Wilo Wilo-CronoLine-IL User manual

Wilo-CronoLine-IL
Wilo-CronoTwin-DL
Wilo-CronoBloc-BL
Pioneering for You
2 136 319-Ed.02 / 2013-11-Wilo
de Einbau- und Betriebsanleitung
en Installation and operating instructions
fr Notice de montage et de mise en service
nl Inbouw- en bedieningsvoorschriften

Fig. 1: IL
Fig. 2: DL

Fig. 3: BL

de Einbau- und Betriebsanleitung 3
en Installation and operating instructions 22
fr Notice de montage et de mise en service 41
nl Inbouw- en bedieningsvoorschriften 60

English
Installation and operating instructions Wilo-IL/-DL/-BL 21
1 General..................................................................................................................................................22
2 Safety.................................................................................................................................................... 22
2.1 Indication of instructions in the operating instructions .................................................................................22
2.2 Personnel qualifications ..................................................................................................................................... 23
2.3 Danger in the event of non-observance of the safety instructions .............................................................. 23
2.4 Safety instructions for the operator .................................................................................................................23
2.5 Safety instructions for inspection and installation work ...............................................................................23
2.6 Unauthorised modification and manufacture of spare parts .........................................................................23
2.7 Improper use ........................................................................................................................................................ 23
3 Transport and interim storage ...........................................................................................................24
3.1 Shipping ................................................................................................................................................................ 24
3.2 Attachment .......................................................................................................................................................... 24
4 Intended use.........................................................................................................................................25
5 Product information............................................................................................................................25
5.1 Type key ...............................................................................................................................................................25
5.2 Technical data .....................................................................................................................................................26
5.3 Scope of delivery ................................................................................................................................................. 27
5.4 Accessories .......................................................................................................................................................... 27
6 Description and function ....................................................................................................................27
6.1 Description of the product .................................................................................................................................27
6.2 Anticipated noise levels ..................................................................................................................................... 28
6.3 Permissible forces and torques on the pump flanges (only BL pumps) .........................................................28
7 Installation and electrical connection ............................................................................................... 29
7.1 Installation ........................................................................................................................................................... 29
7.2 Electrical connection .......................................................................................................................................... 30
7.3 Standby heating connection .............................................................................................................................. 32
8 Commissioning..................................................................................................................................... 32
8.1 Filling and bleeding ............................................................................................................................................. 32
9 Maintenance......................................................................................................................................... 34
9.1 Air supply .............................................................................................................................................................. 34
9.2 Maintenance work ...............................................................................................................................................35
9.2.1 Replacing the mechanical seal........................................................................................................................... 35
9.2.2 Changing the motor............................................................................................................................................ 36
10 Faults, causes and remedies............................................................................................................... 38
11 Spare parts............................................................................................................................................ 38
12 Disposal................................................................................................................................................. 39

English
22 WILO SE 11/2013
Installation and operating instructions
1General
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.
These installation and operating instructions correspond to the rele-
vant version of the product and the underlying safety 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, this declaration loses its validity.
2Safety
These operating instructions contain basic information which must
be adhered to during installation and operation. For this reason, these
operating instructions must, without fail, be read by the service tech-
nician and the responsible operator before installation and commis-
sioning.
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 (seri-
ous) injury to persons is probable if this information is disregarded.
CAUTION!
There is a risk of damaging the product/unit. 'Caution' implies that
damage to the product is likely if this information is disregarded.
NOTE
Useful information on handling the product. It draws attention to
possible problems.

