Wilo Cronoline User manual

Installation and operating instructions

Wilo-Cronoline

2 069 148-Ed.02 / 2007-05-11-Kothes!

2Wilo AG 05/2007

English

Overview

Installation and Operating Instructions

1Overview

Troubleshooting guide >page 19

Safety >page 4

Functionality >page 7

Transport and Storage >page 8

Installation >page 8

Maintenance and Repair >page 13

Screw torques >page 18

Technical data >page 5

Electrical connection >page 10

Mechanical Installation >page 8

Ventilate >page 12

Check direction of rotation

>page 12

Connect condensate drain >page 10

Performance regulation >page 7

Attach pump >page 9

Dismantle motor >page 14

Direction of flow >page 7

Safety sticker >page 4

Installation and Operating Instructions Wilo-Cronoline 3

English

Overview

4567

1011

1Discharge Flange

2Discharge Pressure Gauge Tapping – ¼”

NPT

3Mechanical Seal Air Vent

4Shaft

5Lantern

6Coupling guard

7Coupling

8Motor

9Motor bolt

10 Condensate drain connection (only in some

models)

11 Condensate drain connection

12 Volute Bolt

13 Suction Pressure Gauge Tapping – ¼” NPT

14 Suction Flange

15 Lantern O-ring

16 Stationary seal ring of mechanical seal

17 Mechanical seal

18 Impeller

19 Impeller fastening nut and washer

20 Pump Feet

4Wilo AG 05/2007

English

Safety

2Safety

About these instructions • These instructions must be read in full prior to installation.

Failure to comply with these instructions may lead to serious

injury or damage to the pump.

• Once the pump is installed, give these instructions to the

operator.

• These instructions should be kept in the vicinity of the

pump.They serve as a reference in case of later problems.

• Wilo is not liable for damage arising from non-compliance

with these instructions.

Warning notices Important safety notices are categorized as follows:

Safety sticker Safety stickers are located on the motor giving important

instructions on how to handle the pump.The instructions on the

safety sticker must be strictly obeyed.

Qualifications The pump may only be installed by qualified personnel. The elec-

trical systems may only be connected by qualified electricians.

Additionally, national regulations concerning the Qualifications

of personnel must be obeyed.

Modification, spare parts No technical alterations or modifications may be made to the

pump. Use only original spare parts.

Danger: Indicates life threatening due to electrical cur-

rent.

Warning: Indicates possible life threatening or risk of

injury.

Caution: Indicates possible threats to pump or other

objects.

Note: Highlights tips and information.

Installation and Operating Instructions Wilo-Cronoline 5

English

Technical data

Electrical power supply Working with electrical current could cause serious risk of bodily

injury, therefore:

• Before starting work on the pump, switch off the power and

secure it against reconnection.

• Do not bend or clamp power cable or expose it to heat

sources.

• Do not immerse the pump in water or other liquids or expose

it to spray water or moisture.

Rotating components The pump contains rotating components that are exposed if the

pump housing is open or the coupling guard is missing. Touching

the rotating components can cause serious injury, therefore:

• Before opening the pump housing, switch off the motor and

secure against reconnection.

• Never switch on the motor when the pump housing is open or

the coupling guard is missing.

• Never operate the pump without the coupling guard.

High Deadweight The pump has a very high deadweight, depending on the model.

If the pump is dropped or it falls, there is a risk of death by crush-

ing if pump falls, therefore:

• Exercise caution when lifting or transporting.

• Never walk under suspended loads.

• Always put the pump and pump parts down ensuring they

cannot tip over.

• Only use the transportation methods described in these

operating instructions >Page 8.

• Before loosening screws, secure the pump parts to be

loosened to prevent them from falling.

3 Technical data

3.1 Type plate

IL Series: Inline pump with flange connection

2.5 Nominal diameter of pipe connection (inches)

-50 Maximum pump height (ft)

/260 Maximum capacity (GPM)

-2 Number of poles

115/208-230 Voltage (V)

6Wilo AG 05/2007

English

Technical data

3.2 Data

Description Information Option

Mains voltage 1 ~ 115 / 208-230 V, 60 Hz (≤2HP)

3~208 - 230 / 460V, 60 Hz (≥1 HP)

3~575V, 60 Hz (≥1 HP)

Degree of motor protection ODP

TEFC ●

Protection against overheating Integrated protection PTC / PTO a

a. On-site trip unit required

●

Flange connection Flanges acc. ASME Class 125

Motor flange design acc. NEMA MG1 Type C face Mounting

Special motor design Special voltage/frequency ●

Max. working pressure 175 psi [12 bar]

250 psi [17 bar] ●

Max. permissible liquid temper-

ature range

water only: from 32 °F to 200 °F [-0 °C to +90 °C]

water/glycol up to 50 %:

from -4 °F to 250 °F [-20 °C to +120 °C]

Max. permissible liquid temper-

ature range with high tempera-

ture seal

at 175 psi [12 bar]:

from -4 °F to 250 °F [-20 °C to +120 °C]

at 165 psi [11 bar]:

from -4 °F to 285 °F [-20 °C to +140 °C]

Max. ambient temperature 104 °F [40 °C]

Approved liquids Heating water

Chilled/Cold water

Water/glycol mixtures b

b.Hydraulic corrections necessary depending on liquid's density and viscosity. Only approved additives with

corrosion inhibitors may be used. Observe manufacturer's instructions.

Heat transfer oil ●

Other liquids on request c

c. Contact WILO before using any liquids other than above-listed liquids, different mixture ratios and higher

temperatures.

