The liftinglugsattached tothepump ormotor mustnotbe
used to lift the entire unit. They are only meant for transporting
the individual components during installation or dismantling.
• Only remove the documents fastenedto the pump during installa-
tion. Only remove the sealing devices attached to the flanges of
thepumpduringinstallationinorder topreventany pumpcontam-
ination.
Fig. 1: Transporting the pump
Fig. 2: Transportation of the complete unit

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8WILO SE 07/2013
Transport DANGER! Risk of fatal injury!
Thepumpitselfandthepumppartscanbeextremelyheavy.Falling
parts pose a risk of cuts, crush injuries, bruises or impacts, which
may lead to death.
• Alwaysusesuitableliftingequipmentandsecurepartsagainstfall-
ing.
• Never stand beneath a suspended load.
• The safety zone must be marked so that there is no danger when
the load (or part of it) slips away or if the hoisting gear snaps or is
ripped off.
• Loads must never be suspended for longer than necessary.
Accelerations and braking during the lifting operation must be
done so that danger to people is ruled out.
WARNING! Danger of bodily injury!
Improper transport can lead to personal injury.
• When lifting machines or parts using lugs, only hooks or shackles
can be used which meet the local safety regulations. The holding
chains/ropes must never be guided over or through sharp edges
without protection.
• When lifting, make sure that the load limit of a rope is reduced
when pulling at an angle.
• The safety and efficiency of a rope is best guaranteed when all
load-bearing elements are loaded as vertical as possible.
• Ifnecessary,use aliftingarm,to whichtheattachmentrope canbe
vertically attached.
• Ifblockand tackleorsimilarhoistinggearisused,verticalliftingof
the load must be ensured.The suspended load must be prevented
from swinging. This can be achieved, for example, by using a sec-
ondblock andtackle,wherebythe relativepullingangleto thever-
tical must be less than 30° in both cases.
3.3 Removing/replacing corrosion
protection (only NL pumps) The interior parts of the pump are protected by a corrosion-protec- tion film. This must be removed before commissioning. For this, fill
and empty the pump several times with a suitable product (e.g. petro-
leum-based solvent or an alkaline cleaning agent), and rinse with
water, if necessary.
WARNING! Danger of bodily injury!
Improperhandlingofsolventsor cleaningagentscanleadtobodily
injuries and environmental damage.
• Takeallprecautionarymeasurestoavoidriskstopersonnelandthe
environment during this operation.
• The pump must be installed and put into operation immediately
after this operation.
If the pump is stored for longer than 6 months, the corrosion protec-
tion film for protecting the inner parts of the pump must be applied
again regularly.Contact the manufacturer with regard to choosing
suitable products.

English
Installation and operating instructions Wilo-CronoNorm-NL, NLG 9
4Intendeduse
Purpose The glanded pumps of the Stratos Wilo-CronoNorm-NL/NLG series
are intended for use as circulation pumps in building services.The
pumps are only to be used for the approved fluids according to sec-
tion 5.2 “Technical data” on page 10.
Fields of application The Wilo-CronoNorm NL/NLG pumps may only be used for:
• Hot water heating systems
• Cooling and cold water circulation systems
• Potable water systems (special version)
• Industrial circulation systems
• Heat carrier circuits
Restrictions 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 (res-
idential and work rooms).
For these series, it is only possible to set them up outdoors in their
corresponding, special version (motor with idle heater).
CAUTION! Risk of damage to property!
Impermissible substances in the fluid can destroy the pump.
Abrasive solids (e.g. sand) increase pump wear.
Pumps without an Ex certificate are not suitable for use in poten-
tially explosive areas.
• Intendeduseofthepump/installationalsoincludesfollowingthese
instructions.
• Any use above and beyond these is regarded as improper use.
5 Product information
5.1 Type key The type key of a pump of type Wilo-CronoNorm-NL consists of the
following elements:
The type key of a pump of type Wilo-CronoNorm-NLG consists of the
following elements:
Example: NL 40/200B-11/2
NL Series designation: Standard pump
40 Nominal diameter DN of the pressure port
200 Nominal diameter of the impeller [mm]
BHydraulic version
11 Rated motor power P2[kW]
2 Number of poles
Example: NLG 200/315-75/4
NLG Series designation: Standard pump
200 Nominal diameter DN of the pressure port
315 Nominal diameter of the impeller [mm]
75 Rated motor power P2[kW]
4 Number of poles