English
Installation and operating instructions Wilo-IL/-DL/-BL 23
2.2 Personnel qualifications The installation, operating and maintenance personnel must have the
appropriate qualifications for this work.
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 product/unit. Non-observance of the
safety instructions can result in the loss of any claims to damages.
In detail, non-observance can, for example, result in the following
risks:
• failure of important product/unit functions,
• failure of required maintenance and repair procedures,
• danger to persons from electrical, mechanical and bacteriological
influences,
• property damage.
2.4 Safety instructions for the operator The existing directives for accident prevention must be adhered to.
Danger from electrical current must be eliminated. Local directives or
general directives [e.g. IEC, VDE etc.] and local power supply compa-
nies must be adhered to.
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 playwith the
appliance.
2.5 Safety instructions for inspection
and installation work The operator must ensure that all inspection and installation work is carried out by authorised and qualified personnel, who are sufficiently
informed from their own detailed study of the operating instructions.
Work on the product/unit must only be carried out when at a stand-
still. It is mandatory that the procedure described in the installation
and operating instructions for shutting down the product/unit be
complied with.
2.6 Unauthorised modification and
manufacture of spare parts 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 can
nullify the liability from the results of their usage.
2.7 Improper use The operating safety of the supplied product is only guaranteed when
used properly in accordance with the section in the operating instruc-
tions titled “Intended use”. The limit values must on no account fall
under or exceed those specified in the catalogue/data sheet.

English
24 WILO SE 11/2013
3 Transport and interim storage
3.1 Shipping The pump is enclosed in a box or lashed to a pallet ex works and is pro-
tected against dirt and moisture.
Transport inspection On arrival, inspect the pump immediately for any transport damage.
If damage is found, the necessary procedure 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.
CAUTION! Risk of damage due to incorrect packaging!
Ifthepumpistransportedagainatalatertime,itmustbepackaged
so that it cannot be damaged during transport.
• Use the original packaging for this, or choose equivalent packag-
ing.
3.2 Attachment WARNING! Risk of personal injury!
Improper transport can lead to personal injury.
• Thepumpmustbetransportedusingapprovedloadbearingequip-
ment. This is to be attached to the pump flanges and, if necessary,
to the outer motor diameter (safeguarding against slipping
required!).
• The transport eyes on the motorare only for guiding while bearing
the load (Fig. 4).
• To lift with a crane, the pump must be supported by suitable belts,
as shown. Place loops around the pump which tighten from the
pump's own weight.
• The transport eyes on the motor are only for transporting the
motor, and are not approved for transporting the complete pump
(Fig. 5).
WARNING! Risk of injury due to the weight of the pump!
The pump itself and the parts of pump can be extremely heavy.
Falling parts pose a risk of cuts, crush injuries, bruises or impacts,
which may lead to death.
• Alwaysusesuitableliftingequipmentandsecure partsagainstfall-
ing.
• Never stand underneath a suspended load.
Fig. 4: Attaching the pump
Fig. 5: Attaching the motor

English
Installation and operating instructions Wilo-IL/-DL/-BL 25
4Intendeduse
Purpose The glanded pumps of the IL (Inline), DL (Double) and BL (Monobloc)
series are meant to be used as circulation pumps in building services.
Fields of application They may be used for:
• Hot-water heating systems,
• Cooling and cold water circulation systems,
• Process water systems,
• Industrial circulation systems,
• Heat carrier circuits.
Restrictions Typical installation locations are technical rooms within the building
with other domestic installations. Installing the device directly in
other used rooms (residential and work rooms) is not intended.
For these series outdoor installation is only possible with the corre-
sponding special versions (motor with standby heating and fan cover
protective roof, see section 7.3 on page 32).
CAUTION! Risk of damage!
Impermissible substances in the fluid can destroy the pump. Abra-
sive solids (e.g. sand) increase pump wear.
Pumps without an Ex certificate are not suitable for use in poten-
tially explosive areas.
• The correct use of the pump/installation also includes following
these instructions.
• Any other use is considered to be incorrect use.
5 Product information
5.1 Type key The type key consists of the following elements:
Example: IL 50/170-7,5/2
IL
DL
BL
Flange-end pump as Inline pump
Flange-end pump as Double pump
Flange-end pump as Monobloc pump
50 Nominal diameter DN of the pipe connection
(at BL: pressure side) [mm]
170 Nominal impeller diameter [mm]
7.5 Nominal motor power P2[kW]
2 Number of poles

