Maintenance of circulation pumps
Pump malfunctions and remedies
The design of a circulation pump with a wet rotor is based on a modular principle. Modules can be assembled in different configurations. It all depends on the power and size of the pump.
Circulation pump device
Any repair work can only be carried out if the power is completely disconnected and the area is drained.
- The pump turns on, sounds are heard, but the shaft does not rotate. Why does the heating pump make noise and why did other "symptoms" appear? The reason may be shaft oxidation after prolonged inactivity of the device. If the pump is blocked, the device must not be left on. It is necessary to drain the water and all screws that tighten the pump casing to the electric motor must be unscrewed. Next, we remove the engine itself, and its impeller turns manually. If the pump is of low power, the shaft can be unlocked by turning it with a screwdriver. For this, there is a special notch in the end of the shaft.
- A foreign object has blocked the wheel. How to disassemble a heating circulation pump? We dismantle the pump motor using the above method. To prevent repeated blocking, a mesh filter must be installed in front of the pump.
Circulation pumps for heating wilo
For high-quality debugging of ventilation, heating, air conditioning, underfloor heating and water supply systems, it is necessary to use reliable equipment. For private and industrial arrangement of heating, ventilation and water supply systems, circulating pumps are used. This type of equipment allows you to run water in pipes under the required pressure and pressure. A pump breakdown can lead to the failure of the entire system, and therefore, even at the stage of creating a heating system, water supply and underfloor heating, it is better to choose the highest quality equipment.
Wilo circulation pumps have long been in great demand in the domestic market. The popularity of the products of the mentioned company is due to their durability, simplicity, versatility and a large assortment of models for various technical needs.
The most widely used circulation pumps from Wilo of the STAR-RS series. This series is represented by equipment of various power and throughput, it is characterized by the presence in all models of pumps of the so-called "wet" rotor and threaded transition to pipes. The "wet" rotor protects the motor from overheating, thereby making the circulation pumps of the STAR-RS series resistant to continuous loads and high temperatures.
All Wilo products are created in such a way that the installation of the pumps is as simple and convenient as possible, depending on the purpose of the equipment. Threaded pipe connections allow easy installation of water supply, air conditioning, ventilation and heating equipment, and also easy to remove for maintenance or repair. Spring terminals are designed for quick connection of pumps to the mains (almost all models of Wilo circulation equipment operate from an ordinary 220 V socket). The terminals can be positioned at different angles on the floor for easy connection to the network.
It is quite simple to buy Wilo circulating pumps in Kiev. Turning to a specialized store of climatic technology and equipment for water supply systems, heating and underfloor heating, the buyer will definitely find the necessary circulating model at a reasonable price.The equipment of the above company is widely known not only in the domestic, but also in the European market, therefore it has all the necessary international quality certificates.
Features of the models
The manufacturer Wilo has several popular models of circulation pumps.
Wilo-RS 25 6
Manufacturer's model that creates the pressure pillar 6 meters.
Benefits:
- wet rotor, speed is adjustable;
- the motor does not react to blocking currents, there is no need for a relay;
- coolant with a temperature in the range (from -10 ° С to 110 ° С);
- a filter is installed in front of the cartridge, which increases the reliability of the pump;
- works with full functionality at ambient temperature up to 40 ° С;
- easy installation;
- takes up little space (installation length - 180 mm).
Wilo Star RS series
A range of compact, reliable pumps for domestic use.
Letters in the name indicate the characteristics of the product:
- RS - type, rotor, fittings;
- then there are numbers indicating the diameter of the connection, head, diameter of the nozzle.
The pump is able to provide constant pressure in the heating system, but it is important to choose the right option, taking into account the following factors:
- pressure column in meters;
- pump flow (the amount of water that it can pump over per unit of time).
Photo 3. Wilo circulation pump Star RS model. The device is a wet rotor device.
These values are provided by the manufacturer., which tests the device under conditions as close to real ones as possible. The documentation for the pump contains graphs that reflect the pressure-flow capacity of the pump.
Main characteristics:
- pressure column;
- power (depending on frequency);
- system pressure reaches 10 bar.
Designed for pumping only clean water, the addition of glycol is allowed in the ratio 1:1.
Features:
- The engine does not require additional devices, resistant to blocking currents, does not react to voltage surges.
- The speed is switched, for this there is a toggle switch with markings of different sizes on the terminal box. This helps to achieve the optimal temperature in the home and helps to save energy.
- To remove air from the system, which leads to idle operation of the device, a special screw is used.
Using the frequency change function makes it possible to reduce power consumption up to 50%... If the temperature has dropped, the frequency will have to be increased. If noise is generated at too high a frequency, lowering the frequency will help reduce it.
These versatile devices are used:
- for pumping cold and hot water;
- in cooling and air conditioning circuits;
- in homes and businesses.
The pump is easy to install:
- installation on any segment of the contour is allowed;
- horizontal or vertical installation (restrictions are indicated in the data sheet);
- terminal box can be installed in 4 positions;
- the possibility of two-way cable connection;
- spring terminals are provided for ease of installation.
The product is made of quality materials:
- high-strength gray cast iron alloy (some models are made of bronze);
- polypropylene (for impeller);
- stainless steel (for shaft);
- metallographite (bearings).
Among the advantages, the first positions are occupied by inspirational price and low power consumption.
The lineup
The concern is famous for a fairly wide range of products. The Wilo CAD catalog contains 142 series, among which the most common are:
- Wilo-Economy-CO - multi-pump and single-pump pressure boosting stations. They are assembled on the basis of vertical pumps MVI, Helix V, MVIS, MHI. In the station, 2-4 units are installed in parallel, which increases the reliability of operation and productivity. Supplied with collecting collection tank and solid separation system and control panel. The head varies from 60 to 160 m.The flow rate, depending on the pump, can be 14, 75, 80, 135 cubic meters / h.
- The Wilo-Multivert MVI family is a vertical outdoor centrifugal device. They provide water for irrigation installations, are component parts of boiler rooms, fire extinguishing installations. The design and dimensions of the MVI during installation save space. The MVI 2 series consumes 5 cubic meters / h, the head - 220 m, the fourth series - 8 cubic meters / h, the head - 210 m, the eighth - 14 cubic meters / h with a head of 225 m.
- Star is a line of models with a wet rotor and a threaded connection. There are 3 speed modes. The devices are used for cold water supply, in heating systems. Head - up to 8 m. Flow rate reaches 6 m3 / h.
- TOP are compact circulating pumps with the ability to connect it to a pipe. They work quietly, are ideal for pumping liquids through a pipeline in private houses, they are thermally insulated. Head - 9 m, flow - 65 m3 / h.
- The Wilo Helix pump family is multistage equipment belonging to the subtype of non-self-priming pumps with a flow rate of up to 93 m3 / h and a max. heads up to 240 m. The units are equipped with a dry rotor, each unit has a frequency converter and air cooling.
- Stratos are highly energy efficient circulation devices. Applicable in heating systems, cooling circuits, air conditioning. The company also creates various control devices. For example, Wilo SK 702 is a device for control, protection and monitoring of pumps against overcurrent, dry running.
- The line of Wilo Comfort Vario pumps has 3 series, differing in design features. The regulator can combine up to 4 products in parallel.
Wilo Comfort Vario pumps
Popular models, their technical characteristics
The most popular models were:
- WJ 203 EM is a self-priming water supply station with a 50-liter tank and a power of 0.75 kW. Max. head - 41 m, flow rate - 5 cubic meters / h;
- Star-RS 25/4 is a circulation model of balanced design used in heating and hot water systems. Head - 4 m. Connected to the power supply, the unit operates in one of three stages of rotation. Vit has a 2-sided cable drive, stamps;
- Wilo Hisewlift 3-35 sewage cutter unit with a power consumption of 0.4 kW and a direct start-up type. Rated speed - 2900 rpm. Tank volume - 17 liters;
- Wilo JET HWJ 204 is a horizontal, single-stage portable self-priming jet device. It pumps water in the supply / suction modes. Delivers water to a depth of 8 m thanks to the hydraulic power of the system. Power consumption - 1.3 kW;
- device HWJ 202 EM Wilo for water supply, irrigation, pumping rainfall, is used mainly in garden areas, a 20-liter membrane tank helps to reduce the frequency of starts. Suction head is 8 m, head is 37 m. Max. the water supply is 4.5 cubic meters / h.
