Wilo NL-HE Series User manual

Pioneering for You
Wilo NL-HE
3327453 • Ed.01/2021-01
en Installation and operating instructions

en
Installation and operating instructions Wilo NL-HE 3
Table of contents
1 General information ........................................................................................................................................................................ 5
1.1 About these instructions ..........................................................................................................................................................................................5
1.2 Copyright ....................................................................................................................................................................................................................5
1.3 Subject to change......................................................................................................................................................................................................5
2 Safety................................................................................................................................................................................................ 5
2.1 Identification of safety instructions........................................................................................................................................................................5
2.2 Personnel qualifications............................................................................................................................................................................................7
2.3 Electrical work ............................................................................................................................................................................................................7
2.4 Transport.....................................................................................................................................................................................................................7
2.5 Installing/dismantling................................................................................................................................................................................................7
2.6 During operation ........................................................................................................................................................................................................8
2.7 Maintenance tasks.....................................................................................................................................................................................................9
2.8 Drive: NEMA standard motor....................................................................................................................................................................................9
2.9 Operator responsibilities...........................................................................................................................................................................................9
3 Application/use................................................................................................................................................................................ 9
3.1 Intended use...............................................................................................................................................................................................................9
3.2 Improper use............................................................................................................................................................................................................ 10
4 Product description....................................................................................................................................................................... 10
4.1 Design....................................................................................................................................................................................................................... 10
4.2 Operation with frequency converter.................................................................................................................................................................... 10
4.3 Technical data ......................................................................................................................................................................................................... 10
4.4 Type key................................................................................................................................................................................................................... 11
4.5 Scope of delivery..................................................................................................................................................................................................... 11
4.6 Accessories .............................................................................................................................................................................................................. 12
4.7 Anticipated noise levels ......................................................................................................................................................................................... 12
4.8 Permissible forces and torques on the pump flanges........................................................................................................................................ 13
5 Transportation and storage.......................................................................................................................................................... 13
5.1 Delivery..................................................................................................................................................................................................................... 13
5.2 Transport.................................................................................................................................................................................................................. 14
5.3 Storage ..................................................................................................................................................................................................................... 15
6 Installation and electrical connection ......................................................................................................................................... 16
6.1 Personnel qualifications......................................................................................................................................................................................... 16
6.2 Operator responsibilities........................................................................................................................................................................................ 16
6.3 Preparing the installation....................................................................................................................................................................................... 16
6.4 Setting up the pump by itself (variantB, Wilo variant key) .............................................................................................................................. 17
6.5 Installing the pump unit on a base ....................................................................................................................................................................... 17
6.6 Pipework................................................................................................................................................................................................................... 19
6.7 Aligning the unit...................................................................................................................................................................................................... 20
6.8 Electrical connection.............................................................................................................................................................................................. 24
7 Commissioning............................................................................................................................................................................... 25
7.1 Personnel qualifications......................................................................................................................................................................................... 26
7.2 Filling and venting................................................................................................................................................................................................... 26
7.3 Checking the direction of rotation....................................................................................................................................................................... 27
7.4 Switching on the pump.......................................................................................................................................................................................... 27
7.5 Switching frequency............................................................................................................................................................................................... 28
8 Shutdown........................................................................................................................................................................................ 28
8.1 Switching off the pump and temporary shutdown............................................................................................................................................ 29
8.2 Shutdown and storage ........................................................................................................................................................................................... 29

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4 WILO USA 2021-01
9 Maintenance/repair ....................................................................................................................................................................... 29
9.1 Personnel qualifications......................................................................................................................................................................................... 31
9.2 Operation monitoring............................................................................................................................................................................................. 31
9.3 Maintenance tasks.................................................................................................................................................................................................. 31
9.4 Draining and cleaning............................................................................................................................................................................................. 31
9.5 Dismantling.............................................................................................................................................................................................................. 32
9.6 Installation ............................................................................................................................................................................................................... 34
10 Troubleshooting possible causes and remedies......................................................................................................................... 37
10.1 Troubleshooting...................................................................................................................................................................................................... 38
10.2 Causes and remedies.............................................................................................................................................................................................. 38
11 Spare parts...................................................................................................................................................................................... 39
11.1 Spare parts list......................................................................................................................................................................................................... 40
12 Disposal........................................................................................................................................................................................... 41
12.1 Oils and lubricants................................................................................................................................................................................................... 41
12.2 Water-glycol mixture............................................................................................................................................................................................. 41
12.3 Protective clothing ................................................................................................................................................................................................. 41
12.4 Information on the collection of used electrical and electronic products...................................................................................................... 41