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26 WILO SE 11/2013
5.2 Technical data
When ordering spare parts be sure to state all the information given
on the pump and motor type plates.
Fluids If water/glycol mixtures with up to 40% glycol (or fluids with a differ-
ent velocity to pure water) are used, the pump data must be corrected
to match the higher viscosity, regardless of the percentage mixture
relationship and the fluid temperature. The motor power must also be
adjusted if necessary.
• Only use mixtures with corrosion inhibitors. The respective manufac-
turer's instructions are to be observed.
• The fluid must be sediment-free.
• Wilo's approval must be obtained for use of other media.
NOTE
Always read and follow the material safety data sheet for the fluid
being pumped!
Property Value Remarks
Nominal speed 2900 or 1450 rpm
Nominal diameters DN IL: 32 to 200 mm
DL: 32 to 200 mm
BL: 25 to 125 mm (pressure side)
Permissible min./max. fluid temperature –20 °C to +140 °C
Max. ambient temperature + 40 °C
Max. admissible operating pressure 16 bar (version... -P4: 25 bar)
Insulation class F
Protection class 55
Pipe and pressure measurement connec-
tions
Flange PN 16 in accordance with
DIN EN 1092-2 with pressure measure-
ment connections Rp 1/8 in accordance
with DIN 3858
Approved fluids Heating water according to VDI 2035
Process water
Cooling/cold water
Water/glycol mixture up to 40 Vol.-%
Standard version
Standard version
Standard version
Standard version
Heat transfer oil Special version or auxiliary equip-
ment (at additional charge)
Other fluids (on request) Special version or auxiliary equip-
ment (at additional charge)
Electrical connection 3~400 V, 50 Hz Standard version
3~230 V, 50 Hz
(to 3 kW inclusive)
Alternative application for stand-
ard version (no additional charge)
3~230 V, 50 Hz from 4 kW Special version or auxiliary equip-
ment (at additional charge)
Special voltage/frequency Pumps with motors with different volt-
ages or with other frequencies are
available on request.
Special version or auxiliary equip-
ment (at additional charge)
PTC thermistor sensor –Only for special version
Speed control, pole switchover Control devices (Wilo CC system)
Pole switchover
Standard version
Only for special version
Explosion protection (EEx e, EEx de) –Special version or auxiliary equip-
ment (at additional charge)

English
Installation and operating instructions Wilo-IL/-DL/-BL 27
5.3 Scope of delivery • Pump IL/DL/BL
• Installation and operating instructions
5.4 Accessories Accessories must be ordered separately:
•PTCthermistortripping unit for switch cabinet installation
• IL/DL: 3 mounting brackets with fixation material for installation on a
base
• DL: Blind flange for repair work
• BL: 4 mounting brackets with fixation material for installation on a
base for nominal motor power of 5.5 kW and above
For a detailed list, consult the catalogue/price list.
6Descriptionandfunction
6.1 Description of the product All the pumps described are single-stage low-pressure centrifugal
pumps in compact design with a coupled motor. The mechanical seal
is maintenance free. The pumps can be installed both directly as a
pipe installation pump in a sufficiently anchored pipe or placed on a
foundation base.
In conjunction with a control device (Wilo CC system), the power of
the pumps can also be continuously controlled. This allows optimisa-
tion of the pump output for the demands of the installation and eco-
nomically efficient pump operation.
•IL:
The pump housing has an INLINE construction, i.e. the flanges on the
suction and pressure sides lie along a centre line (Fig. 6). All pump
housings are provided with a pump base. Mounting on a foundation
base is recommended for nominal motor powers of 5.5 kW and higher.
•DL:
Two pumps are arranged in a shared housing (double pump). The
pump housing has an INLINE construction (Fig. 7). All pump housings
are provided with a pump base. Mounting on a foundation base is
recommended for nominal motor powers of 4 kW and higher.
The base-load pump is only operated in control operation in conjunc-
tion with a control device. The second pump is available to fulfil peak-
load requirements. Moreover, the second pump can adopt the reserve
function in the event of a fault.
NOTE
Blind flanges are available for all pump types/housing sizes of the
DL series (see chapter 5.4 “Accessories”), which guarantee replace-
ment of the motor impeller unit even for double pump housings
(Fig. 7 right). A motor can therefore remain in operation while replac-
ing the motor impeller unit.
•BL:
Spiral housing pump with flange dimensions in accordance with
DIN EN 733 (Fig. 8). Pump with screwed on pedestal, up to motor
power of 4 kW. With cast or screwed on feet from a motor power
of 5.5 kW.
Fig. 6: View of IL
Fig. 7: View of DL
Fig. 8: View of BL

