Wilo Helix EXCEL Complete User manual

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Wilo-Helix EXCEL Complete
Wilo-Helix EXCEL Complete - November 2019
Installation and operation manual

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Fig. 3 Fig. 4
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Fig. A4
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en Installation and operating instructions 8

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English
1. General
1.1 About this document
The language of the original operating instruc-
tions is English. All other languages of these inst-
ructions 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 ope-
ration of the product.
These installation and operating instructions cor-
respond to the relevant version of the product and
the underlying safety standards valid at the time
of going to print.
2. Safety
These instructions contain important informa-
tion which must be followed when installing and
operating the pressure boosting package. It is th-
erefore imperative that they be read by both the
installer and the operator before the pump is in-
stalled or operated.
Both the general safety instructions in this section
and the more specic safety points in the follo-
wing sections should be observed.
2.1 Instruction symbols used in this operating ma-
nual
Symbols
General danger symbol
Hazards from electrical causes
NOTE: ...
Signals words:
DANGER! Imminently hazardous situation.
Will result in death or serious injury if not avoi-
ded.
WARNING! Risk of (serious) injury. ‘Warning’ im-
plies that failure to comply with the safety ins-
tructions is likely to result in (severe) personal
injury.
CAUTION! Risk of damage to the pump/ins-
tallation. ‘Caution’ refers to potential product
damage if this information is disregarded.
NOTE: Useful information on the handling of the
product. It attends the user to possible problems.
2.2 Personnel qualication
The personnel installing the pump must have the
appropriate qualication for this work.
2.3 Risks incurred by failure to comply with the
safety instructions
Failure to comply with the safety instructions
could result in personal injury or damage to the
pump or installation. Failure to comply with the
safety instructions could also invalidate any claim
for damages.
In particular, failure to comply with these safety
instructions could give rise, for example, to the
following risks:
• Failure of important pump or installation func-
tions,
• Failure of specied maintenance and repair me-
thods,
• Personal injury due to electrical, mechanical and
environmental causes,
• Damage to property.
2.4 Safety precautions for the operator
The relevant accident precaution regulations must
be observed. Dangers caused by electrical energy
must be excluded. Local or general regulations
[e.g. NEC, IEC, VDE, etc.] and directives from local
electrical supply companies are to be followed.
2.5 Safety precautions for inspection and
installation
The operator must ensure that all inspection and
installation work is carried out by authorized and
qualied specialists who have carefully studied
these instructions.
Work on the pump/unit must be carried out only
with the pump disconnected (locked out) from the
electrical supply and at complete standstill.
2.6 Unauthorized alterations and manufacture of
spare parts
Alterations to the pump or installation may only
be made in agreement with the manufacturer. The
use of original spare parts and accessories autho-
rized by the manufacturer will ensure safety. The
use of any other parts may invalidate claims revo-
king the liability of the manufacturer.
2.7 Improper use
The operation of the pressure booster package
can only be guaranteed if it is used in accordance
with paragraph 4 of the operating instructions. All
values must neither exceed nor fall below the limit
values given in the catalogue or data sheet.
Helix EXCEL Complete - Installation and operation manual (Version 1 11012019)