General information en
Installation and operating instructions Wilo NL-HE 5
1 General information
1.1 About these instructions These installation and operating instructions are an integral part of the device. Read these
instructions before commencing work and keep them in an accessible place at all times.
Strict adherence to these instructions is a requirement for intended use and correctly oper-
ating the device. All specifications and markings on the device must be observed. These in-
stallation and operating instructions correspond to the relevant version of the device and
the underlying safety standards that apply at the time of going to print.
The language of the original operating instructions is German. All other languages of these
instructions are translations of the original operating instructions.
1.2 Copyright These installation and operating instructions have been copyrighted by the manufacturer.
The contents, of whatever type, may not be reproduced or distributed, or used for purposes
of competition and shared with others.
1.3 Subject to change The manufacturer reserves the right to make technical modifications to the device or indi-
vidual components. The illustrations used may differ from the original and are intended as
an example representation of the device.
2 Safety This chapter contains basic information for the individual phases of the life cycle. Failure to
observe this information carries the following risks:
ƒInjury to persons from electrical, mechanical and bacteriological factors as well as elec-
tromagnetic fields
ƒEnvironmental damage from discharge of hazardous substances
ƒProperty damage
ƒFailure of important functions of the product
Failure to observe the information contained herein will result in the loss of claims for dam-
ages.
The instructions and safety instructions in the other chapters must also be observed!
2.1 Identification of safety instruc-
tions These installation and operating instructions set out safety instructions for preventing per-
sonal injury and damage to property. These safety instructions are shown differently:
ƒSafety instructions relating to personal injury start with a signal word, are preceded by a
corresponding symbol and are shaded in grey.
DANGER
Type and source of the danger!
Consequences of the danger and instructions for avoidance.
ƒSafety instructions relating to property damage start with a signal word and are displayed
without a symbol.
CAUTION
Type and source of the danger!
Consequences or information.
Signal words
ƒDANGER!
Failure to observe the safety instructions will result in serious injuries or death!
ƒWARNING!
Failure to follow the instructions can lead to (serious) injuries!
ƒCAUTION!
Failure to follow the instructions can lead to property damage and a possible total loss.

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6 WILO USA 2021-01
ƒNOTICE!
Useful information on handling the product
Symbols
These instructions use the following symbols:
Danger – high voltage
General warning symbol
Warning – danger of crushing
Warning – risk of cutting injuries
Warning – hot surfaces
Warning – high pressure
Warning – suspended loads
Personal protective equipment: wear a safety helmet
Personal protective equipment: wear foot protection
Personal protective equipment: wear hand protection
Personal protective equipment: wear mouth protection
Personal protective equipment: wear safety goggles
Useful information

Safety en
Installation and operating instructions Wilo NL-HE 7
2.2 Personnel qualifications Personnel must:
ƒBe instructed about locally applicable regulations governing accident prevention.
ƒHave read and understood the installation and operating instructions.
Personnel must have the following qualifications:
ƒElectrical work: A qualified electrician must carry out the electrical work.
ƒInstallation/dismantling must be carried out by a qualified technician who is trained in the
use of the necessary tools and fixation materials.
Definition of “qualified electrician”
A qualified electrician is a person with appropriate technical education, knowledge and ex-
perience who can identify and prevent electrical hazards.
2.3 Electrical work ƒElectrical work must be carried out by a qualified electrician.
ƒWhen connecting to the mains, comply with the locally applicable laws and regulations of
the local energy supply company.
ƒBefore commencing work, disconnect the device from the mains and secure it against
being switched on again without authorization.
ƒTrain personnel on how to make the electrical connection as well as on the methods for
switching off the device.
ƒObserve the technical information in these installation and operating instructions as well
as on the rating plate.
ƒGround the device.
ƒObserve the manufacturer’s specifications when connecting to electrical switching sys-
tems.
ƒComply with the specifications on electro-magnetic compatibility when using electronic
start-up controllers (e.g. soft starter or frequency converter). If required, take into ac-
count special measures (shielded cables, filters, etc.).
ƒReplace defective connection cables. Contact customer service.
2.4 Transport ƒWear protective equipment:
–Safety gloves for protection against cuts
–Safety shoes
–Sealed safety goggles
–Safety helmet (when using lifting equipment)
ƒOnly use legally specified and approved lifting gear.
ƒSelect lifting gear based on the available conditions (weather, attachment point, load,
etc.).
ƒAlways attach the lifting gear to the designated attachment points (lifting eyes).
ƒPosition the lifting equipment in a way that ensures stability during use.
ƒWhen using lifting equipment, a second person must be present to coordinate the pro-
cedure if required (e.g. if the operator’s field of vision is blocked).
ƒPersons must not stand underneath suspended loads. Do not move suspended loads over
workplaces where people are present.
Please note the following information during transport and prior to installation:
ƒDo not reach into suction ports, discharge ports or other openings.
ƒAvoid the penetration of foreign objects. To this end, leave the protective covers or
packaging on until they have to be removed for installation.
ƒPackaging and covers may be removed from suction or outlet openings for inspection
purposes. They must be put back on afterwards to protect the pump and ensure safety.
2.5 Installing/dismantling ƒWear the following protective equipment:
–Safety shoes
–Safety gloves for protection against cuts
–Safety helmet (when using lifting equipment)
ƒComply with laws and regulations on work safety and accident prevention in force at the
site of installation.
ƒThe procedure described in the installation and operating instructions for shutting down
the product/unit must be strictly observed.
ƒDisconnect the device from the mains and secure it against being switched on again
without authorization.

