Wilo Medana XCV1 User manual

Pioneering for You
·
Wilo-Medana XCV1
4245266 • Ed.03/04/2023 4245266
en Installation and operating instructions

Fig. 1
D A
E
F
20
ØJ
ØG 2xØK
B
H
C
PN16
F
20
ØG
ØH
4xØK
B
E
A
Ø J
D
C
PN20

Fig. 2
7
8
9
10
1
2
6
3
4
5
12
11
13

Fig. 4 Fig. 5 Fig. 6
Fig. 3
9
6b
6a
2
22
58
4
43
37
5
4
200mm min.
100mm min.
1
1
8
9
MOT. 230-400V (220-380V/240-415V)
3x400V
(3x380V/3x415V)
3x230V
(3x220V/3x240V)
3x400V
(3x380V/3x415V)
3x400V
(3x380V/3x415V)
MOT. 400V (380V∆/415V∆)
>4 KW
≤4 KW

Fig. 7
Fig. 8
6a
22
58
44 3
7
1
5a 5b 5c

en
Installation and operating instructions • Wilo-Medana XCV1 • Ed.03/04/2023 7
Contents
1 General ........................................................................................8
1.1 About this document ........................................................... 8
2 Safety...........................................................................................8
2.1 Symbols .................................................................................. 8
2.2 Personnel qualifications.......................................................9
2.3 Danger in the event of non-observance of the safety in-
structions ............................................................................... 9
2.4 Safety consciousness on the job ........................................ 9
2.5 Safety instructions for the operator................................... 9
2.6 Safety instructions for installation and maintenance work
...............................................................................................10
2.7 Unauthorised modification of components and use of
unauthorised spare parts ...................................................10
2.8 Improper use........................................................................10
3 Product information.................................................................10
3.1 Type key...............................................................................10
3.2 Technical data .....................................................................11
3.3 Scope of delivery.................................................................12
3.4 Accessories ..........................................................................12
4 Transport and interim storage................................................12
5 Application................................................................................12
6 Description and function.........................................................13
6.1 Description of the product ................................................13
6.2 Product features .................................................................13
7 Installation and electrical connection....................................13
7.1 Receipt of the product .......................................................13
7.2 Installation ...........................................................................13
7.3 Mains connection................................................................15
7.4 Electrical connection..........................................................15
7.5 Operation with a frequency converter.............................16
8 Commissioning .........................................................................16
8.1 Filling and degassing the system......................................16
8.2 Starting.................................................................................17
9 Maintenance..............................................................................17
10 Faults, causes and remedies....................................................18
11 Spare parts ................................................................................19
12 Disposal .....................................................................................19

en
8 Installation and operating instructions • Wilo-Medana XCV1 • Ed.03/04/2023
1 General
1.1 About this document The installation and operating instructions are an integral part of the product. Read these
instructions before carrying out any work and keep them at hand at all times. Strict adher-
ence to these instructions is a precondition for the correct installation and application of
the product. Comply with all indications and signs that appear on the product.
The language of the original installation and operating instructions is English. All other lan-
guages of these instructions are translations of the original installation and operating in-
structions.
2 Safety This chapter contains essential instructions that must be followed
during the different phases of the pump’s service life. Non-ob-
servance of these instructions may constitute a danger to per-
sons, the environment and the product, and may invalidate the
warranty. Non-observance may lead to the following hazards:
•Injuries due to electrical, mechanical and bacteriological factors
and electromagnetic fields.
•Damage to the environment due to leakage of hazardous ma-
terials.
•Damage to the installation.
•Failure of important product functions.
Also comply with the indications and safety instructions in
other chapters!
2.1 Symbols Symbols:
WARNING
General safety symbol
WARNING
Electrical risks
NOTICE
Notes
Warnings:
DANGER
Imminent danger.
May result in death or severe injuries if the hazard is not prevented.
WARNING
Non-observance may result in (very) severe injury.