●

Legend:

●Special design or accessories (at added cost on request)

Note: For additional data, see type plate, product informa-

tion sheet or Wilo catalog.

Installation and Operating Instructions Wilo-Cronoline 7

English

Functionality

3.3 Materials

3.4 Scope of delivery

1Pump complete

2Installation and operating instructions (not displayed)

4 Functionality

4.1 Application

The purpose of the pump is to pump the liquids specified in the

technical data for the building services industry and for industrial

plants.

Pumping different liquids and exceeding the limit values speci-

fied in the technical data may destroy the pump.

4.2 Functions

Design The pump is a single-stage circulating pump with an inline design

It is driven by an electric motor according to the NEMA standard.

Assembly For pumps up to an output of 20 HP, the flanges are designed

such that the pump can be mounted without additional support.

For pumps with an output of over 20 HP, the pump must be

screwed onto the three feet >Page 9.

Performance regulation External pressure sensors and an external control unit can be

connected to the suction side and the discharge side by means of

a pressure gauge tapping for each side.

The motor speed can be controlled using an external frequency

converter.

Direction of flow The arrows on the flanges indicate the direction of flow.

Pump housing and lantern Cast iron ASTM A126 Class B

Impeller Bronze (Standard), Cast Iron Optional

Pump shaft Stainless steel 1.4122

8Wilo AG 05/2007

English

Transport and Storage

5 Transport and Storage

5.1 Shipping

Shipping The pump is delivered packaged in cardboard or lashed down on

a pallet and is protected against dust and moisture.

Transport inspection Upon receipt, unpack and check pump and all accessories.

Report transit damage immediately.

Storage Until the pump is installed, the pump must be stored in a dry,

frost-free place where it is also protected against mechanical

damage.

5.2 Impacts

To lift the pump using a crane, the pump has to be tied down as

illustrated using suitable straps. Place the pump in the hanger

which will tighten itself due to the pump's deadweight.

6 Installation

6.1 Mechanical Installation

Caution: Damage due to incorrect packaging!

If the pump needs to be transported again at a later date, it must

be securely packaged for transit. Use the original packaging or

equivalent packaging.

Warning: Risk of injury due to high deadweight!

The pump is heavy and can cause considerable injury if dropped

or if it falls.Only transport the pump using a suitable hoist. Wear

work shoes and a helmet. Never stand under hanging loads.

Danger: Risk to life due to electric shock!

Before starting work, make sure that the pump is disconnected

from the power supply.

Warning: Danger due to high deadweight!

The pump itself and pump components may have a very high

deadweight.There is a risk of potentially fatal impact and crush-

ing caused by falling parts.

Always use suitable lifting equipment and secure parts from

falling.

Installation and Operating Instructions Wilo-Cronoline 9

English

Installation

Installation site The installation site should be a weather-resistant, frost-free

and dust-free area that has good air circulation. Select an easily

accessible installation site.

Keep a minimum distance of 8 inches [20 cm] between the motor

cover and surrounding surfaces.

1. Insure the pump is installed in a way that no piping stresses

are transferred to the pump.

A straight piece of piping of 3 pipe diameters in length is

required on both sides to insure laminar flow.

Attach pump 2. Install only as shown (Figs. A/B):

- Installation with a horizontal motor (Fig. B) is permissible

only for pumps with an output of up to 20 HP.

- The motor may not point downwards (Fig. C).

- In the case of installation with horizontal motor (B), the air

vent valve must point upwards.

3. If necessary, disassemble the motor and rotate >Page 14.

The electrical terminal box may not point downwards (Fig. C).

4. The feet of the pump are drilled and tapped for floor or wall

mounting. Insure the volute is not stressed by the piping.

Connect flangeconnection 5. Screw flange connection onto suction and discharge piping.

Caution: Dirt causes damage!

Dirt can render the pump inoperative.Before installing the

pump, complete all welding and soldering work and thoroughly

clean the pipe system.

min 3 x O

Note: Install an isolation valve (1) on the suction and dis-

charge sides of the pump so that the pump can be replaced

without having to empty the entire piping system.

A B

Note: The arrows on the flanges indicate the direction of

flow.

Note: With motor output of 7.5 HP or more, a housekeep-

ing pad is recommended.

10 Wilo AG 05/2007

English

Installation

Connect condensate drain

6. If desired, a condensate drain can be connected.

(1) Condensate drain for vertical installation position of the

motor

(2) Condensate drain for horizontal motor installation

position (only available in some models)

7. Seal up unused condensate drain.

6.2 Electrical connection

Electrical connection 1. Connect the connecting cable with power switched off and

secure against reconnection.

2. Lay the connecting cable such that it doesn't come into

contact with the pump, the pump housing or the piping.

3. Check whether the voltage and amperage in the mains match

the specifications on the type plate of the pump.

4. Open the terminal box.

5. Lay the cable such that no condensation or spray water can

run into the cable screws (Fig. A).

6. Connect grounding cable.

Caution: Damage due to overheating!

For insulated piping systems, only the pump volute may be

insulated, not the lantern and the motor. These could be

damaged by heat build-up.

Danger: life threatening due to electrical shock!

Touching live parts can be fatal. Work on the electrical connec-

tion may only be performed by a trained electrician. Prior to

connecting, ensure that the connecting line is voltage-free.

Warning: Danger due to a damaged cable!

For pumps that pump hot liquids or that are used in proximity to

hot surfaces with temperatures above 194 °F [90 °C], a heat-

resistant cable must be used.

Note: For the correct cable size, refer to local wiring

restrictions.

Caution: Damage due to incorrect voltage!

Never operate the pump with incorrect voltage. This could

damage the motor.

A B

Table of contents

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