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8 WILO USA 2021-01
ƒAll rotating parts must be at a standstill.
ƒClose the gate valve in the inlet and in the pressure pipe.
ƒProvide adequate aeration in enclosed spaces.
ƒClean the device thoroughly. Disinfect devices that use fluids hazardous to health!
ƒMake sure that there is no risk of explosion when carrying out any type of welding work
or work with electrical devices.
2.6 During operation ƒWear protective equipment:
–Safety shoes
–Safety helmet (when using lifting equipment)
ƒThe work area in which the device is used is not a recreational area. No persons are al-
lowed in the work area during operation.
ƒThe operator must report any faults or irregularities to a line manager immediately.
ƒIf hazardous defects occur, the operator must immediately deactivate the device. Haz-
ardous defects include:
–Malfunction of safety and monitoring devices
–Damage to housing parts
–Damage to electrical equipment
ƒOpen all gate valves in the piping on both the suction and pressure sides.
ƒCollect any leakage of fluids and operating fluids immediately and dispose of it according
to the locally applicable guidelines.
ƒTools and other objects should only be kept in their designated places.
Thermal hazards
Most drive surfaces can become hot during operation. The areas of the mechanical seal and
bearing bracket on the pump can become hot in the event of a malfunction or incorrect set-
ting.
The surfaces in question also remain hot after switching off the unit. These surfaces may
only be touched with extreme caution. Wear protective gloves if it is essential to touch hot
surfaces.
Make sure that the drained water is not too hot for more intensive contact with skin.
Introduce appropriate equipment to protect components that may become hot against ac-
cidental contact.
Hazard due to articles of clothing or other objects being caught
To avoid the dangers presented by the rotating parts of the device:
ƒDo not wear loose or frayed clothing or jewellery.
ƒDo not dismantle devices for protecting against accidental contact with moving parts
(e.g. coupling guard).
ƒOnly put the device into operation once this protection is in place.
ƒThe devices for protecting against accidental contact with moving parts may only be re-
moved when the system is at a standstill.
Hazards due to noise
Observe the sound pressure specifications on the motor rating plate. The sound pressure
value of the pump is generally about the same value as that of the motor +2dB(A).
Observe the applicable health and safety regulations. If the device is operated under normal
operating conditions, the operator must measure the sound pressure.
Sound pressure levels of 80dB(A) and above must be noted in the work regulations! The op-
erator must also introduce the following preventative measures:
ƒInform the operating personnel
ƒProvide hearing protection
For a sound pressure level of 85dB(A) and above, the operator must:
ƒMake it a mandatory requirement to wear hearing protection
ƒDemarcate the noisy areas.
ƒTake measures to reduce noise (e.g. insulation, noise barriers)

Application/use en
Installation and operating instructions Wilo NL-HE 9
Leakages
Observe local standards and regulations. Avoid pump leakages to protect persons and the
environment against hazardous (explosive, toxic or hot) substances.
Ensure that a dry run of the pump is not possible. A dry run can damage the shaft seal and
thereby cause leakages.
2.7 Maintenance tasks ƒWear the following protective equipment:
–Sealed safety goggles
–Safety shoes
–Safety gloves for protection against cuts
ƒOnly carry out the maintenance tasks described in these installation and operating in-
structions.
ƒOnly original parts from the manufacturer may be used for maintenance and repairs. Use
of parts other than original parts releases the manufacturer from any liability.
ƒCollect any leakage of fluid and operating fluid immediately and dispose of it according
to the locally applicable guidelines.
ƒStore tools at the designated locations.
ƒAfter completing work, reattach all safety and monitoring devices and check that they
function properly.
2.8 Drive: NEMA standard motor The hydraulics have a standardized connection flange for installing a NEMA standard motor.
See the technical data for the performance data (e.g. size, construction, hydraulic rated
power, speed) needed to select a motor.
2.9 Operator responsibilities The operator must:
ƒProvide the installation and operating instructions in a language which the personnel can
understand.
ƒMake sure that personnel are suitably trained for the specified work.
ƒEnsure that safety and information signs mounted on the device are always legible.
ƒTrain personnel with regard to the operating principles of the system.
ƒEliminate any risk from electrical current.
ƒEquip hazardous components (extremely cold, extremely hot, rotating, etc.) with an on-
site guard.
ƒDemarcate and cordon off the hazardous area.
ƒDefine personnel responsibilities to ensure safe working practice.
Children and persons younger than 16years or with reduced physical, sensory or mental ca-
pacities or limited experience are prohibited from handling the device! Persons under the
age of 18 must be supervised by a technician.
3 Application/use
3.1 Intended use The glanded pumps in the Wilo NL-HE series are intended for use as circulators in building
services.
The Wilo NL-HE pumps may only be used for:
ƒHot-water heating systems
ƒCooling and cold water circulation systems
ƒDrinking water systems (special version)
ƒIndustrial circulation systems
ƒHeat carrier circuits
ƒIrrigation
The pumps are only approved for the fluids specified in the “Technical data” section.