- Wilo Hisewlift 3-15 - automatic installations that drain wastewater from the sink, wastewater with feces from the toilet bowl. The volume of the tank is 17 liters. Power - 0.4 kW. Liquid temperature - from +5 to +35 degrees;
- in the model range of circulating Star RS, a special place is occupied by the Wilo RS 30/6. This is a standard glandless pump with a threaded connection. Has 3 stages of rotation frequency, manual control. The head is 6 m, the flow rate is 4 cubic meters / h.
Consider how long submersible pumps for wells serve, work
In ascending order of service life.
1) Screw, screw pumps for wells. These include such brands and models as: Caliber NCPS, Unipump Eco Screw, Belamos 3sp 60 / 1.8, Vortex SN 90 and a lot of electric pumps similar in design. These models have a rubber screw as a working part, and not a polymer impeller like centrifugal pumps.
Screw screw pumps work from 5 minutes to 1.5 years according to our statistics. On average, 7 months - 1 year. However, there is still a possibility that the screw electric pump can work for 5 years. It's just extremely small. The price of these downhole units is from 4 to 9 thousand approximately.
With screw pumps, there may be such problems (to watch the video, click on the image just below):
Here is a video about the operation of a 4-inch screw pump:
2) Centrifugal pumps of the budget price segment. From 8 thousandfor pumps for shallow wells up to 30 thousand; for pumps for wells over 100 - 150 meters 150 meters.
These are Chinese pumps Belamos, Aquatek SP, Dzhileks Vodomet Prof, Vortex SN, Unipump, etc., Ukrainian Aquarius BTsPE.
Three-inch Chinese work an average of 2.5 years. Aquarius can safely be given primacy, he often lives for more than 5 years and up to 10-12. Four-inch Chinese pumping equipment lasts longer, but Aquarius BTsPE in our practice, and according to reviews from the forums, is a clear leader here.
From time to time, the problem of non-working Chinese pumps can be eliminated quickly and inexpensively, we talk about this in the video below:
4) Pumps of the middle price segment of the Italian brands Pedrollo, Aquarium ASP. The service life of Pedrollo is from 5 to 15 years - much depends on the operating conditions. Often, in the case when the owners forget to monitor the pressure in the hydraulic tank, the pump often starts to turn on and off. So, under such conditions, Chinese submersible centrifugal electric pumps burn out, and Pedrollo (and Grundfos) simply damage the downhole underwater power cable of the engine, the engine itself remains intact.
With constant proper maintenance, the service life of such borehole pumps can be 6-8 years. And in some cases, more.
4) Expensive pumps. The service life of Grundfos SQ submersible electric pumps can fluctuate significantly. In our practice, in poor conditions (highly ferrous water, salt water, problems with electricity), pumps work for 5-6 years. If the conditions are good, they can work for more than 10 years. Also, the statistics on Grundfos SQ pumps needs to be adjusted, since the last 5 years, Grundfos made in Mexico have been supplied to Russia, and not Denmark, as it was before. For this brand, there are still some complaints and the need to diagnose problems after 1-3 years of operation, but in the overwhelming majority of cases we can say that Grundfos SQ is the electric pump that was installed and forgotten. One of the proven pumps.
There are, of course, also cases when Grundfos are worked out for 2-7 years:
Application and purpose
Jileks Compasses are circulation devices designed for heating and cooling, air-conditioned and ventilation systems. The purpose of the units is to circulate the working fluid in closed systems. When operating the apparatus, pipes of a smaller diameter are used than with natural circulation. Provides an even distribution of temperatures in systems. The unit series features a wet rotor and a three-speed motor. The engine houses a block for manual adjustment of the speed of the working fluid in a closed system.
Dzhileks Compass provides heating of the heated room and uniform distribution over all parts of the working fluid circuit.
Standard complete set of the Jileks pump Compasses
The presence of a wet rotor allows the system to be adjusted. It features high performance, energy efficiency and low operating noise.
The lineup
Jileks Compasses series consists of six models with different characteristics.
Description of models Compasses:
- 25 40. Circulating pumps Jileks Compass 25 40 operate with a temperature range from ten to one hundred and ten degrees Celsius. Creates a head of four meters. The throughput is three cubic meters per hour. Has three speeds. Operated at indoor temperatures up to fifty degrees. Weighs three kilograms;
- 25 60. The difference between the model and the previous one in the generated head of six meters and a throughput of 3.8 cubic meters per hour. Creates a noise of 65 dB;
- 25 80. The model creates a maximum head of eight meters. The throughput is eight cubic meters per hour. Pumps Dzhileks Zirkul 25 80 emit noise 45dB;
- 32 40. Model of circulation pumps Dzhileks Compasses 32 40 are made of cast iron. Works with liquid temperatures up to one hundred and ten degrees Celsius. Circulating pumps Compass 32 40 have a rated power of 32 W, a head of four meters, a weight of 3600 grams, a hole diameter of 1.25 inches;
- 32 60. The power of the model is 55 W, creates a head of six meters, a throughput of 3.8 cubic meters per hour. Emits noise 45 dB;
- 32 80. Pump model 32 80 The compass weighs six kilograms. The rated power of the device is 135 W. Circulating pumps Dzhileks Zirkul 32 80 operate at three speeds. The maximum head and flow capacity is eight meters.
Design and application features
Compass devices have a number of features that distinguish them from other models and manufacturers.
Model range of pumps Jileks Compass
Features of the devices:
- devices are distinguished by high performance;
- used for domestic hot water supply and heating systems;
- it is forbidden to use in systems for drinking water;
- wet rotor for all models;
- three-speed manual control motor;
- works with water and liquids with ethylene glycol;
- cast iron body, not subject to corrosion;
- mounted horizontally and vertically;
- reducing the rotation speed reduces energy consumption and the volume of the device;
- the complete set includes nuts for mounting;
- low vibration.
High efficiency circulation pumps
Advertising
Such systems have indisputable advantages - non-volatility and ease of operation. But at the same time, they also have disadvantages. Due to the fact that the liquid has to overcome the hydraulic resistance in the pipes only due to the density difference between hot and cooled, its flow is too slow to evenly and quickly warm up all the rooms. In addition, on the way to the heating device, the coolant has time to cool down by several degrees. The coolant returns to the boiler noticeably cooled, therefore, more energy is required to heat it. To ensure natural circulation, it is required to use pipes of large diameters, hence the rise in cost and cumbersomeness of the system. The use of forced circulation of the coolant eliminates these disadvantages.
Circulation pumps for heating systems are designed to solve a similar problem. Thanks to this device, a continuous circulation of the coolant through the pipes is carried out. The room heats up evenly and quickly, and the heating equipment works more efficiently.
But how to choose a circulation pump for yourself, if today the equipment market is oversaturated with offers from both domestic and foreign manufacturers, and how to understand whose products are really of high quality? In addition, in addition to the qualitative characteristics, one should not forget that the pump for the heating system is a device that has rather serious quantitative parameters of work, which can be very difficult for an uninitiated homeowner to understand. And how do you know if this particular model is right for you?
It is no secret that modern highly efficient heating systems have a very precise setting, they are equipped with various temperature sensors, regulators, as well as automation, which significantly increases their efficiency. In such conditions, it would be not just frivolous, but wasteful to approach the choice of a circulation pump without proper thoroughness.