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28 WILO SE 11/2013
6.2 Anticipated noise levels
6.3 Permissible forces and torques on the pump flanges (only BL pumps)
The following condition must be fulfiled:
(FV), (FH) and (Mt) are the totals of the absolute amounts of the
corresponding loads acting on the connecting pieces. For these
totals, neither the direction of the loads nor their distribution is taken
into consideration.
Motor power PN [kW] Sound-pressure level Lp, A [dB (A)] 1)
1450 rpm 2900 rpm
IL, BL, DL
(DL in individual
operation)
DL
(DL in parallel
operation)
IL, BL, DL
(DL in individual
operation)
DL
(DL in parallel
operation)
0.55 51 54 54 57
0.5 51 54 60 63
1.1 53 56 60 63
1.5 55 58 67 70
2.2 59 62 67 70
359 62 67 70
459 62 67 70
5.5 63 66 71 74
7.5 63 66 71 74
11 65 68 74 77
15 65 68 74 77
18.5 71 74 74 77
22 71 74 76 79
30 72 75 79 82
1) Spatial mean value of sound-pressure levels on a square measuring surface at a distance of 1 m from the surface of the motor
Pump type BL Suction flange DN [mm] Pressure flange DN [mm] Force FVmax
[kN] Force FHmax [kN] Torques  Mtmax [kNm]
40/... 65 40 2.4 1.7 0.55
2.4 1.7 0.52
2.4 1.7 0.50
2.5 1.8 0.62
50/... 65 50 2.4 1.7 0.55
2.4 1.7 0.52
2.4 1.7 0.50
2.5 1.8 0.62
65/... 80 65 2.6 1.8 0.7
2.6 1.8 0.7
2.6 1.8 0.7
2.6 1.8 0.7
2.6 1.8 0.7
80/... 100 80 3.3 2.4 1.1
3.3 2.4 1.1
3.3 2.4 1.1
3.3 2.4 1.1
Fig. 9: Forces affecting the connecting pieces