9
3. Transport and interim storage
When receiving the material, check that there has
been no damage during the transport. If shipping
damage has occurred, take all necessary steps
with the carrier within the allowed time.
CAUTION! Outside inuences may cause damages !
If the delivered material is to be installed later on,
store it in a dry place and protect it from impacts
and any outside inuences (humidity, frost etc.).
Handle the pump carefully so as not to damage the
unit prior to installation!
4. Application
This pump’s basic function is to pump hot or cold
water, water with glycol or other low viscosity
uids that contain no mineral oil, solid or abra-
sive substances, or materials having long bres.
The manufacturer’s approval is required for use to
pump corrosive chemicals.
DANGER! Risk of explosion!
Do not use this pump to handle ammable or ex-
plosive liquids.
Application areas:
• water distribution and boosting installations
• industrial circulation systems
• process uids
• cooling water circuits
• re-ghting and washing stations
• watering installations, etc.
5. Technical data
5.1 Pump designation
Helix EXCEL 80 - 02 - 2 / A3 / E / KS
Verticale
Multistages Pump
in-line with high
hydraulic efcient
With high efciency
Drive (motor/converter)
Nominal ow rate in gpm
Number of stages
1: pump casing in stainless steel 304
+ hydraulic in stainless steel 304
2: pump casing in stainless steel 316L
+ hydraulic in stainless steel 316L
3: pump casing in cast iron
GJL-250 + hydraulic
in stainless steel 304
A3: ANSI anges 300 lb
E : O rings EPDM
V : O rings VITON
KS : Cartridge seal + System orientation
5.2 Technical data
- Maximum operating pressure
• Pump casing: 363 PSI (25 BAR)
• Maximum suction pressure: 145 PSI (10 BAR)
- Temperature range
• Fluid temperature: 5 to 248 F (120°C)
• Ambient temperature: 5 to 104 F (40°C)
- Electrical data:
• Motor efciency: >93% (>IE4)
• Motor protection index: Enclosure Type 5
Indoor Use Only
• Electrical voltage: 400V (±10%) 50Hz
380V (±10%) 60Hz
460V (±10%) 60Hz
- Ambient humidity: < 90 % without
condensation
- Acoustic pressure level: ≤ 68 dB(A)
- Electromagnetic
compatibility (*)
• residential emission -
1st environment: EN 61800-3
• industrial immunity -
2nd environment: EN 61800-3
- Internal electrical circuit: Isolated secondary
circuit,
• PLEV, galvanically isolated Limited
voltage/current
circuit.
- Section of the power cable
(cable equipped of 4 wires):
• 1,1kW : 4 x 15 AWG
(1,5 mm2) Minimum
4 x 13 AWG
(2,5 mm2)Maximum
• 2,2/3,2/4,2 kW : 4 x 13 AWG
(2,5 mm2) Minimum
4 x 11 AWG
(4 mm2) Maximum
• 5,5/6,5/7,5 kW : 4 x 11 AWG (4
mm2)
(*) In the frequency range between 600 MHz and 1 GHz,
the display or the pressure indication in the display
might be disturbed in the direct vicinity (< 1 m from the
electronic module) of radio transmission installations,
transmitters or similar devices working in this frequency
range. The functioning of the pump is at no time af-
fected.
Helix EXCEL Complete - Installation and operation manual

10
English
Outline and pipe dimensions (Fig. 4).
5.3 Scope of Supply
• Multistage pump.
• Installation and operating instructions.
5.4 Accessories
Original accessories are available for Helix EXCEL
range.
The accessories must be ordered separatly.
• IF-Module PLR for connecting to PLR/interface
converter.
• IF-Module LON for connection to the LONWORKS
network (Fig. A6).
• Non-return valves (with nose or spring ring when
operating in constant pressure).
• protection kit against dry-running.
• sensor kit for pressure regulation (accuracy:
≤ 1 % ; use between 30 % and 100 % of the rea-
ding range).
Use of new accessories is recommended.
6. Description and function
6.1 Product description
Fig. 1
1 - Motor connection bolt
2 - Coupling guard
3 - Mechanical seal
4 - Hydraulic stage casing
5 - Impeller
6 - Pump shaft
7 - Motor
8 - Coupling
9 - Lantern
10 -Tube liner
11 -Flange
12 -Pump housing
13 -Base plate
Fig. 2 and 3
1 - Strainer
2 - Suction side isolation valve
3 - Discharge side isolation valve
4 - Check valve
5 - Drain + priming plug
6 - Air bleed screw + Filling plug
7 - Tank
8 - Foundation block
10 -Lifting hook
Fig. A1, A2, A3 and A4
1 - Dip Switches
2 - Pressure sensor (180 degrees from gauge)
3 - Tank
4 - Tank isolation valve
5 - Pressure Gauges
6 - Check Valve
7 - Isolation Valve
6.2 Design of product
• Helix EXCEL pumps are vertical high pressure
non-self priming pumps with inline connection
based on multistage design.
• Helix EXCEL pumps combine use of both high
efciency hydraulics and electronically- commu-
tated motors.
• All metallic parts in contact with water are made
of stainless steel.
• For models equipped with heaviest motor > 90lbs
, a specic coupling allows to change the seal
without removing the motor. A cartridge seal is
then used in order to ease maintenance.
• Special handling devices are integrated in order to
facilitate pump installation.
7. Installation and electrical connection
Installation and electrical work in compliance
with any local codes and by qualied personnel
only.
WARNING! Bodily injury!
Existing regulations for the prevention of acci-
dents must be observed.
WARNING! Electrical shock hazard!
Dangers caused by electrical energy must be ex-
cluded.
7.1 Commissioning
Unpack the pump and dispose of the packaging
in an environmentally-responsible manner.
7.2 Installation
The pumping booster package must be installed
in a dry, well-ventilated and frost-free place.
CAUTION! Possible damage of the pump!
Dirt and solder drops in to the pump body can af-
fect the pump operation.
• It is recommended that any welding and solde-
Dimensions Types
Helix EXCEL 10.../20.../30... Helix EXCEL 50.../80...
A 12 5/8”
B 18 1/4”
C 17 5/16”
D 16 1/8”
E 9 7/8” 11 3/4”
F 6 3/4” 7 1/4”
G 1 1/4” 2”
H 4” 5”
J 4x Ø9/16”
Helix EXCEL Complete - Installation and operation manual (Version 1 11012019)