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10 WILO USA 2021-01
3.2 Improper use WARNING!Misuse of the pump can lead to dangerous situations and damage.
ƒNever use with fluids that have not been approved by the manufacturer.
ƒNon-permitted substances in the fluid can destroy the pump. Abrasive solids (e.g. sand)
increase pump wear.
ƒHighly flammable materials/fluids should always be kept at a safe distance from the
device.
ƒNever allow unauthorized persons to carry out work.
ƒNever operate the pump beyond the specified limits of use.
ƒNever carry out unauthorzsed conversions.
ƒUse authorized accessories and genuine spare parts only.
Typical installation locations are technical rooms within the building with other domestic in-
stallations. No provision has been made for direct installation of the pump in rooms used for
other purposes (residential and work rooms).
Outdoor installation requires a corresponding, special version (motor with anti-condensa-
tion heater).
Intended use also includes compliance with this manual. Any other use is regarded as non-
compliant with the intended use.
4 Product description
4.1 Design The Wilo NL-HE pump is a single-stage back pull-out-centrifugal pump with spiral housing
for horizontal installation. Motor dimensions in accordance with NEMA standards.
Suitable Wilo control devices (e.g. Wilo-EFC Variable Frequency Drive) can control the power
of the pumps continuously. This allows optimization of the pump output for the demands of
the installation and particularly economically efficient pump operation.
4.1.1 Hydraulics The pump consists of a radially divided spiral housing and cast-on pump support feet. The
impeller is a closed radial impeller. The pump shaft is supported by grease-lubricated radial
ball bearings.
4.1.2 Motor The system is driven by NEMA standard motors in a three-phase current version.
NOTICE
Use a heat-resistant mains connecting cable in systems where fluid temperatures exceed
194°F!
4.1.3 Seal The fluid pump is sealed via a mechanical seal in accordance with EN12756.
4.2 Operation with frequency con-
verter Operation on the frequency converter is permitted. Refer to the documentation from the
motor manufacturer for the relevant requirements and observe its contents.
4.3 Technical data General
Date of manufacture [MFY] See rating plate
Mains connection [U/f] See motor rating plate
Power consumption [P1]See motor rating plate
Rated power [P2]See motor rating plate
Rated speed [n] See rating plate
Max. delivery head [H] See rating plate
Max. volume flow [Q] See rating plate
Permissible fluid temperature [t] -4°F to +284°F

Product description en
Installation and operating instructions Wilo NL-HE 11
Permissible ambient temperature
[t]
+104°F
Permissible operating pressure
[Pmax]
232psi
Flanges 125# ANSI in accordance with ASMEB16.1
Permissible fluids
– Heating water
– Cooling/cold water
– Water-glycol mixture up to 40% vol.
Protection class IP21, IP23, IP55
Insulation class [Cl.] F
Motor protection See manufacturer’s documentation
Special version or with auxiliary equipment (at additional charge)
Permissible fluids – Heating water
– Water-glycol mixture up to 40% vol.
Special voltages/frequencies Pumps with motors with different voltages or other
frequencies are available on request
Additional information CH
Approved fluids for heating pumps
– No oxygen binding agents, no chemical sealant.
– Ensure enclosed system from corrosion perspect-
ive.
Statement of date of manufacture
The date of manufacture is stated in the format: MMDDYYYY
ƒMM = month
ƒDD = day
ƒYYYY = year
4.4 Type key Example: NL-HE 2x1.25x5-5-182/4T-460-2-TEFC
NL-HE Product family
2Nominal diameter of Suction Flange
1.25 Nominal diameter of Discharge Flange
5Nominal diameter of the impeller in inches
5Rated motor power in hp
182/4T Motor Frame size
460 Motor rated voltage
2Motor poles
TEFC Motor Enclosure
4.5 Scope of delivery Complete unit
ƒNL-HE pump
ƒBaseplate
ƒCoupling and coupling guard
ƒWith or without electric motor
ƒInstallation and operating instructions
Pump by itself:
ƒNL-HE pump
ƒBearing bracket without baseplate
ƒInstallation and operating instructions