English
Installation and operating instructions Wilo-IL/-DL/-BL 29
7 Installation and electrical connection
Safety DANGER! Risk of fatal injury!
Incorrect installation and improper electrical connections can
result in fatal injury.
• Have the electrical connections established by approved 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 module cover or near the
coupling can cause electrical shock or contact with rotating parts,
potentially resulting in life-threatening injuries.
WARNING! Risk of injury due to the weight of the pump!
The pump itself and the parts of pump can be extremely heavy.
Falling parts pose a risk of cuts, crush injuries, bruises or impacts,
which may lead to death.
• Alwaysuse suitableliftingequipmentandsecure partsagainstfall-
ing.
• Never stand underneath a suspended load.
CAUTION! Risk of damage!
Danger of damage due to incorrect handling.
• Have the pump installed by qualified personnel only.
CAUTION! Damage to the pump due to overheating!
The pump must not be allowed to operate dry for more than
1 minute. Dry running causes a build-up of energy in the pump,
which can damage the shaft, impeller, and mechanical seal.
• A minimum flow of approximately 10% of the maximum flow rate
must be ensured at all times.
7.1 Installation The motor terminal box must not face downward. If necessary, the
motor or motor impeller unit can be rotated once the hexagon head
bolts have been loosened.
Preparation • The pump should only be installed after completion of all welding and
soldering work and, if necessary, flushing of the pipe system. Dirt can
cause pump failure.
• Standard pumps must be protected from the weather and installed in
a frost/dust-free, well-ventilated environment which is not poten-
tially explosive.
• Install the pump in a place that is easy to access so that subsequent
inspections, maintenance (e.g. mechanical seal) or replacement is
easily possible.
Positioning/alignment • A hook or a lug with sufficient load-bearing capacity must be installed
vertically over the pump (total weight of the pump: see catalogue/
data sheet). This is to allow hoisting gear or similar aids to be attached
to the pump during maintenance or repair work.
CAUTION! Risk of damage!
Danger of damage due to incorrect handling.
• Only use lifting eyes on the motor for carrying the weight of the
motor and not for carrying the entire pump.
• Lift the pump using permitted load-bearing equipment (see chap-
ter 3 “Transport and interim storage” on page 24.
• Minimum axial distance between a wall and the fan cover of the
motor: Free dismantling dimension of at least 200 mm + diameter
of the fan cover.
• The suction and pressure flange are both marked with a cast arrow
which indicates the flow direction.

English
30 WILO SE 11/2013
• Shut-off devices must always be installed in front of and behind the
pump in order to avoid having to drain the complete system when the
pump is inspected or replaced.
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 (Fig. 10). This measure serves to avoid
flow cavitation.
• The lantern has an opening on the underside which allows a drain pipe
for condensation water/condensate to be connected (e.g. when used
in air-conditioning or cooling systems). The condensate generated
can then be effectively drained.
• 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.
• The bleed valve (Fig. 1/2/3, Item 1.31) must always face upwards.
• All installation positions except for “motor facing down” are allowed.
NOTE
The installation position with horizontal motor shaft is permitted
for the IL and DL series only up to a motor power of 15 kW (Fig. 11).
A motor support is not necessary. Only the installation position with
vertical motor shaft is intended for a motor power >15 kW. BL series
monobloc pumps are to be mounted on a sufficiently strong base or
mounting brackets (Fig. 12).
NOTE
The motor terminal box must not face downward. If necessary, the
motor or motor impeller unit can be rotated once the hexagon head
bolts have been loosened. While rotating the motor or motor impeller
unit, ensure that the housing O-ring seal does not become damaged.
NOTE
When pumping out a tank, ensure that the fluid level is always high
enough above the suction port of the pump so that the pump never
runs dry. The minimum intake pressure must be maintained.
NOTE
In the case of insulated systems, only the pump housing may be insu-
lated, not the lantern, motor and motor (Fig. 1/2/3, Item 1.3 to 2).
7.2 Electrical connection
Safety DANGER! Risk of fatal injury!
A fatal shock may occur if the electrical connection is not made
correctly.
• Only allow the electrical connection to be made by an electrician
approved by the local electricity supplier and in accordance with
the local regulations in force.
• Observe the installation and operating instructions for the acces-
sories!
Fig. 10: Settling section before and after the pump
r
5 x DN
d s
r ⬇2,5 · (d · 2s)
Fig. 11: IL/DL
DL
IL
Fig. 12: BL