It would be logical to assume that when choosing a specific manufacturer of such a device, the buyer's approach should be the same as when choosing any other equipment. If possible, it is better to take equipment from European manufacturers. They have been on the market for a long time, their name in itself is synonymous with quality, and their many years of experience guarantee the reliability of the products.
According to all the selection criteria among manufacturing companies, a special position is taken by the German company Wilo, which offers a wide range of pumps for cooling systems, heating, water supply, air conditioning.
Wilo products have a number of undeniable advantages over products from other manufacturers. Thanks to their clever design, careful selection of materials and flawless assembly, circulation pumps from Wilo are distinguished by:
- durability;
- silent and uninterrupted operation;
- the highest energy efficiency;
- compactness;
- ease of management;
- insensitive to voltage surges.
Today the company presents on the Russian market the widest range of pumps for domestic use. Let us dwell in more detail on the most popular models of circulation pumps.
Wilo-Yonos PICO - It is a glandless circulation pump for all hot water heating and air conditioning systems. Ideal for both new installation and renovation of old heating systems. Yonos PICO is specially designed for private houses and cottages to work in systems with a temperature of the pumped liquid from -10
° С to +95 ° С. The device is equipped with an electronically commutated EC motor, resistant to blocking currents, and built-in electronic power regulation. The standard threaded connection, as well as the specially developed electrical Wilo connector, make the connection of such a pump to the system easy, even for a layman.
The use of high-quality materials in the production, precision of assembly and control at each stage of production allow the manufacturer to establish a warranty operation for the device for 5 years, and it is no secret that the actual service life of the pump will be much longer.
The benefits of Yonos PICO include:
- automatic regulation of power consumption;
- low power consumption from 4 W;
- venting function and manual restart;
- easy selection of the operating mode depending on the type of system;
- electricity consumption indicator;
- and finally, energy savings of up to 90% compared to other types of pumps.
Wilo-Stratos PICO is a "smart" pump that automatically adjusts to changing parameters of the heating system. Like the previous device, Stratos PICO is suitable for any heating and air conditioning systems installed in private houses, with a pumped liquid temperature of +2
° C to 110 ° C. The intuitive control system, implemented through an interactive LCD display, makes the pump setup and control simple and straightforward. The Stratos PICO is equipped with a wide range of functions: Dynamic Adapt automatic regulation, ventilation program, night power reduction, key lock and reset function.
Benefits:
- minimum power consumption - only 3 W;
- automatic regulation of power consumption;
- built-in energy meter;
- automatic air exhaust mode;
- interactive pump control menu on the LCD display;
- heat-insulating casing included;
- and as in the previous device, energy savings of up to 90%.
The Wilo-Varios PICO is the ideal replacement solution for legacy equipment with the most complete compatibility for all applications thanks to its compact design and new synchronization function. The synchronization function is an innovative development from Wilo that allows the Varios PICO to reproduce the hydraulic response of the pump to be replaced. More than 40 different hydraulic characteristics are stored in the memory of the device, which are selected using LED coding.
As with previous models, the Varios PICO is characterized by:
- Easy installation due to compact design, adjustable electrical connections and maintenance features such as ventilation.
- Highest operational and maintenance safety thanks to proven technology.
- Maximum serviceability thanks to the use of an LCD display and "green button technology", with a button for regulation mode and a button for preset characteristics.
Many skeptics and opponents of the use of forced circulation of the coolant in heating systems point to such a general disadvantage of circulation pumps as their volatility.However, even long power outages are not scary for Wilo pumps, because due to the very low consumption (from 3 W), such a pump, using an uninterruptible power supply, will ensure the full functioning of the heating system for a sufficiently long period.
Now let's get back to the original question of choice. How can an inexperienced homeowner understand that this particular pump model is right for him?
To determine the required operating parameters of circulation pumps for a specific heating system, there is a set of formulas and graphs, but not everyone can figure it out on their own. For this reason, Wilo has developed a special free software application for smartphones and tablets that offers planning assistance, customer consultation and installation assistance. In addition, the user is provided with information on a variety of valid retail outlets for energy efficient, economical and environmentally friendly heating, air conditioning and hot water pump technologies.
The app also provides the user with targeted access to comprehensive product information and pumping know-how. Most of the data and functions are installed on smartphones and tablets and are thus available even if there is no connection to the mobile network operator. The program, available for Android and iOS platforms, has wide functionality:
- Interactive pump replacement function for heating and hot water systems: enter the name of the pump to be replaced and the user will be given a recommendation which Wilo high-efficiency pump is suitable for replacement.
- Energy Savings Calculator: Calculates potential savings in terms of energy costs and CO2 emissions. Compares Wilo energy saving and high efficiency pumps with uncontrolled pumps.
- Fault decoding assistant.
- Short catalog: Displays a description of dry rotor pumps.
- Pump selection: according to the set duty point, Wilo will recommend the right pump in a matter of seconds.
And this is not a complete list of useful functions of the program. Thanks to a customer-oriented policy, Wilo and its products are highly trusted by customers. Wilo pumps are distinguished by their high efficiency and compliance with international quality and safety standards.
Overall dimensions of the Wilo TOP S pump range
Pump sizes
| Wilo TOP S ... | Piping connection / nominal diameter | Thread | Pump dimensions | Weight approx. | Outline drawing | ||||||
| [Rp / DN] | G | I | a1 | a2 | l1 | b1 | b2 | b3 | PN 6/10 | – | |
| – | – | – | |||||||||
| 25/5 | Rp 1 | G 11/2 | 180 | 40 | 70 | 150 | 50 | 87,5 | 92 | 4,5 | A |
| 25/7 | Rp 1 | G 11/2 | 180 | 34 | 56 | 165 | 66 | 80 | 92 | 5,0 | A |
| 25/10 | Rp 1 | G 11/2 | 180 | 52 | 72,5 | 171,5 | 68,5 | 92 | 102 | 6,3 | A |
| 30/4 | Rp 11/4 | G 2 | 180 | 50 | 70 | 156 | 53 | 87,5 | 92 | 5,0 | A |
| 30/5 | Rp 11/4 | G 2 | 180 | 40 | 70 | 150 | 50 | 87,5 | 92 | 4,5 | A |
| 30/7 | Rp 11/4 | G 2 | 180 | 34 | 64 | 172 | 66 | 88 | 92 | 5,0 | A |
| 30/10 | Rp 11/4 | G 2 | 180 | 52 | 72,5 | 171,5 | 68,5 | 92 | 102 | 6,3 | B |
| 40/4 | 40 | – | 220 | 54 | 76 | 178 | 83 | 103 | 92 | 9,5 | C |
| 40/7 | 40 | – | 250 | 46 | 72 | 193 | 78 | 97 | 102 | 11 | D |
| 40/10 | 40 | – | 250 | 58,5 | 88 | 217 | 90 | 121 | 110 | 14,5 | D / E |
| 40/15 | 40 | – | 250 | 55 | 83 | 258 | 99 | 135 | 119 | 20,6 | D / E |
| 50/4 | 50 | – | 240 | 53 | 80 | 200 | 93 | 112 | 104 | 13 | D |
| 50/7 | 50 | – | 280 | 63 | 82 | 225 | 91 | 119 | 110 | 16,5 | D / E |