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10 WILO SE 07/2013
5.2 Technical data
Please state all the information on the pump name plate when order-
ing spare parts.
Fluids If water/glycol mixtures with up to 40% glycol (or fluids with viscosi-
ties different from pure water) are used, the pump data must be cor-
rected accordingly (depending on the percentage mixture ratio and
fluid temperature). The motor power must also be adjusted if neces-
sary.
• Only use mixtures with corrosion inhibitors. The respective manufac-
turer's instructions are to be observed.
• The fluid must be free of sediments.
• 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:
The safety data sheet of the pumped fluid must always be observed!
Property Value Remarks
Nominal speed 2900, 1450, 960 rpm
Nominal diameters, DN NL: 32 - 150
NLG: 150 - 300
Permissible min./max. fluid temperature NL: -20 °C to +120 °C
NLG: -20 °C to +120 °C
Design with seal ring classifi-
cation
Permissible min./max. fluid temperature NL: -20 °C to +105 °C
NLG: -20 °C to +105 °C
Design with stuffing box
packing
Max. ambient temperature + 40 °C
Max. permissible operating pressure 16 bar
Insulation class F
Protection class IP 55
Flanges NL: PN 16 in acc. with DIN EN 1092-2
NLG: PN 16 in acc. with ISO 7005-2
Approved fluids • Heating water according to VDI 2035
• Cooling/cold water
• Water/glycol mixture up to 40% vol.
•Heattransferoil
• Other fluids (on request)
•Standardversion
•Standardversion
•Standardversion
• Special version or auxiliary
equipment (at additional
charge)
• Special version or auxiliary
equipment (at additional
charge)
Electrical connection 3~400 V, 50 Hz Standard version
Special voltages/frequencies Pumps with motors with different volt-
ages or with other frequencies are avail-
able on request.
Special version or auxiliary
equipment (at additional
charge)
Motor protection PTC thermistor sensor
Tab. 1: Technical data

English
Installation and operating instructions Wilo-CronoNorm-NL, NLG 11
5.3 Scope of delivery The pump can be delivered
• as a complete unit, consisting of the pump, electric motor, baseplate,
coupling and coupling protection (but without the motor)
or
• as a pump with bearing bracket without a baseplate.
Scope of delivery respectively:
• NL/NLG pump
• Installation and operating instructions
5.4 Accessories Accessories of any kind must be ordered separately.
See catalogue for detailed list.
6Descriptionandfunction
6.1 Description of the product The NL/NLG pump is a single-stage back pull out centrifugal pump
with spiral housing, which is sealed by a mechanical seal or a stuffing
box packing.
The mechanical seal is maintenance-free.
In conjunction with a Wilo control device (e.g. VR-HVAC, CC-HVAC),
the power of the pumps can be continuously controlled. This allows
optimisation of the pump output for the demands of the installation
and economically efficient pump operation.
The main purpose of the pumps is pumping pure fluids, such as water,
in heating, ventilating and air-conditioning systems or in irrigation
systems.
6.2 Design set-up Design:
Single-stage spiral housing pump in process design for horizontal
set-up.
NL: Powers and dimensions in acc. with EN 733
NLG: Extension series, not covered by EN 733
The pump consists of a radially divided spiral housing (NLG, addition-
ally with exchangeable stationary wear rings) and cast-on pump
bases. The impeller is a closed radial impeller. The pump shaft is sup-
ported by grease-lubricated radial ball bearings. The pump is sealed
via a mechanical seal in acc. with EN 12756 or by a stuffing box pack-
ing.