English
Installation and operating instructions Wilo-IL/-DL/-BL 31
DANGER! Risk of fatal injury!
Contact voltage can be life-threatening
Work on the terminal boxes may only be started once 5 minutes
have passed, due to the dangerous residual contact voltage
(capacitors).
• Before working on the pump, disconnect the power supply and
wait for 5 minutes.
• Checktoensureallconnections(includingpotential-freecontacts)
are voltage-free.
• Never use an object to poke around the openings on the terminal
box and never insert anything into the terminal box!
WARNING! Risk of mains overload!
Aninadequatemainsdesigncanleadtosystemfailuresandevento
cable fires due to mains overload.
• Whendesigningthemains, with regardtothecablecross-sections
and fuses, give special consideration to the fact that short-term
simultaneous operation of all pumps is possible in multi-pump
operation.
Preparation/notes • The electrical connection must be made in accordance with
VDE 0730/part 1 via a fixed power cable, which is provided with a plug
device or an all-pole switch with a contact opening width of at least
3mm.
• In order to ensure drip protection and strain relief on the threaded
cable connection, cables with a sufficient outer diameter must be
used and must be screwed sufficiently tightly. Also, the cables near
the threaded cable connection are to be bent to form a drainage loop,
to drain any accumulated drips. Position the threaded cable connec-
tion or lay the cables accordingly to ensure that no drips can run into
the module. Non-assigned threaded cable connections must remain
sealed with the plugs provided by the manufacturer.
• The connection line is to be placed in such a way that it can under no
circumstances come into contact with the pipe and/or the pump and
motor housing.
• When pumps are used in systems with water temperatures above
90 °C, a suitably heat-resistant connection line must be used.
• Check the current type and voltage of the mains connection.
• Observe the rating plate information for the pump. The current type
and voltage of the mains connection must correspond to the specifi-
cations on the rating plate.
• Mains side fuse protection: dependent on nominal motor current.
• Take additional earthing into account!
• The motor must be secured against overloading using a motor pro-
tection switch or the PTC thermistor tripping unit.
NOTE
• The connection diagram for electrical connections is in the cover of
the terminal box cover (see also Fig. 13).
Setting the motor protection switch • Set according to the nominal motor current specified on the rating
plate of the motor, Y-Δstarting. If the motor protection switch is
switched in the supply line to a Y-Δcontactor combination, set the
switch as for direct starting. If the motor protection switch is switched
in a thread of the motor supply line (U1/V1/W1 or U2/V2/W2), set the
motor protection switch to 0.58 x nominal motor current.
• The special motor design is equipped with PTC thermistor sensors.
Connect the PTC thermistor sensors to the PTC thermistor tripping
unit.

English
32 WILO SE 11/2013
NOTE
• The PTC thermistor sensor terminals must not be supplied with more
than 7.5 V. Higher voltages will destroy the PTC thermistor sensors.
• The mains connection to the terminal board is dependent on the
motor power P2, the mains voltage and the start-up type. The recom-
mended switching arrangement of the connection bridges in the ter-
minal box should be taken from the following table and Fig. 13.
• When connecting automatic switching devices, observe the relevant
installation and operating instructions.
7.3 Standby heating connection We recommend standby heating for motors which, due to climatic
conditions, are at risk of condensation (e.g. stationary motors in moist
atmospheres, or motors exposed to extreme variations in tempera-
ture). Corresponding motor variations which are equipped with
standby heating at the factory, can be ordered as a special version.
Standby heating is used to protect the motor windings against con-
densation water inside the motor.
• The standby heating is connected to the terminals HE/HE in the ter-
minal boxes (connection voltage: 1~230 V/50 Hz).
NOTE
• The standby heating may not be switched on during motor operation.
8 Commissioning
Safety DANGER! Risk of fatal injury!
Failure to install safety devices on the terminal box or module
cover or near the coupling can cause electrical shock or contact
with rotating parts, potentially resulting in life-threatening inju-
ries.
• After commissioning or maintenance, all safety devices such as
terminal box covers, module coversor coupling covers that were
removed must be reinstalled!
• Keep a safe distance during commissioning.
Fig. 13: Mains connection
L1 L2 L3
W2 U2 V2
U1 V1 W1
L1 L2 L3
W2 U2 V2
U1 V1 W1
W2 U2 V2
U1 V1 W1
Start-up type Motor power P2 3kW Motor power P24kW
Mains voltage 3 ~ 230 V Mains voltage 3 ~ 400 V Mains voltage 3 ~ 400 V
Direct ∆-circuit (Fig. 13 top) Y-circuit (Fig. 13 centre) ∆-circuit (Fig. 13 top)
Y-∆starting Remove connection bridges
(Fig. 13 below)
Not possible Remove connection bridges
(Fig. 13 below)