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12 WILO USA 2021-01
4.6 Accessories Accessories have to be ordered separately. For a detailed list, consult the catalogue and
spare parts documentation.
4.7 Anticipated noise levels
4.7.1 Pump with three-phase motor,
60Hz without speed control Motor power PN [hp] Measuring surface sound-pressure level Lp, A [dB(A)] 1)
2-Pole (3550rpm) 4-Pole (1750rpm)
0.75 – 52
168 52
1.5 68 52
268 52
366 56
566 56
7.5 68 59
10 68 59
15 72 64
20 72 64
25 72 64
30 73 64
40 76 66
50 76 66
60 79 69
75 84 69
100 84 69
125 84 73
150 84 78
200 85 78
250 85 78
300 85 75
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
Table1: Anticipated noise levels for standard pump (60Hz)

Transportation and storage en
Installation and operating instructions Wilo NL-HE 13
4.8 Permissible forces and torques on
the pump flanges
Z
Y
X
Y
X
Z
Fig.1: Permissible forces and torques on the
pump flanges–pump made of grey cast iron
(see table “Permissible forces and torques on
the pump flanges”
ANSI Forces F [lb] Torques M [lb]
FXFYFZΣ Forces F MXMYMZΣ Torques M
DISCHARGE
1.25" 71 67 83 130 3407 2328 2637 4956
1.5" 87 79 98 154 4027 2788 3257 5885
2" 118 106 130 205 4337 3098 3567 6354
2.5" 146 134 165 260 4646 3407 3717 6815
3" 177 161 197 311 4956 3567 4027 7284
4" 236 212 264 413 5425 3876 4496 8054
5" 279 252 311 488 6505 4646 5885 9452
6" 354 319 393 618 7744 5425 6354 11310
SUCTION
2" 130 118 106 205 4337 3098 3567 6354
2.5" 165 146 134 260 4646 3407 3717 6815
3" 197 177 161 311 4956 3567 4027 7284
4" 264 236 212 413 4525 6531 4496 8054
5" 311 279 252 477 6505 4646 5885 9452
6" 393 354 319 618 7744 5425 6354 11310
8" 527 472 425 822 10071 7124 823 14868
Values in acc. with ISO/DIN 5199 – class II (2002) – Appendix B, Family no. 1A
Table2: Permissible forces and torques on the pump flanges
If not all working loads reach the maximum permitted values, one of these loads may exceed
the normal limit value. This is under the condition that the following additional conditions
are fulfilled:
ƒAll force and torque components are limited to 1.4times the maximum permitted value.
ƒThe forces and torques acting on each flange meet the requirements of the compensa-
tion equation.
Fig.2: Compensation equation
Σ Feffective and Σ Meffective are the arithmetic sums of the effective values of both pump flanges
(inlet and outlet). Σ Fmax. permitted and Σ Mmax. permitted are the arithmetic sums of the maximum
permitted values of both pump flanges (inlet and outlet). The algebraic signs of Σ F and Σ M
are not taken into consideration in the compensation equation.
5 Transportation and storage
5.1 Delivery The pump is secured to a pallet ex works and is protected against dirt and moisture.
Check the shipment immediately on receipt for defects (damage, completeness). Defects
must be noted on the freight documentation. Any defects must be notified to the transport
company or the manufacturer immediately on the day of receipt of shipment. Subsequently
notified defects can no longer be asserted.

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14 WILO USA 2021-01
5.2 Transport
DANGER
Risk of fatal injury due to suspended loads!
Never allow anyone to stand under suspended loads! Danger of (serious) injuries caused
by falling parts. Loads may not be carried over work places where people are present!
The safety zone must be marked so that there is no danger when the load (or part of it)
slips away or if the lifting device snaps or is ripped off.
Loads must never be suspended for longer than necessary.
Accelerations and braking during the lifting operation must be performed in a way that
rules out any danger to people.
WARNING
Hand and foot injuries due to lack of protective equipment!
Danger of (serious) injuries during work. Wear the following protective equipment:
• Safety shoes
• Safety gloves for protection against cuts
• Sealed safety goggles
• Safety helmet must be worn if lifting equipment is used!
NOTICE
Use only properly functioning lifting equipment!
Use only properly functioning lifting equipment to lift and lower the pump. Ensure that
the pump does not become jammed during lifting and lowering. Do not exceed the maxi-
mum bearing capacity of the lifting equipment! Check that lifting equipment is function-
ing properly before use!
CAUTION
Property damage due to incorrect transport
To ensure proper alignment, all equipment is pre-assembled. If dropped or if improperly
handled, there is a risk of misalignment or deficient performance due to deformations.
The pipes and valves will not withstand loads and should not be used to secure loads in
transit.
• Only use permitted lifting gear for transport. Ensure the stability of the load since, with
this particular pump design, the centre of gravity is shifted to the top (top-heavy).
•Never attach lifting gear to shafts in order to lift the unit.
• Do not use the transport lugs on the pump or motor to lift the entire unit. They are only
meant for transporting the individual components during installation or dismantling.
Only remove the outer packaging at the place of utilization to ensure that the pump is not
damaged during transport.