en
Installation and operating instructions • Wilo-Medana XCV1 • Ed.03/04/2023 9
CAUTION
The product risks becoming damaged. “Caution” is used when there is a
risk to the product if the user does not observe procedures.
NOTICE
Note containing useful information for the user about the product. It as-
sists the user in the case of an issue.
2.2 Personnel qualifications The installation, application and maintenance personnel must
have the appropriate qualifications to complete this work. The
operator must ensure the personnel’s areas of responsibility,
terms of reference and their supervision. If the personnel are not
in possession of the necessary knowledge, they are to be trained
and instructed. If necessary, this training can be carried out by the
product’s manufacturer on the operator’s behalf.
2.3 Danger in the event of
non-observance of the
safety instructions
Non-observance of the safety instructions may constitute a
danger to persons, the environment and the product/unit. Non-
observance of the safety instructions also results in the loss of
any claims to damages. More specifically, non-observance can re-
sult in the following risks:
•danger to persons from electrical, mechanical and bacteriolo-
gical influences,
•damage to the environment due to leakage of hazardous ma-
terials,
•damage to property,
•failure of important product/unit functions,
•failure of required maintenance and repair processes.
2.4 Safety consciousness on
the job
The existing directives for accident prevention must be adhered
to. Danger from electrical current must be eliminated. Local dir-
ectives or general directives [e.g. IEC, VDE etc.] and instructions
from local energy supply companies must be respected.
2.5 Safety instructions for
the operator
This device is not intended for use by persons (including children)
with reduced physical, sensory or mental capabilities, or a lack of
experience or knowledge, unless they are monitored or have been
given detailed instructions concerning use of the device by a per-
son responsible for their safety.
Children must be supervised to ensure that they do not play with
the device.
•If hot or cold components of the product or installation pose a
danger, it is the customer’s responsibility to guard them against
being touched.

en
10 Installation and operating instructions • Wilo-Medana XCV1 • Ed.03/04/2023
•Guards protecting against touching moving components (such
as the coupling) must not be removed whilst the product is in
operation.
•Hazardous fluids (i.e. which are explosive, toxic or hot) which
have leaked (e.g. from the shaft seals) must be disposed of so
that they pose no danger to persons or to the environment.
National statutory provisions must be respected.
•Danger from electrical current must be eliminated. Local direct-
ives or general directives [e.g. IEC, VDE etc.] and instructions
from local energy supply companies must be respected.
2.6 Safety instructions for
installation and mainten-
ance work
The operator must ensure that all maintenance and installation
work is carried out by authorised and qualified personnel, who are
sufficiently informed from their own detailed study of the install-
ation and operating instructions. Work on the product/unit must
only be carried out when at a standstill. The procedures described
in the installation and operating instructions for deactivating the
product/installation must always be complied with.
Immediately on conclusion of the work, all safety and protective
devices must be put back in position and recommissioned.
2.7 Unauthorised modifica-
tion of components and
use of unauthorised
spare parts
Unauthorised modification of components and use of unauthor-
ised spare parts will impair the safety of the product/personnel,
and will render the manufacturer’s declarations regarding safety
void. Modifications to the product are only permissible following
consultation with the manufacturer.
Original spare parts and accessories authorised by the manufac-
turer ensure safety. The use of other parts absolves the manufac-
turing company of any and all liability.
2.8 Improper use The operational reliability of the supplied product is only guaran-
teed for conventional use in accordance with Chapter4 of the In-
stallation and operating instructions. The limit values must on no
account fall below or exceed the values specified in the cata-
logue/data sheet.
3 Product information
3.1 Type key
Example: Medana XCV1-C.606-5/E/E/16O
Wilo Brand
Medana Product family – Surface pump
XCompact design with coupling
CCommercial series
VVertical pump
1Series level (1 = entry level, 3 = standard level, 5 = premium level)
CCast housing
6Volume flow in m3/h