| 50/10 | 50 | – | 280 | 67 | 91 | 223 | 101 | 123 | 110 | 17 | D / E |
| 50/15 | 50 | – | 340 | 81 | 112,5 | 242 | 105 | 137 | 119 | 25,5 | D / E |
| 65/7 | 65 | – | 280 | 72 | 97 | 234 | 111 | 124 | 110 | 18,5 | D / E |
| 65/10 | 65 | – | 340 | 79 | 100 | 256 | 118 | 136 | 119 | 23,5 | D / E |
| 65/13 | 65 | – | 340 | 79 | 100 | 256 | 118 | 136 | 119 | 25,5 | D |
| 65/15 | 65 | – | 340 | 79 | 100 | 283 | 118 | 136 | 119 | 29 | D |
| 80/7 (1~) | 80 | – | 360 | 95 | 130 | 258 | 135 | 159 | 119 | 28 | E |
| 80/7 (3~) | 80 | – | 360 | 96 | 130 | 227 | 111 | 149 | 110 | 25,5 | D |
| 80/10 | 80 | – | 360 | 95 | 130 | 258 | 135 | 159 | 119 | 28/30 | D |
| 100/10 | 100 | – | 360 | 95 | 130 | 258 | 135 | 159 | 119 | 28,5/30,5 | D |
Flange dimensions
| Wilo-TOP-S ... | Flange | Nominal inner diameter | Pump flange dimensions | Outline drawing | |||
| – | DN | Ø D | Ø d | Ø k, Ø kL1 / kL2 | n x ØdL, n x ØdL1 / dL2 | – | |
| – | – | – | |||||
| 40/4 | Combination flange PN 6/10 (flange PN 16, according to DIN 2533) | 40 | 150 | 88 | 100/110 | 4 x 14/19 | F |
| 40/7 | |||||||
| 40/10 | |||||||
| 40/15 | Combination flange PN 6/10 (flange PN 16, according to EN 1092-2) | 40 | 150 | 84 | 100/110 | 4 x 14/19 | F |
| 50/4 | Combination flange PN 6/10 (flange PN 16, according to DIN 2533) | 50 | 165 | 102 | 110/125 | 4 x 14/19 | F |
| 50/7 | |||||||
| 50/10 | |||||||
| 50/15 | Combination flange PN 6/10 (flange PN 16, according to EN 1092-2) | 50 | 165 | 99 | 110/125 | 4 x 14/19 | F |
| 65/7 | Combination flange PN 6/10 (flange PN 16, according to DIN 2533) | 65 | 185 | 122 | 130/145 | 4 x 14/19 | F |
| 65/10 | |||||||
| 65/13 | |||||||
| 65/15 | |||||||
| 80/7 (3~) | Flange PN 6 (designed for PN 16, according to EN 1092-2) | 80 | 200 | 132 | 150 | 4 x 19 | G |
| Flange PN 16 (according to EN 1092-2) | 80 | 200 | 132 | 160 | 8 x 19 | G | |
| 80/7 (1~) 80/10 | Flange PN 6 (according to DIN 2531, holes according to EN 1092-2) | 80 | 190 | 128 | 150 | 4 x 19 | G |
| Flange PN 16 (according to DIN 2533, holes according to EN 1092-2) | 80 | 200 | 138 | 160 | 8 x 19 | G | |
| 100/10 | Flange PN 6 (according to DIN 2531, holes according to EN 1092-2) | 100 | 210 | 148 | 170 | 4 x 19 | G |
| Flange PN 16 (according to DIN 2533, holes according to EN 1092-2) | 100 | 220 | 158 | 180 | 8 x 19 | G |
The most popular models of Vilo drainage pumps
- Wilo-DrainTMT 32H102 / 7,5Ci pump Submersible unit for vertical installation. It can be used for pumping hot water and aggressive liquid media.
- Drainage pump Wilo-Drain TMW 32/11. Used for pumping waste water. Prevents the accumulation of precipitated substances, destroys them together with the pumped out liquid. The temperature environment is not more than 35 degrees.
- DrinVC model. The vertical positioner can handle contaminated environments that contain a 5mm particle. The VC30 / 10 type pumps water at a speed of 7m³ per hour with a head of ten meters.
- The EMU KS unit is used for pumping wastewater from flooded basements or pits, ingress of grains with a diameter of 5-45 millimeters is allowed.
Wilo produces versatile equipment that can be used in different areas of life. Each drainage pump of this brand will delight you with excellent quality and optimal technical characteristics.
Models at a glance
Consider several models in each section from the middle price category:
- Wilo TWU 4-0207-SK - a centrifugal downhole tool capable of operating at a depth of 200 meters, installed vertically and horizontally. 7 steps, 3.6 m3 per hour, diameter 98 mm. Price - 26 thousand.
- Wilo Drain TMW 32/11 - a vortex drainer made of composite materials, pumps slightly polluted water (particles up to 10 mm), from a depth of 3 meters. There is overheating protection and a float mechanism, no cutting knives. 15 m3 per hour, head - 11 m, section 16.5 cm. Price - 10.5 thousand rubles.
- Wilo PB-201EA - centrifuge with a wet rotor to increase the pressure in the water supply. Designed for clean water, with a temperature of no more than 60 ° C. Protection against overheating, 3.3 m3 per hour, diameter 17.6 cm. Price - 9 thousand rubles.
- Wilo Drainlift TMP 32-0.5 - pressure station for sewerage (surface). Without a cutting mechanism, designed for dirty water, 4.5 m3 per hour, head 5.5 m. Height 30 cm, length - 50 cm. Price - 20.7 thousand rubles.
- STS 40 / 10A - cast iron fecal pump. It has a float mechanism, protection against overheating, liquid temperature - up to 35 ° С. 20 m3 per hour. Head 10 m, power 750 W. Price 17 thousand rubles.
Pumps for heating systems are recommended to be installed on the last floors of city houses, where, due to poor circulation in the system, it is cold in apartments in winter. Circulation pump for heating systems: selection features and installation procedure.
Read about the purpose of a thermostat for a heating radiator here. And also everything about the selection and installation of the device.
We will analyze the principle of operation of a heat pump for heating a home using this link: https://microklimat.pro/otopitelnoe-oborudovanie/otopitelnye-pribory/teplovoj-nasos-dlya-otopleniya-doma.html. Types of structures and examples of calculation.
Design and principle of operation of Wilo pumps
- Noise characteristics - the operation of the module is absolutely silent, which allows installation directly in living quarters, in the kitchen and in the bathroom.
- Air removal - a valve is installed in the structure through which air is removed from the heating system.
- Reduced energy consumption - all models consume the minimum amount of electricity. At the same time, high productivity is maintained.
- Long service life. Wilo pumps for heating systems have a cast iron casing. All important parts of the structure have anti-corrosion properties. All models are subject to mandatory testing and certification.
- Convenient control - a mechanical or electronic switch is provided. The power and speed of movement of the coolant is regulated.
- Electronically controlled models are equipped with a built-in thermostat.
- Protection of the electric motor and rotor against voltage surges is provided.
- Operating parameters - head of water column from 1 to 7.5 m, heated area from 100 to 2200 m², throughput from 1 to 12 m³ / hour. The working temperature range of the coolant is from -10 ° С to + 110 ° С.
The Wilo pump device is distinguished by thoughtfulness, high performance and efficiency. The models are ideally suited for radiator heating, multi-circuit systems, as well as DHW and air conditioning.
Heating pump Wilo Star
- Wilo Star RS - 12 equipment models are produced in the series, with markings from 15-4 to 30-8. The body is made of heat-resistant cast iron, the rotor, bearings and other elements in contact with the coolant are made of stainless steel. Star RS is a manually controlled circulating pump with the ability to generate pressures up to 10 bar. Maximum throughput up to 6 m³ / hour.
- Wilo Star RSD are dual circulation pumps that perform several tasks at once: they raise the pressure in the heating system, increase the service life of the devices and make it possible to simultaneously connect the module to two independent circuits. The set includes a switch that regulates the operation of two electric motors.
Heating pumps Wilo Top
- Wilo TOP-RL and TOP-S are the most efficient pumps in the series.Models are equipped with 1-2 motors, wet rotor. One-two-phase connection to the mains is possible. The Wilo three-speed pump uses a mechanical switch.
- Wilo TOP-Z is a model of the Tor series, for which the quality of the heat carrier used is insignificant. The module has found wide application in systems with possible deposition of calcium and magnesium deposits. The pumping equipment is located in any places, the most unsuitable for this.