Transportation and storage en
Installation and operating instructions Wilo NL-HE 15
CAUTION
Risk of damage due to incorrect packaging.
If the pump is transported again at a later date, it must be packaged so that it cannot be
damaged during transport. Use the original packaging for this, or choose equivalent
packaging.
5.2.1 Proper lifting of the pump
Fig.3: Lifting of the pump
ƒComply with applicable national safety regulations.
ƒUse legally specified and approved lifting gear.
ƒSelect the lifting gear based on the prevailing conditions (weather, attachment point,
load, etc.).
ƒOnly attach the lifting gear to the attachment point. Fix in place with a shackle.
ƒNever feed the lifting gear over or through transport lugs without protection.
ƒNever feed the lifting gear over sharp edges without protection.
ƒUse lifting equipment with sufficient bearing capacity.
ƒThe stability of the lifting equipment must be ensured during operation.
ƒWhen using lifting equipment, ensure a second person is present to coordinate the pro-
cedure if required (e.g. if the operator’s field of vision is blocked).
ƒWhen lifting, make sure that the load limit of the lifting gear is reduced when pulling at
an angle. The safety and efficiency of the lifting gear is best guaranteed when all load-
bearing elements are loaded vertically. If necessary, use a lifting arm, to which the lifting
gear can be vertically attached.
ƒEnsure the load is lifted vertically!
ƒPrevent the suspended load from swinging!
5.2.2 Proper lifting of the complete unit
Fig.4: Lifting the complete unit
ƒComply with applicable national safety regulations.
ƒUse legally specified and approved lifting gear.
ƒSelect the lifting gear based on the prevailing conditions (weather, attachment point,
load, etc.).
ƒOnly attach the lifting gear to the attachment point. Fix in place with a shackle.
ƒNever feed the lifting gear over or through transport lugs without protection.
ƒNever feed the lifting gear over sharp edges without protection.
ƒUse lifting equipment with sufficient bearing capacity.
ƒThe stability of the lifting equipment must be ensured during operation.
ƒWhen using lifting equipment, ensure a second person is present to coordinate the pro-
cedure if required (e.g. if the operator’s field of vision is blocked).
ƒWhen lifting, make sure that the load limit of the lifting gear is reduced when pulling at
an angle. The safety and efficiency of the lifting gear is best guaranteed when all load-
bearing elements are loaded vertically. Make sure that the motor terminal box does not
interfere with the lifting equipment. If necessary, use a lifting arm, to which the lifting
gear can be vertically attached.
ƒEnsure the load is lifted vertically!
ƒPrevent the suspended load from swinging!
5.3 Storage
NOTICE
Improper storage can lead to damage to the equipment.
Damage caused by improper storage is not covered by the guarantee or warranty.
ƒRequirements at the storage location:
–dry
–clean
–well-ventilated
–free from vibrations
–free from humidity

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16 WILO USA 2021-01
–free from rapid or extreme changes in temperature
ƒStore the product somewhere safe against mechanical damage.
ƒProtect the bearings and couplings from sand, gravel and other foreign objects.
ƒLubricate the unit to prevent rust and bearing seizing.
ƒManually rotate the drive shaft several times once a week.
Storage for more than three months
Additional precautionary measures:
ƒAll rotating parts must be coated with a suitable protective medium to protect them from
rust.
ƒIf the pump is to be stored for more than a year, consult the manufacturer.
6 Installation and electrical con-
nection
6.1 Personnel qualifications ƒElectrical work: A qualified electrician must carry out the electrical work.
6.2 Operator responsibilities ƒObserve locally applicable accident prevention and safety regulations of professional and
trade associations.
ƒObserve all regulations for working with heavy loads and under suspended loads.
ƒProvide protective equipment and ensure that the protective equipment is worn by per-
sonnel.
ƒAvoid pressure surges!
Pressure surges can occur in long pressure pipes. These pressure surges can lead to the
destruction of the pump!
ƒStructural components and foundations must be of sufficient stability in order to allow
the device to be fixed in a secure and functional manner. The operator is responsible for
the provision and suitability of the building/foundation!
ƒCheck that the available consulting documents (installation plans, design of the operat-
ing space, inflow conditions) are complete and correct.
6.3 Preparing the installation
WARNING
Risk of personal injury and property damage due to improper handling!
• Never set up the pump unit on unfortified surfaces or surfaces that cannot bear
loads.
• Flush the pipe system if required. Dirt can cause the pump to fail.
• Install only after completion of all welding and soldering work and after the pipe sys-
tem has been flushed, if required.
• Observe the minimum axial distance between a wall and the fan cover of the motor:
8inches + diameter of the fan cover
ƒThe pumps (in the standard version) must be protected from the weather and installed in
a frost/dust-free, well-ventilated environment that is not potentially explosive.
ƒMount the pump in a readily accessible place. This makes it easier to complete inspec-
tions, maintenance (e.g. mechanical seal change) or replacement in the future.
ƒA travelling crane or a device for attaching hoisting gear should be installed above the
set-up site of large pumps.