en
Installation and operating instructions • Wilo-Medana XCV1 • Ed.03/04/2023 11
Example: Medana XCV1-C.606-5/E/E/16O
06 Number of impellers
51 = Pump housing in stainless steel (1.4301)
5 = Pump housing in cast iron (GJL250)
EE = EPDM seal
EE = 230/400V - Frequency 50Hz – Three-phase
16 Nominal pressure in bar
16 = PN16
20 = PN20
OO = oval flange
F = round flange
3.2 Technical data
Maximum utilisation pressure
Pump housing 16 bar or 20 bar
Maximum suction pressure:
The discharge pressure must not exceed the maximum pressure of the pump
10bar
Temperature range
Fluid temperature -20°C to +120°C with EPDM seals
-15°C to +90°C with FKM gasket (op-
tional)
Ambient temperature max. -15°C to +50°C
Electrical data
Motor protection rating IP55
Insulation class F
Frequency See motor plate
Voltage See motor plate
Motor efficiency In accordance with IEC60034-30
Sound-pressure level dB(A) 0/+3dB(A)
Power (kW) 1.5 2.2 3 4 5.5
Noise level (dB(A)) 61 61 180 157 204
Size and connection dimensions in mm (Fig.1)
Cast iron baseplate + stainless steel housing (PN16)
Type A B C D E F G H J K
2/4m3/h 100 212 180 157 204 50 DN32 75 4x M12 2x M10
6m3/h 100 212 180 157 204 50 DN32 75 4x M12 2x M10
Cast housing (PN16)
Type A B C D E F G H J K
2/4m3/h 100 212 180 162 166 50 DN32 75 4x M12 2x M10
6m3/h 130 251 215 181 208 80/90 DN50 100 4x M12 4x M14
Cast iron baseplate + stainless steel housing (PN20)
Type A B C D E F G H J K
2/4m3/h 100 212 180 171 250 75 DN32 63 4x M12 4x M14
6m3/h 100 212 180 171 250 80 DN40 74 4x M12 4x M18
Cast housing (PN20)
Type A B C D E F G H J K
2/4m3/h 100 223 215 169 25 75 DN32 85 4x M14 4x M14

en
12 Installation and operating instructions • Wilo-Medana XCV1 • Ed.03/04/2023
Cast housing (PN20)
Type A B C D E F G H J K
6m3/h 130 258 215 178 280 80 DN40 110 4x M13 4x M19
3.3 Scope of delivery For PN16 connection:
•High-pressure multistage centrifugal pump
•Installation and operating instructions
•Oval counter flanges + screws and O-rings for PN16 connection
For PN20 connection:
•High-pressure multistage centrifugal pump
•Installation and operating instructions
3.4 Accessories The following original accessories are available for the MEDANA XCV1 (2/4/6) PN16 series:
Type key Article
2oval stainless steel 1.4301 counter flanges (screwing) (PN16 – 1") 416168
2oval stainless steel 1.4301 counter flanges (screwing) (PN16 – 1"1/4) 416169
Use only accessories that are new. Please contact the Wilo customer service for the list of
accessories.
4 Transport and interim storage When receiving the product, check that it has not been damaged during transport. If any
damage is found, take all necessary measures with the carrier in the time provided.
CAUTION
Risk of material damage
If the delivered material is to be installed at a later date, store it in a dry
place and protect it from impacts and any external influences (humidity,
frost etc.). Temperature range for transport and storage: -30°C to
+60°C.
Handle the product with care so as not to damage it prior to installation.
5 Application This pump has been designed to pump hot or cold water, potable or non-potable water,
water/glycol mixtures or other low-viscosity fluids that are free of mineral oil, solid or ab-
rasive substances, or materials containing long fibres. Pumping corrosive chemicals requires
the manufacturer’s prior approval.
DANGER
Risk of explosion
Do not use this pump to convey flammable or explosive liquids.
Fields of application:
MEDANA XCV1
Steam boiler
Reverse osmosis system
Pressure-maintaining system
Industrial cooling
Industrial circulation systems
Industrial processes
Cleaning systems
Water supply and pressure boosting