English
Installation and operating instructions Wilo-IL/-DL/-BL 33
8.1 Filling and bleeding • Fill and bleed the system as required.
CAUTION! Damage to the pump!
Dry running will destroy the mechanical seal.
• Make sure that the pump does not run dry.
• To avoid cavitation noise and damage, a minimum intake pressure
must be guaranteed at the suction port of the pump. This minimum
intake pressure depends on the operating situation and the duty point
of the pump, and must be defined accordingly. The main parameters
for defining the minimum intake pressure are the NPSH of the pump
at its duty point and the vapour pressure of the fluid.
• Bleed the pumps by releasing the vent screws (Fig. 1/2/3, Item 1.31).
WARNING! Danger due to extremely hot or extremely cold pressu-
rised fluid!
Depending on the temperature of the fluid and the system pres-
sure, when the vent screw is opened completely, extremely hot or
extremely cold fluid in liquid or vapour form may escape or shoot
out at high pressure.
• Always exercise caution when opening the vent screw.
WARNING! Risk of burns or freezing to the pump when body parts
come into contact with the pump!
Dependingonthepumporsystemoperatingconditions (fluid tem-
perature), the entire pump can become very hot or very cold.
• Keep a safe distance during operation!
• Allowthepump/systemtocooloff/warmupbeforeperformingany
work.
• Always wear protective clothing and gloves when working.
WARNING! Risk of injury!
If the pump/system is installed improperly, liquid may be ejected
during commissioning. Individual components may also become
loose.
• Keep a safe distance from the pump during commissioning.
• Wear protective clothing and gloves.
DANGER! Risk of fatal injury!
Fallingpumpsor pump parts may resultinlife-threateninginjuries.
• Whenperforming installationwork,protect thepumpcomponents
against falling.
• Switch on briefly and check whether the direction of rotation corre-
sponds to the arrow on the motor. If the direction of rotation is incor-
rect, proceed as follows:
• for direct starting: Swap the 2 phases on the motor terminal board
(e.g. L1 for L2),
• for Y-V starting: Swap the thread start and thread end of 2 windings
on the motor terminal board (e.g. V1 for V2 and W1 for W2).

English
34 WILO SE 11/2013
9 Maintenance
Safety Maintenance and repair may only be carried out by qualified per-
sonnel!
It is recommended to have the pump serviced and checked by Wilo-
Customer Service.
DANGER! Risk of fatal injury!
Thereisa riskoffatalinjurydue toelectricshockwhen working on
electrical equipment.
• Work on electrical equipment may only be done by electricians
approved by the local electricity supplier.
• Before working on electrical equipment, switch it off and prevent
it from being switched on again.
• Follow the installation and operating instructions for the pump,
level control device and other accessories.
DANGER! Risk of fatal injury!
Failure to install safety devices on the terminal box or near the
coupling can cause electrical shock or contact withrotating parts,
potentially resulting in life-threatening injuries.
• After maintenance, all safety devices such as terminal box covers
or coupling covers that were removed must be reinstalled!
WARNING! Risk of injury due to the weight of the pump!
The pump itself and the parts of pump can be extremely heavy.
Falling parts pose a risk of cuts, crush injuries, bruises or impacts,
which may lead to death.
• Alwaysusesuitableliftingequipmentandsecure partsagainstfall-
ing.
• Never stand underneath a suspended load.
DANGER! Risk of burns or freezing to the pump when body parts
come into contact with the pump!
Dependingonthepumporsystemoperatingconditions(fluidtem-
perature), the entire pump can become very hot or very cold.
• Keep a safe distance during operation!
• Inthecaseofhighwatertemperaturesandsystempressures,allow
the pump to cool down before all work.
• Always wear protective clothing and gloves when working.
NOTE
For all installation work, the forked spacer (Fig. 14, Item 10) is a man-
datory requirement for setting the correct impeller position in the
pump housing!
9.1 Air supply The air supply to the motor housing must be checked at regular inter-
vals. In case of contamination, ensure that an air supply is re-estab-
lished in order to allow the motor to cool sufficiently.
Fig. 14: Forked spacer for setting work