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12 WILO SE 07/2013
6.3 Anticipatednoise levelsfor standard
pumps Anticipated noise levels for standard pumps:
Tab. 2: Anticipated noise levels for standard pumps
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
Motor power
PN[kW] Measuring surface sound-pressure level Lp, A [dB(A)] 1)
Pump with three-phase motor
without speed control
2900 min-1 1450 min-1
≤0.55 52 58
0.75 60 51
1.1 60 53
1.5 67 55
2.2 67 59
3.0 67 59
4.0 67 59
5.5 71 63
7.5 71 63
11 74 65
15 74 65
18.5 74 71
22 76 71
30 79 72
37 79 73
45 79 73
55 79 74
75 80 72
90 81 70
110 81 72
132 -72
160 -72
200 -73
250 -74
315 -74

English
Installation and operating instructions Wilo-CronoNorm-NL, NLG 13
6.4 Permissible forces and torques on
the pump flanges
Wilo-CronoNorm-NL series Wilo-CronoNorm-NL series (see Fig. 3 and Tab. 3)
Values in acc. with ISO/DIN 5199 - class II (1997) - Appendix B,
Family no. 2
• for installing on the cast frame without concrete casting and a
pumping temperature up to 110 °C, or
• for installing on the cast frame with concrete casting and a pumping
temperature up to 120 °C .
Tab. 3: Permissible forces and torques on the pump flanges - Wilo-CronoNorm-NL series
Fig. 3: Permissible forces and torques on
the pump flanges - Wilo-CronoNorm-NL
series
ZY
X
Y
X
Z
DN Forces F [N] Torques M [Nm]
FYFZFXForces F MYMZMXTorques M
Pressure port
32 400 500 440 780 360 420 520 760
40 400 500 440 780 360 420 520 760
50 540 660 600 1040 400 460 560 820
65 820 1000 900 1580 460 520 640 940
80 820 1000 900 1580 460 520 640 940
100 1080 1340 1200 2100 500 580 700 1040
125 1620 2000 1800 3140 700 820 1000 1460
150 1620 2000 1800 3140 700 820 1000 1460
200 2160 2680 2400 4180 920 1060 1300 1920
250 2700 3340 2980 5220 1260 1460 1780 2620
300 3220 4000 3580 6260 1720 1980 2420 3560
Suction port
50 600 540 660 1040 400 460 560 820
65 900 820 1000 1580 460 520 640 940
80 900 820 1000 1580 460 520 640 940
100 1200 1080 1340 2100 500 580 700 1040
125 1800 1620 2000 3140 700 820 1000 1460
150 1800 1620 2000 3140 700 820 1000 1460
200 2400 2160 2680 4180 920 1060 1300 1920
250 2980 2700 3340 5220 1260 1460 1780 2620
300 3580 3220 4000 6260 1720 1980 2420 3560
350 4180 3760 4660 7300 2200 2540 3100 4560

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14 WILO SE 07/2013
Wilo-CronoNorm-NLG series Wilo-CronoNorm-NLG series (see Fig. 4 and Tab. 4)
Values in acc. with ISO/DIN 5199 - class II (1997) - Appendix B,
Family no. 2
• for installing on the cast frame without concrete casting and a
pumping temperature up to 110 °C, or
• for installing on the cast frame with concrete casting and a pumping
temperature up to 120 °C .
Tab. 4: Permissible forces and torques on the pump flanges - Wilo-CronoNorm-NLG series
Fig. 4: Permissible forces and torques on
thepump flanges-Wilo-CronoNorm-NLG
series
ZY
X
Y
X
Z
DN Forces F [N] Torques M [Nm]
FYFZFXForces F MYMZMXTorques M
Pressure port
150 2050 3110 2490 4480 1180 1760 2300 3127
200 3110 4890 3780 6919 1760 2580 3560 4736
250 4450 6670 5340 9634 2440 3800 5020 6752
300 5340 8000 6670 11705 2980 4610 6100 8206
350 5780 8900 7120 12779 3120 4750 6370 8537
400 6670 10230 8450 14851 3660 5420 7320 9816
Suction port
200 3780 3110 4890 6919 1760 2580 3530 4713
250 5340 4450 6670 9634 2440 3800 5020 6752
300 6670 5340 8000 11705 2980 4610 6100 8206
350 7120 5780 8900 12779 3120 4750 6370 8537
400 8450 6670 10230 14851 3660 5420 7320 9816
450 9120 7220 10920 15955 4150 5960 7720 10599