en
Installation and operating instructions • Wilo-Medana XCV1 • Ed.03/04/2023 13
NOTICE
Depending on the fluid properties, please contact the Wilo customer ser-
vice for material compatibility if necessary.
6 Description and function
6.1 Description of the product See Fig.2
1. Motor fixation bolt
2. Coupling guard
3. Mechanical seal
4. Hydraulic stage housing
5. Impellers
6. Pump shaft
7. Motor
8. Coupling
9. Lantern
10. Sleeve
11. Flange
12. Pump housing
13. Baseplate
See Fig.3
1. Strainer
2. Valve on the suction side
3. Valve on the discharge side
4. Non-return valve
5. Drain/priming plug
6. a-b Filling plug and venting plug
7. Tank
8. Foundation block
9. Lifting hook
6.2 Product features MEDANA XCV1 pumps are vertical non-self-priming high-pressure multistage centrifugal
pumps for in-line connection. All metal components in contact with the fluid are made of
stainless steel or coated grey cast iron. MEDANA XCV1 pumps are equipped with a simple
mechanical seal. Special handling devices are integrated to facilitate pump installation.
7 Installation and electrical con-
nection
All installation and electrical connection work must be carried out solely by authorised
and qualified personnel, in accordance with applicable regulations.
WARNING
Physical injuries
The applicable regulations for the prevention of accidents must be com-
plied with.
WARNING
Risk of electric shock
Hazards from electric current must be prevented.
7.1 Receipt of the product Unpack the pump and recycle or dispose of the packaging in an environmentally respons-
ible manner.
7.2 Installation The pump must be installed in a dry, well-ventilated location free of frost.

en
14 Installation and operating instructions • Wilo-Medana XCV1 • Ed.03/04/2023
CAUTION
Risk of damaging the pump
The presence of foreign matter or impurities in the pump housing may
affect the functioning of the product.
It is recommended to perform any welding and soldering work before in-
stalling the pump.
Rinse the circuit completely before installing and commissioning the
pump.
•The pump must be installed in a place easy to access for the purposes of inspection or
replacement.
•For heavy pumps, install a lifting hook (rep9) above the pump to facilitate its dismantling
(Fig.4).
WARNING
Risk of accident due to hot surfaces!
The pump must be installed in such a way that no one can touch the hot
surfaces of the product when it is in operation.
•Install the pump in a dry and frost-free place on a flat concrete block using appropriate
accessories. If possible, use an insulating material under the concrete block (cork or re-
inforced rubber) to avoid any noise and vibration transmission into the unit.
WARNING
Risk of tipping
Ensure that the pump is secured to a flat, rigid surface.
•The pump must be installed in an easily accessible location to facilitate inspection and
maintenance work. The pump must always be installed perfectly upright on a concrete
baseplate.
CAUTION
Risk of foreign matter in the pump
Ensure that all blanking plugs are removed from the pump housing be-
fore installation.
NOTICE
All pumps are factory-tested for their hydraulic properties and may
therefore contain a small amount of residual water. For hygiene pur-
poses, it is recommended to rinse the pump before installing it in any
potable water supply.
•For installation and connection dimensions, see section 5.2.
•Lift the pump only with appropriate lifting devices and suitable hoists and slings in com-
pliance with lifting regulations.
WARNING
Risk of tipping
There is a high risk of tipping due to the high centre of gravity, especially
for larger pumps. Take special care over the safe fixation of the pump
when handling.