English
Installation and operating instructions Wilo-IL/-DL/-BL 35
9.2 Maintenance work DANGER! Risk of fatal injury!
Fallingpumpsor pump parts may resultinlife-threateninginjuries.
• When performing maintenance work, protect the pump compo-
nents against falling.
9.2.1 Replacing the mechanical seal During operation, there may be a slight amount of drip leakage. A vis-
ual inspection should be performed from time to time, however.
If there is clearly detectable leakage, the seal must be changed. Wilo
offers a repair kit which contains the necessary parts for replacement.
Replacement • Disconnect the system from the power supply and secure it against
being switched back on again
• Close the check valves in front of and behind the pump.
• Depressurise the pump by opening the bleed valve (Fig. 1/2/3,
Item 1.31).
DANGER! Risk of scalding!
Due to high fluid temperatures there is a risk of scalding.
• Ifthefluidishot,allowittocooldownbeforeperforminganywork.
NOTE
When tightening screw connections in conjunction with the work
described in the following: Observe the screw tightening torque for
the thread type (see section “Screw tightening torques” on page 37).
• Disconnect the motor or power cables if the cable for dismantling the
drive is too short.
• Dismantle the coupling protection (Fig. 1/2/3, Item 1.32).
• Loosen the coupling screws (Fig. 1/2/3, Item 1.5) on the coupling unit.
• Loosen the motor fastening screws (Fig. 1/2/3, Item 5) on the motor
flange and lift the drive off the pump with suitable hoisting gear.
On BL pumps, the adapter ring comes loose (Fig. 3, Item 8).
• By loosening the lantern fastening screws (Fig. 1/2/3, Item 4), dis-
mantle the lantern unit with coupling, shaft, mechanical seal and
impeller from the pump housing.
• Loosen the impeller fastening nut (Fig. 1/2/3, Item 1.11), remove the
washer underneath (Fig. 1/2/3, Item 1.12) and pull the impeller
(Fig. 1/2/3, Item 1.13) off the pump shaft.
• Pull the mechanical seal (Fig. 1/2/3, Item 1.21) off the shaft.
• Pull the coupling (Fig. 1/2/3, Item 1.5) with the pump shaft out of the
lantern.
• Thoroughly clean the sliding/mating surfaces of the shaft. If the shaft
is damaged, it must be replaced.
• Remove the counter ring of the mechanical seal with the sealing collar
from the lantern flange, as well as the O-ring (Fig. 1/2/3, Item 1.14)
and clean the seal seats.
• Press a new mechanical seal counter ring with sealing collar into the
seal seat of the lantern flange. A commercially available dishwashing
liquid can be used as a lubricant.
• Install a new O-ring in the O-ring seat groove on the lantern.
• Check the coupling sliding surfaces. If necessary, clean and lightly oil
them.
• Pre-install coupling shells on the pump shaft with spacer discs
inserted in between and insert the pre-mounted coupling/shaft unit
carefully into the lantern.
• Pull a new mechanical seal onto the shaft. A commercially available
dishwashing liquid can be used as a lubricant.
• Install the impeller with washer and nut, countering at the impeller's
outer diameter while doing so. Avoid damage to the mechanical seal
due to jamming.