English
Installation and operating instructions Wilo-CronoNorm-NL, NLG 15
7 Installation and electrical
connection
Safety DANGER! Risk of fatal injury!
Improper installation and electrical connection can result in fatal
injury.
• Have the electrical connections established by licensed electri-
cians only, in compliance with the applicable regulations.
• Accident prevention regulations must be observed!
DANGER! Risk of fatal injury!
Failure to install safety devices on the motor, terminal box or on
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
coversor couplingcovers)thatwereremovedbeforemust berein-
stalled.
DANGER! Risk of fatal injury!
Thepumpitselfandthepumppartscanbeextremelyheavy.Falling
parts pose a risk of cuts, crushing injuries, bruises or impacts,
which may lead to death.
• Alwaysusesuitableliftingequipmentandsecurepartsagainstfall-
ing.
• Never stand beneath a suspended load.
CAUTION! Risk of damage to property!
Danger of damage due to improper handling.
• Have the pump installed by qualified personnel only.
CAUTION! Damage to the pump due to overheating!
Never allow the pump to run dry. Dry running can damage the
pump, particularly the mechanical seal or the stuffing box packing.
• Make sure that the pump never runs dry.
7.1 Preparation CAUTION! Risk of injury and damage to property!
Danger of damage due to improper handling.
• Never set up the pump unit on unfortified surfaces or surfaces
which cannot bear loads.
• Install only after completion of all welding and soldering work and
after the pipe system has been flushed, if required. Dirt can cause
pump failure.
• The pumps (in the standard version) must be protected from the
weather and installed in a frost/dust-free, well-ventilated environ-
ment which is not potentially explosive.
• Install the pump in a place that is easy to access so that later inspec-
tions, maintenance (e.g. exchanging the mechanical seal) or replace-
ment is easily possible.
• A travelling crane or a device for attaching hoisting gear should be
installed above the set-up site of large pumps.
7.2 Setting up the pump alone (variant
B, according to Wilo variant key)
7.2.1 General When installing a pump by itself (variant B, according to the Wilo var-
iant key), the required components (coupling, coupling protection
and baseplate of the manufacturer) should be used.

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16 WILO SE 07/2013
In any case, all components must meet the CE regulations. The cou-
pling protection must be compatible with EN 953.
7.2.2 Motor selection • Motor and coupling must be CE compliant.
• Select a motor with sufficient power (see Tab. 5).
Tab. 5: Motor/shaft power
Example:
• Water duty point:
Q = 100 m3/h
H = 35 m
Efficiency = 78 %
• Hydraulic power:
12.5 kW
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.
7.2.3 Coupling selection • 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 manufacturer.
• Follow the instructions of the coupling manufacturer.
• After installation on the base and connecting the lines, the coupling
alignment must be checked and corrected, if necessary. See also sec-
tion 7.5.2 “Check the coupling alignment” on page 19.
• After reaching the operating temperature, the coupling alignment
must be checked again. The coupling must be protected in acc. with
EN 953 to prevent accidental contact during operation.
7.3 Installation on a base of the pump
unit CAUTION! Danger of property and material damage! A flawed base or an incorrect installation of the unit on the base
can lead to a malfunction of the pump; this is not covered by the
warranty.
• Only have the pump unit installed by skilled personnel.
• A professional from the concrete area must be hired for all base
work.
7.3.1 Base
Wilo recommends installing the pump unit on a stable, flat concrete
base, which can support the unit long-term (see Fig. 5). This would
prevent vibrations from being transmitted.
The base, made of non-shrinking mortar, must be able to accommo-
date the forces, vibrations and impacts which occur during operation
of the pump unit. The base should be approx. 1.5 to 2x heavier than
the unit (guide value). The width and length of the base should each
be about 200 mm greater than the baseplate.
Shaft power < 4 kW 4 kW < P2< 10 kW 10 kW < P2< 40 kW 40 kW < P2
Limit value for
the P2motor 25 % 20 % 15 % 10 %
Fig. 5: Installing the pump on a base