en
Installation and operating instructions • Wilo-Medana XCV1 • Ed.03/04/2023 15
WARNING
Risk of tipping
Use integrated lifting hooks only if they are not damaged (e.g. by corro-
sion). Replace them if required.
WARNING
Risk of tipping
Never lift the complete pump using the motor hooks as these are de-
signed to lift the motor only.
7.3 Mains connection Connect the pump to the pipes by using only the counter flange accessories supplied with
the product.
CAUTION
Risk of damaging the pump
Tightening of screws or bolts must not exceed:
Tightening torque PN16 = M10 - 20Nm / PN20 = M12 - 30Nm
The use of an impact wrench is prohibited.
•The flow direction of the fluid is indicated on the pump housing – cast iron/stainless
steel (Fig.5).
•The suction and discharge pipe sockets must be installed so that they do not induce any
stress into the pump. The pipes must be attached so that the pump does not bear their
weight.
•We recommend installing gate valves on the suction and pressure sides of the pump.
•Use expansion joints to mitigate noise and vibration from the pump if required.
•The pipe cross-section must be at least equal to the diameter of the suction opening.
•The installation of a non-return valve in the discharge pipe is recommended to protect
the pump against pressure surges.
•If connected directly to the public drinking water mains, the suction pipe socket must
also be fitted with a non-return valve and a stop valve.
•If connected indirectly via a tank, the suction pipe socket must be fitted with a suction
strainer to stop impurities from entering the pump, and a non-return valve.
7.4 Electrical connection
DANGER
Risk of electrocution
In case of a non-compliant electrical connection, there is a risk of elec-
trocution.
Danger from electrical current must be eliminated.
■ Have the electrical connection established by an electrician approved
by the local energy supply company in accordance with local regulations.
■ Prior to the electrical connection, the pump must be voltage-free and
protected against unauthorised restart.
■ To ensure safe installation and operation, the unit must be earthed
correctly with the earth terminals of the power supply.
•Check that the rated current, voltage and frequency used match the information on the
motor.
•The pump must be connected to the power supply by means of a solid cable fitted with
a male connector or a main power switch.
•The three-phase motors must be connected to an authorised protection system. The
setting rated current must match the value indicated on the motor label.
•The connection cable must be placed in such a way that it never comes into contact
with the main sewer system and/or the pump housing and motor frame.

en
16 Installation and operating instructions • Wilo-Medana XCV1 • Ed.03/04/2023
•The pump/installation should be earthed in accordance with local regulations. A circuit
breaker can be used as additional protection.
•The power supply connection must comply with the wiring diagram (Fig.6).
7.5 Operation with a frequency con-
verter
•The pumps’ electric motors can be connected to a frequency converter in order to adapt
the product’s performance to the design duty point.
•It must not generate voltage spikes over 850V or variations of dU/dt over 2500V/μs at
the motor terminals.
•For higher values, an appropriate filter must be used: please contact the converter man-
ufacturer for the definition and selection of this filter.
•Please follow the converter manufacturer’s instructions carefully.
•The minimum variable speed must not fall below 40% of the rated speed of the pump.
8 Commissioning
8.1 Filling and degassing the system Check whether the water level in the tank and the inlet pressure are sufficient.
CAUTION
Risk of damage to the pump
Never run the pump dry. The pump must be filled before starting.
Venting process – Pump in inlet mode (Fig.7)
•Close the gate valves.
•Open the drain cock of the filling plug [6a].
•Slowly open the valve on the suction side [2].
•Close the drain cock again once the air has been removed and the liquid flows from the
pump [6a].
WARNING
Risk of burns
If the pumped fluid is hot and under high pressure, the fluid escaping at
the drain cock may cause burns or other injuries.
•Open the valve on the suction side completely [2].
•Start the pump and check that the direction of rotation complies with the specification
indicated on the pump label.
CAUTION
Risk of damaging the pump
An incorrect direction of rotation will cause poor pump performance and
may damage the coupling.
•Open the valve on the discharge side [3].
Venting process – Pump in suction mode (Fig.8)
•Close the valve on the discharge side [3]. Open the valve on the suction side [2].
•Remove the filling plug [6a].
•Partially open the priming/drain plug [5b].
•Fill the pump and the suction pipe with water.
•Ensure that there is no air trapped in the pump or suction pipe. Fill the system com-
pletely until all air is removed.
•Close the filling plug [6a].
•Start the pump and check that the direction of rotation complies with the specification
indicated on the pump label.