- Wilo TOP - basic configuration. The circulation pump for heating Wilo Top is offered in more than 50 items. The difference lies solely in the mounting size of the flange, as well as in the performance parameters: pressure from 6-10 bar, temperature of the coolant from -20 ° C to + 130 ° C.
Mounting equipment of the TOP series is optimally suited for industrial use, in conditions of an aggressive heat carrier environment.
Heating pumps Wilo Stratos
- The power consumption of the Wilo pump is from 2 to 48 W.
- The night mode is set when the power consumption drops to a minimum.
- Automatic adjustment of operating parameters - the controller is connected to a room thermostat, which allows it to select the optimal speed, performance, depending on actual needs.
Wilo Stratos are suitable for energy-efficient heating systems. Compared with ordinary pumping equipment, the energy savings are at least 80%.
Specifications
First of all, the main technical characteristics of any pumps are:
- The volume of the pumped-over medium per hour;
- The head or the amount by which the pressure can be raised;
- Purpose of the pump - for what purposes it is intended;
- At what voltage the unit can operate one or three-phase electric motor connection;
- By type of connection - can be flanged or threaded.
The most common Wilo brand pumps designed for heating systems in small industrial premises, residential buildings and apartments are:
Wilo Star-RS - are available in three modifications, designed for heating systems and are produced with a block for adjusting the flow rate of the pumped liquid. Depending on the series, they can pump a volume of 2 to 5 m3 / hour, while the head can be from 0.2 to 0.6 atmospheres, the type of execution is with a wet rotor, the connection is threaded;
Wilo-TOP-RL - almost identical to the previous pump, it has a large performance indicator. The volume of the pumped-over liquid is from 6 to 9 m3 / hour, the head is from 0.4 to 0.77 atmospheres. Execution type - wet rotor, threaded connection;
Wilo-BL - differs from previous pumps with a higher capacity from 5 to 60 m3 / h, head from 0.6 to 1.6 atmospheres. Execution type - with a wet rotor, threaded or flanged connection.
Comparison tables of the main parameters of WILO pumps of the Drainlift family.
All installations of this group are used for pumping untreated wastewater in the sewage mains, in cases where it is impossible to drain them by gravity, i.e. due to the natural height difference.
| Series (varieties) | Max. delivery height, m | The total volume of the tank, l | Max. diameter of solid particles, mm | Max. inflow at S3 mode, l / h | Max. level (volume) of inclusion, l | Pumped liquid temperature range | Features of the |
| (S 1/5) | 5 | 45 | 40 | 600 | 20 | from +3 to + 40 ° C, short-term up to + 60 ° C | One built-in pump. Single or three phase motors. The motor unit is located outside the tank. |
| (M 1/8, M 2/8) | 8 | 62 or 115 | 45 | 1080 or 3600 | 24 or 40 | from +3 to + 40 ° C, short-term up to + 60 ° C | One or two built-in pumps. Single or three phase motors. The motor unit is located outside the tank. |
| (L1 /…, L2 /…) | 25 | 115 or 140 | 40 | 1050 or 3000 | 35 or 50 | from +3 to + 40 ° C, short-term up to + 60 ° C | One or two built-in pumps. Three-phase motors only. The motor unit is located outside the tank. |
| RexaLift FIT L | 115 or 140 | 40 | 1050 or 3000 | 35 or 50 | from +3 to + 40 ° C, short-term up to + 60 ° C | One or two built-in pumps. Three-phase motors only | |
| (XL2 / ...) | 25 | 380 | 40 | 15600 | 260 | from +3 to + 40 ° C, short-term up to + 60 ° C | Two built-in pumps. Three-phase motors only. The motor unit is located outside the tank. |
| (XXL 840, XXL 880, XXL 1040, XXL 1080) | 400 or 800 | 78 or 95 | 26400, 27600, 52800 or 55200 | 305, 315, 610 or 630 | from +3 to + 40 ° C, short-term up to + 65 ° C | Two pumps - Drain TP 80 or Drain TP 100 - dry (not in tank). Three-phase motors only. |
Mine sewage pressure pumping stations for installation both inside buildings and outside (in the ground).
Shaft pumping stations of this group are used for collection and pressure discharge of wastewater into main sewer networks, in cases where their drainage by gravity is impossible, i.e. due to the natural height difference under the influence of gravity.
| Series (varieties) | The total volume of the tank, l | Max. diameter of solid particles, mm | Max. inflow at S3 mode, l / h | Max. level (volume) of inclusion, l | Pumped liquid temperature range | Features of the |
| (WC 40 D, WC 40 E) | 255 or 400 | 40 | 1950, 3000 or 9600 | 65, 100 or 160 | from +3 to + 40 ° C | Installed in a building or in the ground. One or two Drain TC 40 pumps. Single or three phase motors. The pumps are included in the scope of delivery. |
| Mine installations-tanks for waste water. The pumps are not included in the scope of delivery. | ||||||
| (WS 40, WS 50) | 255 or 400 | 44 | depends on the pump | depends on the pump | from +3 to + 35 ° C or + 40 ° C, depending on the pump | Installed in a building or in the ground. One or two Drain TP 50 / TP 65 or MTS 40 pumps. Single or three phase motors. The pumps are not included in the scope of delivery! |
| (WS 625 E /…) | 368, 460, 552, 664 | 10 or 40 | depends on the pump | depends on the pump | +3 to + 35 ° C, + 40 ° C or + 90 ° C, depending on the pump | Installed only in the ground (outside buildings). Only one pump is used - TMW 32/11, TC 40, STS 40 or MTS 40. Motors can be single or three phase. The pumps are not included in the scope of delivery! |
| (WS 830 E) | 929 or 1261 | depends on the pump | depends on the pump | from +3 to + 40 ° C | Installed only in the ground (outside buildings). Only one pump is used - MTC 32 or MTS 40. Motors can be single or three phase. The pumps are not included in the scope of delivery! | |
| (WS 900, WS 1100) | 880, 900, 1215, 1220 or 1240 | 10, 44, 50, 65 or 80 | depends on the pump | depends on the pump | from +3 to + 35 ° C or + 40 ° C, depending on the pump | Installed only in the ground (outside buildings). One or two pumps are used - TS 40, TP 50 / TP 65, Rexa FIT V05, Rexa PRO V05, TP 80, MTC 32 or MTS 40. Motors can be single or three phase. The pumps are not included in the scope of delivery! |
Tips & Facts & nbsp // Facts
This year, at the WILO stand, energy-efficient German pumping equipment was widely presented, mainly for municipal and industrial use, with a warranty service from 2 to 5 years. Many types of pumps can be ordered by the Buyer with a special ceramic coating "Ceram" patented by Wilo, which guarantees the pump resistance to aggressive media and increases the service life and efficiency of the equipment.