English
Installation and operating instructions Wilo-CronoNorm-NL, NLG 17
The baseplate must be mounted on a firm base, which must be made
of high-quality concrete of sufficient thickness. The baseplate must
NOT be strained or pulled down on the surface of the base, but must
be supported so that the original alignment isn't changed.
Drilled holes for the anchor bolts must be provided in the base using
pipe sleeves. The diameter of the pipe sleeves is equivalent to about
2 ½ times the diameter of the screws, so that these can be moved to
reach their final positions.
Wilo recommends initially pouring the base up to about 25 mm below
the planned height. The surface of the concrete base should be well
contoured before curing. Remove the pipe sleeves after the concrete
cures.
If it is planned to pour out the baseplate, then a sufficient number of
steel rods (depending on the size of the baseplate) should be placed
evenly distributed in the base. The rods should project into the base-
plate by up to 2/3.
7.3.2 Preparing the baseplate for
anchoring • Thoroughly clean the base surface.
• Place shims (approx. 20-25 mm thick) on every screw hole on the
base surface (see Fig. 6). Alternatively, levelling screws can also be
used (see Fig. 7).
• For a length spacing of the fastening bores ≥800 mm, shims should
be additionally placed in the middle of the baseplate.
• Apply the baseplate and level this in both directions with additional
shims (see Fig. 8).
• Align the complete unit when installing on the base using a spirit level
(at the shaft/pressure port) (see Fig. 8). The baseplate should be hor-
izontal with a tolerance of 0.5 mm per meter.
• Fit anchor bolts (see Fig. 9) in the provided drilled holes.
NOTE:
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.
• Pour in anchor bolts with concrete. After the concrete has set, the
anchor bolts can be evenly and firmly tightened.
• Align the unit so that the pipes can be connected to the pump stress-
free.
Fig. 6: Shims on the base surface
Fig. 7: Levelling screws on the base surface
Fig. 8: Levelling and aligning the baseplate
Fig. 9: Anchor bolts

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18 WILO SE 07/2013
7.3.3 Pouring out the baseplate • If vibrations are to be reduced to a minimum, after fastening, the
baseplate can be poured out with a non-shrinking mortar over its
openings (the mortar must be suitable for installation on a base).
Hollow spaces are to be avoided. The concrete surface must be mois-
tened beforehand.
• The base/baseplate is to be planked.
• After curing, the anchor bolts are to be checked for a tight fit.
• The unprotected surfaces of the base are to be protected against
moisture with a suitable coating.
7.4 Pipework CAUTION! Risk of damage to property!
Improper pipework/installation can lead to property damage .
• The pipe connections of the pump are provided with protective
caps so that no foreign objects can penetrate during transport and
installation. These caps must be removed before connecting pipes.
• Welding beads, cinder and other contaminants can damage the
pump.
• The pipes must be sufficiently dimensioned, taking the pump inlet
pressure into account.
• The pump and pipes are to be connected using suitable seals, tak-
ingthepressure,temperatureandfluidintoaccount.Makesurethe
seals are correctly fit.
• Thepipesmustnottransferany forcesto thepump.Theyareto be
braceddirectlyinfrontofthepumpandconnectedwithouttension
(see Fig. 10).
• The permissible forces and torques on the pump connecting piece
aretobeobserved(seesection6.4“Permissibleforcesandtorques
on the pump flanges” on page 13).
• The expansion of the pipes in the event of a temperature rise is to
be compensated by suitable means (see Fig. 10). Air enclosures in
the pipes must be avoided by means of a corresponding installa-
tion.
NOTE:
The installation of return flow inhibitors and check valves is recom-
mended. This allows the pump to be drained and maintained without
having to drain the entire system.
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. This measure serves to avoid flow
cavitation.
• 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.
• Before connecting the pipes, the system must be cleaned, flushed and
blown through.
• The covers must be removed from the suction port and discharge
port.
• If required, a dirt filter is to be inserted in front of the pump in the pipe
on the suction side.
• Then connect the pipes to the pump connecting piece.
Fig. 10: Connecting the pump stress-free