en
Installation and operating instructions • Wilo-Medana XCV1 • Ed.03/04/2023 17
CAUTION
Risk of damaging the pump
An incorrect direction of rotation will cause poor pump performance and
may damage the coupling.
•Slightly open the valve on the discharge side [3].
•Unscrew the drain cock to remove the air [6a].
•Close the drain cock once the air has escaped and the liquid is flowing in the pump.
WARNING
Risk of burns
If the pumped fluid is hot and under high pressure, the fluid escaping at
the drain cock may cause burns or other injuries.
•Open the valve on the discharge side fully [3].
•Close the priming/drain plug [5].
8.2 Starting
CAUTION
Risk of damaging the pump
The pump must not be operated at a zero flow rate (valve on the dis-
charge side closed).
WARNING
Risk of injury
Coupling guards must be in place and properly secured by all required
screws when the pump is running.
WARNING
High noise levels
High-power pumps may emit a high noise level. Use appropriate protec-
tion when working close to the pump for any extended period.
WARNING
The installation must be designed in such a way that there is no risk of
injury in case of fluid leakage (e.g. caused by mechanical seal failure).
9 Maintenance All maintenance work must be carried out by authorised and qualified personnel!
WARNING
Risk of electric shock
Danger from electrical current must be eliminated. Ensure that the
pump’s power supply is switched off and secured against unauthorised
reactivation before performing any work on the electric system.

en
18 Installation and operating instructions • Wilo-Medana XCV1 • Ed.03/04/2023
WARNING
Risk of burns
In case of high water temperatures and high system pressures, close the
guard valves upstream and downstream of the pump. First, allow pump
to cool down.
•No special maintenance required during operation.
•For replacement of the mechanical seal, please contact the Wilo customer service.
•Always keep the pump perfectly clean.
•Pumps that are not being used during periods of frost should be drained to avoid dam-
age.
Close the guard valves, open the drain/priming plug completely and the drain cock.
10 Faults, causes and remedies WARNING
Risk of electric shock
Danger from electrical current must be eliminated. Ensure that the
pump’s power supply is switched off and secured against unauthorised
reactivation before performing any work on the electric system.
WARNING
Risk of burns
In case of high water temperatures and high system pressures, close the
guard valves upstream and downstream of the pump. First, allow pump
to cool down.
Faults Causes Remedies
The pump is not functioning No electrical power supply Check the fusible cut-outs, the wiring and the
connections
The motor protection device has cut off the
power
Eliminate any motor overload
The pump is functioning but is fail-
ing to reach its duty point
Wrong direction of rotation Check the direction of rotation and correct it if
necessary
Parts of the pump are obstructed by foreign bod-
ies
Check and clean the pump
Presence of air in the suction pipe Make the suction pipe air-tight
Suction pipe too narrow Install a wider suction pipe
The valve on the suction side is not open enough Open the valve completely
The output of the pump is irregular Presence of air in the pump Remove the air from the pump and ensure that
the suction pipe is sealed. Possibly start the pump
for 20–30s. Open the drain cock to let air es-
cape. Close the drain cock and repeat the process
several times until no more air comes out of the
drain cock
The pump is vibrating or is noisy Foreign matter in the pump Remove foreign matter
The pump is not correctly secured to the ground Tighten the anchor screws
Bearing damaged Contact Wilo customer service
The motor is overheating, the mo-
tor protection engages
A phase is interrupted Check the fusible cut-outs, the wiring and the
connections
Ambient temperature too high Provide cooling
The mechanical seal is leaking The mechanical seal is faulty Replace the mechanical seal
If the fault cannot be resolved, please contact the Wilo customer service.

en
Installation and operating instructions • Wilo-Medana XCV1 • Ed.03/04/2023 19
11 Spare parts All spare parts should be ordered directly from the Wilo customer service. To prevent errors,
always quote the data on the pump’s rating plate when making an order. The spare parts
catalogue is available at www.wilo.com
12 Disposal Information on the collection of used electrical and electronic products.
Proper disposal and appropriate recycling of this product prevents damage to the environ-
ment and dangers to your personal health.
NOTICE
Disposal as domestic waste is forbidden!
In the European Union, this symbol can appear on the product, the pack-
aging or the accompanying documentation. It means that the electrical
and electronic products in question must not be disposed of along with
domestic waste.
To ensure proper handling, recycling and disposal of the used products in question, please
note the following points:
•Only hand over these products at designated, certified collecting points.
•Observe the locally applicable regulations! Please consult your local municipality, the
nearest waste disposal site, or the dealer who sold the product to you for information on
proper disposal. For further information on recycling, go to www.wilo-recycling.com.
Subject to change without prior notice.