Installation and electrical connection en
Installation and operating instructions Wilo NL-HE 17
6.4 Setting up the pump by itself
(variantB, Wilo variant key) When installing a pump by itself, the required coupling guard and baseplate of the pump
manufacturer should be used. In any case, all components must meet the local regulations.
An OSHA compliant coupling guard should be used.
6.4.1 Selecting the motor Select a motor with sufficient power.
Shaft power <5hp 5hp <P2
<15hp
15hp <P2
<50hp
50hp <P2
Limit value P2 for
the motor
25% 20% 15% 10%
Table3: Motor/shaft power
Example:
ƒDuty point water: Q=440gpm; 115feet
ƒEfficiency: 78%
ƒHydraulic power: 16.75hp
The required limit value for this duty point lies at 16.75hpx1.15=19.26hp. A motor with a
power of 20hp would be the correct choice.
6.4.2 Selecting the coupling ƒTo establish the connection between the pump with bearing bracket and motor, use a
flexible coupling.
ƒSelect the coupling size according to the recommendations of the coupling manufac-
turer.
ƒFollow the instructions of the coupling manufacturer.
ƒAfter installation on the base and connecting the pipes, check the coupling alignment
and correct it if necessary. The procedure is described in the chapter “Coupling align-
ment”.
ƒAfter reaching the operating temperature, the coupling alignment must be checked
again.
ƒAvoid accidental contact during operation. The coupling should be protected with an
OSHA compliant coupling guard.
6.5 Installing the pump unit on a base
CAUTION
Danger of property and material damage!
A missing foundation or incorrect installation of the unit on the base can lead to a mal-
function of the pump. Incorrect installation is not covered by the warranty.
• Only have the pump unit installed by qualified personnel.
• A professional from the concrete sector must be hired for all base work.
6.5.1 Base
Fig.5: Installing the unit on a base
The base must be able to support the unit installed on the baseplate indefinitely. The base
must be level to ensure there is no tension on the baseplate or unit. Wilo recommends using
premium, non-shrink concrete of an adequate thickness for manufacturing. This would pre-
vent vibrations from being transmitted.
The base must be able to accommodate the forces, vibrations and impact that occur.
Guidance values for dimensioning the base:
ƒApprox. 1.5to 2x heavier than the unit.
ƒThe width and length should each be about 8inches greater than the baseplate.
The baseplate must not be strained or pulled down on the surface of the base. It must be
supported so that the original alignment is not changed.
Prepare drilled holes for the anchor bolts. Position pipe sleeves vertically in the base at the
corresponding points. Diameter of the pipe sleeves: Around 2½x the diameter of the
screws. This allows the screws to be moved in order to achieve their final positions.