For example:
| — | Wilo network pumps with double inlet for municipal water supply and heating, in industrial cooling systems and in heat supply, in fire extinguishing systems and agricultural irrigation. Each pump is produced to a predetermined performance curve with an impeller trim point. The shaft is sealed with a high-quality mechanical seal for all capacities. It is possible to use special cast hydraulic materials: bronze, stainless steel, ductile iron, etc. |
| — | Wilo-COR MVI compact booster systems for municipal and industrial water supply are completely ready for operation. Low noise level, maintaining the set pressure level regardless of the water flow ensure energy efficient water supply. The pump and piping are made of stainless steel. |
| — | Axial pumps Wilo-EMU KPR for land reclamation, treatment facilities, irrigation systems and circulating water supply systems of thermal and nuclear power plants.The version with a protective ceramic coating "Ceram" is possible, which guarantees the pump resistance to aggressive media and increases the service life. Cast impeller blades are made of corrosion-resistant stainless steel 1.4581.The pump is constructed using a reliable sealed motor. |
| — | Multistage high-pressure pumps Wilo-MVIL, Wilo-MVI, Wilo-Helix V for high-pressure liquid supply in water supply, heating or cooling systems. The features of these pumps are high quality hydraulics, corrosion resistance, long service life, low operating costs. The new high-performance pump for water supply Helix - an innovative development of the specialists of the WILO SE concern - has a hydraulic part, as well as an EFF1 energy efficiency class motor, which ensures high efficiency rates. At the same time, the high quality of the material from which the pump is made guarantees its durability and reliability in operation at the lowest possible operating costs. |
| — | Linear pump Wilo-IL for supplying liquids in water supply, heating or cooling systems. Powerful and compact, the WILO IL pump is easy to install and easy to operate. The pump is used in municipal water supply systems, industrial cooling and heating systems, agricultural irrigation systems. The main features of the pump are: cast impeller made of cast iron of the GG20 brand, reduced cavitation characteristic. The special painting protects the pump from negative environmental influences. The cassette mechanical seal allows easy replacement in just 20 minutes. |
| — | Fully sealed submersible pump Wilo-FA05… FA15 with F and T motors for supplying liquids in wastewater or water supply systems. The special wear-resistant Ceram coating guarantees the pump resistance to aggressive media and also contributes to a longer service life. Features of the pump: Large joint ball passage (up to 100mm depending on the model), self-cleaning cast impeller made of EN-GJL-200 cast iron. All pumps of the FA series are completely sealed, have a reliable sealed motor, possibly a special chemical and abrasion resistant design. The pumps are used in water supply systems, sewage treatment plants, industrial cooling systems, sewage pumping stations, storm water stations. |
| — | The Wilo-Booster municipal and industrial booster pump for the supply of high-pressure liquids in fire extinguishing or water supply systems. Features of the pump: vertical or horizontal dry installation indoors, efficient operation at full flooding, sealed reliable stainless steel construction, individual selection of the location of the suction inlet |
| — | 8 '' Municipal Borehole Pump - High Efficiency Pump Up to 83% energy savings thanks to sophisticated molded parts and special coatings. Wear-resistant impellers are made of high quality bronze, and the cast edges are made with a metal thickness margin. Individual adjustment and balancing of each impeller is possible. The pump is used to supply drinking water from wells, wells, cisterns, to supply technical water, water supply for municipal and industrial purposes: watering and irrigation, increasing pressure, lowering the water level; use of geothermal energy; as well as in the coastal area; water supply to fountains, snow cannons and water bodies. |
| — | High efficiency pump Stratos for hot water heating systems, industrial circulation systems. Energy efficiency class A. Energy savings of up to 80% compared to fixed circulation pumps. Maximum efficiency is achieved through ECM technology.The independent European test pump Wilo-Stratos ECO was awarded the highest marks for energy efficiency, easy installation and user-friendliness. Electricity consumption for 20 years in a house where Wilo-Stratos ECO operates is equal to electricity consumption for 2-4 years in a house with unregulated pumps. From a "devourer" of electricity, the pump turns into the most economical device in your home. An electronic energy efficiency benchmark allowed visitors to see how high the Stratos was compared to a standard pump. |
| — | The glandless circulation pump Wilo-TOP-S is used in hot water heating systems, industrial circulation systems, cold water supply systems and air conditioning systems. The communication system with the pump is ensured by means of easily and reliably retrofitted plug-in technology. Features of the pump: reliable protection against corrosion thanks to cataphoresis coating, three hydraulic characteristics thanks to a three-speed motor; |
| — | Hydraulic elements of Wilo-K, KD, NK pumps for supplying liquids with high pressure in water supply or fire extinguishing systems. Impellers and stage casing of borehole pumps for municipal use. Features of the pump: made of high-quality bronze as a standard for long-term operation, complex cast structure allows to obtain high efficiency, individual adjustment and balancing of each impeller, optional use of a ceramic coating to obtain increased efficiency. |
| — | Special heavy-duty cable with sealed connector for FA submersible pumps. Features of the cable: submerged and dry operation in harsh mechanical conditions, hermetically sealed reliable structure made of special materials, operation in hazardous areas according to DIN VDE 0165 |
| — | The protective ceramic coating of Wilo-Ceram submersible pumps, which was introduced by the specialists of the WILO SE concern in 1997. The wear-resistant Ceram coating guarantees an extended service life of the wastewater pumps. Scope: any systems where it is necessary to have increased corrosion and abrasive protection of pumping units, as well as increased efficiency. |
All WILO equipment is certified in accordance with all standards of the Republic of Belarus and is available from a warehouse in Minsk with special discounts within the framework of Belarus-Germany partnership.
The WILO stand was visited by a large number of specialists from design organizations, as well as representatives of housing and communal services, professionals of the construction market. The visitors were presented with feasibility studies of the payback period for WILO pumping equipment, which once again confirmed the well-known truth that equipment that is cheaper at the time of purchase turns out to be many times more expensive during operation.
Within the framework of the exhibition on April 23, 2009. a WILO seminar was held on the topic “WILO energy-saving pumping equipment for municipal and industrial use. New items in the production program. " Presentations were made by the leading engineer of the WILO SE Representative Office in the Republic of Belarus and the technical specialist of the WILO SE concern (Dortmund, Germany).
The participants of the seminar got acquainted with the novelties in the production program of the WILO SE concern, learned about the current directions of modernization of the manufactured products, and also received updated discs with the WILO SELECT selection program, WILO ACAD Library (library of pump drawings for Auto CAD), WILO Library (electronic version of technical documentation )
At the end of the seminar, a trip to the WILO reference objects was organized for everyone, in particular, a visit to the facilities of the State Unitary Enterprise "Zhodinsky Vodokanal": PNS No. 1, PNS No. 9, Severny water intake. WILO pumping equipment has been installed and is successfully operating at all facilities: COR multi-pump pressure boosting units based on MVI pumps, downhole pumping equipment of the NR, TWI series, double-suction pumps of the ASP series. According to the company's management, the economic effect from the use of WILO equipment (installed in 2007-2008) amounted to 160 thousand kW / h per year.
Dear designers, please note:
WILO training class invites! Every Thursday from 14:00 to 16:00 for seminars for designers Conference class address: Minsk, st. Timiryazeva 65B, room 507.preliminary registration by T. 375 (17) 228-22-28
The WILO representative office in the Republic of Belarus offers:
| — | Energy saving pumps with low noise level |
| — | A wide range of products in a wholesale warehouse in Minsk |
| — | Delivery system to all regions of the country |
| — | Installation supervision and post-warranty service |
| — | Warranty from 2 to 5 years |
| — | Electronic pump selection software WILO-Select |
| — | Technical advice when creating a project |
Customer opinion on Wilo products:
GOMELENERGO recommends WILO pumping equipment for widespread use in all spheres of housing and communal services of the Republic of Belarus, as equipment that can significantly reduce energy consumption (letter No. 22-15 / 2845f dated 12.06.2007)
Zhodino Vodokanal: economic effect from the use of WILO equipment - 160 thousand kWh per year; Gorvodokanal Mogilev: the economic effect from the use of 30 WILO pumps - $ 206,000 with a payback period of less than 7 months.
Slonim Vodokanal: The economic effect from the use of the TWI series borehole pumps is 17,000 kW
Krichevsky communal worker: The economic effect from the use of WILO pumps is 35,000 kW per year
Lida ZhKKh: the use of borehole pumps of the TWI series, which are installed in the water supply system of the city of Lida, made it possible to reduce the cost of electricity consumed on average for each well by 30%, and in the Lida district up to 60%
Lida ZhKKh: The use of WILO FA series submersible sewage pumps in the Lida region made it possible to reduce energy consumption by an average of 35% for each sewage pumping station.
Brestvodokanal: The use of downhole pumps of the NR series made it possible to reduce energy consumption with the same hydraulic parameters by 40% in comparison with the previously installed ones.
Energy audit: When comparing WILO borehole pumps with pumps from CIS manufacturers with long-term operation and the same required parameters, WILO pumps will help reduce energy costs by up to 50%.
| For all questions, as well as for technical catalogs and disks with a convenient electronic WILO selection program, please contact our office: | |
| Phones: +375 (0) 17 253-53-63 - INFOLINIA +375 (0) 17 228-55-28 +375 (0) 17 228-55-29 +375 (0) 17 250-33-93 fax +375 ( 0) 17 250-33-83 Website: www.wilo.by Email: | |
Pumping station and its types
A pumping station is a complex system of pumping equipment that is used for pumping liquid and consists of a main pump and an additional pump, a tank or water tank, a hose, a pressure gauge for pressure control, a pressure switch and a union. Simple and common pumping stations in this design: diaphragm tank, self-priming pump and pressure control switches.
Modern equipment has reached a high level and a dozen types of pumping stations have appeared. Stations that are capable of pumping liquid are divided into two types:
- household;
- industrial.
Self-priming station Wilo HWJ 201 25L
Household pumping units are necessary for water supply of private houses and summer cottages, cottages, farms and agricultural holdings, automatic and manual irrigation of gardens, personal plots and greenhouses. Such Wilo pumping equipment is widely used in the sewage mains of water supply and wastewater disposal, where they collect and discharge wastewater into special treatment facilities.
Industrial pumping stations:
- Boost station. Such a station is used to increase the pressure or to maintain it at a given level in the hydraulic line.
- Fire station. In fire extinguishing, high pressure and pressure stations are used.
- Hydraulic. With the help of such stations, hydraulic tools are supplied with working fluid and tools under constant pressure.
- Modular. Used for collecting and discharging waste water. Most often, modular equipment is supplied ready-made and assembled. This increases reliability, quality and saves time during further assembly.
- Pumping and filtering.Such installations are necessary when it is required to provide cities and villages with drinking water. Modern filtration systems cope with the elimination of impurities and bacteria in the water. Filtration takes place using ultraviolet cleaning technology without the use of chemicals.
Wilo pumps
Among the pumping equipment, the products of the Wilo company have proven themselves. Vilo pumping equipment of high quality and reliability.
About Wilo
Wilo SE is a world famous manufacturer of pumping equipment in various directions: air conditioning systems, ventilated systems, water supply systems, heating and fire extinguishing, founded in 1872. The main office of the company is located in Dortmund, Germany and has 60 representative offices in the world. Wilo was founded in 2002. The company uses innovative and highly efficient technologies for production.
The advantages of Vilo products
- low consumption of electrical energy by equipment;
- high level of assembly quality, mechanisms and components are carefully selected;
- pumping equipment of this manufacturer is convenient to use and repair;
- low noise level of equipment during operation, which is appreciated by owners of houses and estates;
- availability of specialized Wilo service centers in large cities. This allows for quick service and repair of equipment.
Use of Vilo pumps and stations:
- Vilo pumps for houses with a small number of apartments and low buildings;
- Vilo pumps for houses, summer cottages, cottages;
- Vilo pumps for business buildings;
- Vilo pumps for industrial use;
- Vilo pumps for use by public utilities and enterprises.
Pump increasing the pressure in the water supply
Introduction, Safety, Personnel qualifications
Page 9
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- Text
Russian
Installation and operating instructions Household plumbing systems Wilo Hxx
9
1. Introduction
Information about this document
The original installation and operating instructions were drawn up in German. All other languages of this manual are translations of the original instructions. The installation and operating instructions are an integral part of the product. Therefore, it should always be kept close to the device. Strict adherence to these instructions is a prerequisite for using the device as intended and for correct operation of the device. The installation and operating instructions correspond to the version of the appliance and the basic safety standards in force at the time of going to print.
EC Declaration of Conformity:
A copy of the EC Declaration of Conformity is part of these installation and operating instructions. If technical changes are made to the design specified in the certificate without agreement with the manufacturer, the certificate becomes invalid.
2 Safety precautions
This manual contains basic recommendations that must be observed during installation and operation. In addition, these instructions are essential for installers for installation and commissioning, as well as for the user. Not only must the general safety requirements given in this section be observed, but also the special safety requirements.
2.1 Indication of recommendations in the instructions for
exploitation
Symbols: General danger symbol
Danger of electric shock
NOTE: ...
Warning Symbols:
DANGEROUSLY! Extremely dangerous situation. Failure to comply will result in death or serious injury.
CAUTION! The user can be injured (severely). The "Caution" symbol indicates that (serious) injury to persons is probable if the instructions are not followed.
ATTENTION! There is a risk of damage to the product / installation. Caution refers to possible damage to the product if the instructions are not followed.
NOTE: Useful information on the use of the product.It also indicates potential difficulties.
2.2 Personnel qualifications
The installation and commissioning personnel must be suitably qualified to carry out the work.
2.3 Dangers if the recommendations are not followed
on safety
Failure to follow the safety instructions can lead to personal injury and damage to the product / system. Failure to comply with the safety regulations may result in the loss of the right to claim. Non-observance of the safety regulations can, in particular, have the following consequences:
• failure of important functions of the product / installation, • failure of prescribed technical
maintenance and repair work,
• mechanical injury to personnel and injury
electric shock, mechanical and bacteriological effects,
• material damage.
2.4 Safety recommendations for
user
The existing regulations must be observed to prevent accidents. The risk of electric shock must be avoided. Observe the instructions of the local power supply company. Persons (including children) with physical, sensory or mental disabilities, as well as persons without sufficient knowledge / experience, are allowed to use this device only under the supervision or guidance of a person responsible for the safety of the aforementioned persons. Children should be supervised to ensure that they do not play with the device.
How to correctly install a Wilo pump in a heating system
- Only vertical installation is allowed. Do not install a Wilo pump horizontally in the system. The only exceptions are models specially designed for horizontal connection. The installation position of the pump can be found in the operating instructions.
- Connecting underfloor heating - the pump is installed in a special mixing unit. The correct location of the Vilo heating pump is indicated by arrows on the body and on the hydraulic wiring.
- Connection to a radiator-type heating system - installed in the heating return line, directly in front of the boiler. To prevent a complete stop of the circulation of the coolant, they are mounted in a bypass. The rules for installing Vilo pumps allow the use of equipment for heating systems with natural and forced circulation.
- Installation and maintenance - the pump is installed in a vertical position, observing the direction of the coolant indicated by the arrows on the body and mixing unit. It is recommended that the installation be carried out by a qualified technician. The installation methods of the pump depend on the selected model and are described in detail in the technical documentation. Provided that it is correctly connected, no special maintenance of the Wilo pump is required.
- On the bypass frame, it is necessary to install a coarse filter in front of the pump.
- You can leave the pump on at all times. It is recommended to turn on the device for a few minutes after the end of the heating season.
- Hum when the pump is running - indicates several possible malfunctions. The air vent is clogged, as a result of which no air is removed from the system. Another malfunction lies in the incorrectly selected operating mode. Reducing the operating speed usually stops the hum. If not, pump service will be required.
- It is possible to turn on the pumping equipment only when the heating system is full. Wet rotor models use heat transfer fluid for lubrication. When turned on, if there is no lubricant, the bearings burn out quickly.
Only a qualified specialist can take into account all the details of the installation of a Wilo circulation heating pump. Equipment installation is completed in just a few hours. When installing a bypass, it will take 3-6 hours.
Waterworks - Pumps Wilo, Grundfos, Ebara, Lowara, DAB.
We offer services for aligning the shafts of pumping units from Wilo, Grundfos, KSB, DAB and other manufacturers.
Shaft misalignment is one of the most common causes of equipment failure: broken bearings and mechanical seals. Rotating offset shafts create vibrations and complex oscillatory radial and axial loads, which lead to failure of the pump unit parts. Shaft alignment is a pumping equipment manufacturer's requirement for accurate maintenance and, if not performed, will result in significant equipment wear and downtime.