en Installation and electrical connection
18 WILO USA 2021-01
Wilo recommends initially pouring the concrete base up to about 1inch below the planned
height. The surface of the concrete base must be well contoured before curing. Remove the
pipe sleeves after the concrete cures.
When the concrete base is poured out, insert steel rods vertically into the base at regular in-
tervals. The required number of steel rods is dependent on the size of the baseplate. The
rods must project into the baseplate by up to 2/3.
6.5.2 Preparing the baseplate for an-
choring
Fig.6: Shims on the base surface
Fig.7: Levelling screws on the base surface
ƒThoroughly clean the base surface.
ƒPlace shims (approx. ⅞to1inch thick) on every screw hole on the base surface.
Alternatively, levelling screws can also be used.
ƒFor a length spacing of the fixation bores ≥32inches, shims should be additionally
placed in the middle of the baseplate. Shims should also be placed under all middle bra-
cing C channels (see below in figure “Levelling and aligning the baseplate showing shim
locations”).
ƒLevel in both directions with additional shims.
ƒAlign the unit when installing on the base using a spirit level (at the shaft/pressure port).
The baseplate must be horizontal; tolerance: 0.006inches per foot
ƒFit anchor bolts in the provided drilled holes.
NOTICE
The anchor bolts must fit in the fastening bores (6; 3 per side) of the base-
plate.
They must meet the relevant standards and be sufficiently long, so that a firm fit in the
base is guaranteed.
Fig.8: Levelling and aligning the baseplate
showing shim locations
Fig.9: Anchor bolt
ƒPour in anchor bolts with concrete. After the concrete has set, tighten the anchor bolts
evenly and firmly.
ƒAlign the unit so that the pipes can be connected to the pump stress-free.
6.5.3 Grouting the baseplate The baseplate can be grouted after fixing. The process of grouting reduces vibrations to a
minimum.
ƒWet the base surface before grouting.
ƒUse a suitable, non-shrink grout.
ƒPour the grout through the available openings in the baseplate. Be sure to avoid hollow
spaces.

Installation and electrical connection en
Installation and operating instructions Wilo NL-HE 19
ƒBefore pouring concrete or grout create an enclosed frame around the base.
ƒAfter curing, check the anchor bolts for a tight fit.
ƒCoat the unprotected surfaces of the base to protect from moisture.
6.6 Pipework The pipe connections of the pump are fitted with dust caps so that no foreign objects can
penetrate during transport and installation.
ƒThese caps must be removed before connecting pipes.
r
5 x DN
d s
r ≈ 2,5 · (d - 2s)
Fig.10: Connecting the pump without tension,
settling section upstream and downstream of
the pump
CAUTION
Improper pipework/installation can lead to property damage! Welding beads,
cinder and other contaminants can damage the pump!
• The pipes must be sufficiently dimensioned, taking the pump inlet pressure into ac-
count.
• Connect the pump and pipes using suitable gaskets. Take the pressure, temperature
and fluid into account. Check the gaskets for proper fitting.
• The pipes must not transfer any forces to the pump. Brace the pipes directly before the
pump and connect them without tension.
• Observe the permissible forces and torques on the pump connecting pieces!
• The expansion of the pipes in the event of a temperature rise is to be compensated by
suitable means.
• Avoid air pockets in piping by means of appropriate installations.
NOTICE
Simplify subsequent work on the unit!
• To ensure the entire unit does not have to be emptied, install a check valve and
shut-off devices before and after the pump.
NOTICE
Avoid flow cavitation!
• A settling section must be provided upstream and downstream of the pump in the
form of a straight pipe. The length of the settling section must be at least 5times
the nominal diameter of the pump flange.
ƒThe pipes and pump must be free of mechanical stress when installed.
ƒThe pipes must be fixed in such a way that the pump does not have to support the
weight of the pipes.
ƒClean, flush and purge the unit before connecting the pipes.

en Installation and electrical connection
20 WILO USA 2021-01
ƒRemove the covers from the suction and discharge ports.
ƒIf required, install a dirt filter upstream of the pump in the pipe on the suction side.
ƒThen connect the pipes to the pump connecting pieces.
6.7 Aligning the unit
CAUTION
Incorrect alignment can result in property damage!
The transport and installation of the pump can affect the alignment. The motor must be
aligned to the pump (not vice versa).
• Check the alignment before the first start.
CAUTION
Changes to the alignment during operation can result in property damage.
The pump and motor are usually aligned at ambient temperature. Thermal expansion at
operating temperature can change the alignment, particularly in the case of very hot flu-
ids.
Adjustment may be required if the pump is required to pump very hot fluids:
• Allow the pump to run at the actual operating temperature.
• Switch off the pump then immediately check the alignment.
Precondition for reliable, smooth and efficient operation of a pump unit is proper alignment
of the pump and the drive shaft.
Misalignments can be the cause of:
ƒexcessive noise development during pump operation
ƒvibrations
ƒpremature wear
ƒexcessive coupling wear
6.7.1 Coupling alignment
EPDM Coupling Alignment
G
1
(ref)
P A
Fig.11: EPDM Coupling Alignment
P Parallel Alignment A Angular alignment
Sleeve size Max.
RPM
G1 (ref) EPDM Allowable Misalignment
Parallel Angular
in mm in mm in mm
47600 1.5 38 0.01 0.25 0.043 1.09
57600 1.9 49 0.015 0.38 0.056 1.42
66000 2.4 60 0.015 0.38 0.07 1.78
75250 2.6 65 0.02 0.51 0.081 2.06
84500 2.9 75 0.02 0.51 0.094 2.39
93750 3.5 89 0.025 0.64 0.109 2.8