When talking about a pump unit, two different types of alignment / alignment are important: alignment of the pump shaft and motor shaft, and alignment of the pump flanges with the connecting pipes.
The importance of shaft alignment
Shaft alignment is the process of aligning pump and motor shafts within acceptable limits. Displacement results in increased pump vibration, increased pump noise, reduced bearing life, ruptured mechanical seal, and clutch problems. To prevent this - the shafts must be aligned within tight tolerances.
The importance of flange alignment
It is important that piping loads are not transferred to the pump casing. This leads to stresses on the casing of the pumping unit, displacement of the shaft relative to the casing, increased vibration, bearing failure, damage to the mechanical seal, wear of the coupling and cracks in the pump casing.
Offset types
There are two types of offsets that require correction: parallel and angular.
Parallel offset can be horizontal, vertical, or a combination of both parallel and horizontal.
Angular misalignment occurs when two shafts are at an angle to each other and not aligned. As with parallel displacement, angular displacement can be vertical when one shaft is at an angle downward to the other, or horizontal when the shafts are in the same horizontal plane but at an angle to each other.
In practice, there are practically no situations when there is only one type of displacement. Offset often includes a combination of angular and parallel misalignment.
In almost all cases, the pump is already secured to the pipeline, which means that the pump housing can move slightly, if at all. Motors are usually easier to move as the motor is not connected to the process system other than the cable.
Correct shaft alignment is achieved by moving the motor. The motor adjusts vertically to achieve the correct mark to align with the pump, both parallel (offset) and angled. The motor moves horizontally to achieve the correct horizontal alignment to align the shaft centerlines, both parallel and angular.
Motor-pump alignment is critical for the following reasons:
- This minimizes the forces acting on the bearings and seals of both components.
- This minimizes coupling wear.
- This can reduce energy costs.
- This extends the life of the pump components by minimizing wear, increasing the time between failures and reducing vibration.
Motor and pump alignment should be an important part of any maintenance program.
Shaft alignment tolerances
Historically, shaft alignment tolerances were governed by the design specifications of the coupling manufacturers. The original function of the flexible coupling was to accommodate the slight misalignment of the shafts remaining after completing the shaft alignment using a ruler or feeler gauges.Some coupling manufacturers have designed their couplings to withstand the forces resulting from an angular offset of 3 degrees and an offset of 2 mm, depending on the manufacturer and type of coupling. The tolerances provided by the coupling manufacturers are designed to ensure the life of the coupling, assuming that the flexible member will fail rather than being a critical component of the machine.
When the shafts are misaligned, forces appear that can create large stresses. It is possible that the clutch will not fail when exposed to high stresses as a result of displacement, but the bearings and seals will fail earlier. Typically, bearings and mechanical seals have small internal clearances.
In extreme cases of shaft misalignment, bending stresses applied to the shaft can destroy the shaft itself.
Bearing Life Expectancy
The most common bearings used in pumps have a bearing life rating, sometimes referred to as bearing life, a rating for the fatigue life of a particular bearing. Statistical analysis of bearing life relative to the forces applied to the bearings has shown that as the force applied to a given bearing increases, life expectancy decreases by the third power of that change. For example, if the magnitude of the force due to displacement is increased by 3 times, the expected bearing life is reduced by 27 times.
Over the past 20 years, a lot of research has been done in the field of shaft alignment. The results led to a completely different method for assessing the quality of shaft alignment and increasingly accurate alignment methods.
The main causes of misalignment
To avoid bias from becoming a major cause of hardware failure, you need to understand why it is happening so that it can be corrected. The table lists the most common causes of shaft misalignment and explains what to do in each case:
| Cause | Recommendations |
| Violations during installation and commissioning | Align shafts, ensure displacements within tolerances |
| The foundation and fastening to it do not meet the requirements | The mass of the concrete foundation should be 1.5-2 times the mass of the equipment that it supports. The base plates must be thick and stiff to prevent distortion when torque is applied. Retaining bolts should be bonded to the concrete and not simply held in place by friction. On drives of 2.2 - 11 kW, bolts with a diameter of 16 mm are used, from 15 - 75 kW - 20 mm bolts, for 100 kW and above - 25 mm bolts. |
| Damaged or worn pump components | Check bearings. Replace bent shafts. Check the clutch, its wear. |
| "Soft foot" - the gap between one of the feet of the engine / pump and the foundation | Check the contact of the machine feet with the base plate or frame. It is easy to lower the share with the hold down bolts, but the result is a machine with tense internal parts. Use stainless steel pads under each foot |
| Excessive pipe loads | Check that the connecting bolts can slide in the flange holes by hand. |
| Failure of the supports and fasteners of the unit | Repair and rebuild |
The specialists of VodoKonstruktsiya LLC perform the alignment of cantilever pumps from Wilo, Grundfos, KSB, DAB and other manufacturers.
All cantilever pumps undergo preliminary alignment of the pump shafts when they go out of production. But during further transportation to the installation site, loading and unloading operations, as well as during installation, the alignment of the shafts gets confused. Re-alignment of shafts is required during installation.
Shaft alignment / alignment process
When aligning pumps, there are three distinct steps: pre-alignment check, rough alignment and fine alignment.
The preliminary check includes a check and a work plan.The foundation, fastening is checked. The base plates must be mortar-fixed under their entire surface. Rotating pump components and coupling must comply with manufacturer's tolerances. The serviceability of bearings and seals is checked and changed if the runout is out of tolerance. Shaft runout is checked for bent shafts and loose bearings. The maximum values are shown in the table:
| Shaft revolutions | Maximum displacement |
| Up to 1500 rpm | 0.025 mm |
| More than 1500 rpm | 0.013 mm |
The quality of the coupling is checked to ensure that it is in good condition. The fastening is checked using a set of plates for each support foot. The release tolerance must be less than 0.05 mm. The voltage from the pipelines connected to the pump is checked. Each bolt in the flanges should be easy to insert.
The last preparatory step is to ensure sufficient movement of the implement on each foot to make leveling adjustments. The bolts must have sufficient clearance to move. Jacks may need to be made and secured by drilling and tapping into the base plate or base frame.
Rough alignment involves aligning the pump coupling and motor driveshaft using variable plate thicknesses until they are within 0.5mm of offset.
Modern pumping equipment requires precise alignment, for which 2 devices can be used: cand laser-guided dial indicators and instruments. Each method requires training and experience.
More advanced laser alignment systems provide consistently better accuracy than other methods. Laser-guided shaft alignment tools usually consist of two units, each capable of emitting and detecting a precise laser beam. The blocks are securely attached to the shafts using magnetic brackets and / or a magnetic circuit. To trigger them, the operator activates the tool with a handheld control device, and each unit emits a precise laser line projected onto the detector of the other unit. The display on the handheld device provides real-time grip and foot values during the alignment process, eliminating the need to remove and reinstall the gauge blocks after each alignment adjustment.
The entire process can take 3 to 4 hours the first time the pump is aligned. Re-alignment usually takes about 2 hours.
Once misalignment has been identified, analyzed and corrected, it is important to periodically perform maintenance to ensure smooth operation.
After completing the alignment work, the pump is started up for 72 hours for running-in, followed by a check of alignment.
In addition, the maintenance program should include periodic checks to verify that conditions are still within tolerance. It is recommended to check the alignment of the shafts once every six months or a year, depending on the operating time.
Following these simple steps to locate, fix, and maintain proper shaft and belt alignment can prevent costly, unplanned downtime.
LLC "Vodokonstruktsii" has extensive experience in commissioning pumping units and their further maintenance. Our service department exists to provide professional alignment and start-up of pumps. A stock of spare parts and pumps ensures that we can meet your requirements in a timely manner.
