Installation - Operation - Maintenance

Vertical In-line Pumps

IL - IS – IX

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 TABLE OF CONTENTS

Page
A- General Instruction 3
B- Receiving & Pump Identification 3
C- Temporary storage 3
D- Location – Foundation 3
E- Suction Piping Arrangement 4
F- General Piping Recommendation 5
G- Alignment of Vertical Inline Pumps 5
H- Mechanical & Electrical installation 5
I- Priming of pump 6
J- Pre-start-up check list 6
K- Pump start-up 7
L- Lubrication (Motor & Pump) 8
M- Preparation for Disassembly 8
N- Pump Disassembly (type IL) 9
O- Mechanical Seal Replacement (IL) 10
P- Wear Ring Replacement 10
Q- Pump Exploded View (Type IL) 11
R- Pump Exploded View (Type IS) 12
S- Pump Disassembly (type IS) 13
a) Seal replacement 13
b) Disassembly of pump 14
T- Pump Exploded View (Type IX) 15
U- Pump Disassembly (type IX) 16
a) Seal replacement 16
b) Disassembly of pump 17
V- Trouble Shooting 15

This document contains specific information regarding the installation, operation and maintenance of your
pumps and should be read carefully before installation by personnel.

The equipment supplied has been designed and constructed to be safe and without risk to health and safety
when properly installed, operated and maintained. The instructions following must be strictly adhered to. If
clarification is needed on any point please contact WILO USA, LLC. Please make sure you have the
pump serial number on hand when calling.

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A- GENERAL INSTRUCTIONS
Read these instructions carefully before installing and operating your new WILO centrifugal Vertical
in-line pump. Keep this manual handy for future use.

B- RECEIVING AND IDENTIFICATION OF PUMPS

Check pumps for shortage and damage immediately upon arrival.
Pump accessories may have been shipped in separate boxes.

Unload and handle the units with a sling. Never lift the unit by the eyebolts on the motor.
Notify carrier immediately of any damages done in transit and make notations on the freight bill.

All WILO pumps are identified with a catalogue number and a serial number. These numbers are stamped
on each unit nameplate.

C- TEMPORARY STORAGE
If the pump needs to be stored before its installation, make sure you store it in a clean, dry area of moderate
temperature. Rotate the shaft by hand periodically to coat bearings with lubricant to retard oxidation and
corrosion.

D- LOCATION - FOUNDATION
Locate the pump as close as possible to the suction supply. Use the shortest and most direct suction piping
practical. (See figure 1)

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 Figure 1

D- LOCATION – FOUNDATION
The pumps should be installed on a level concrete foundation, preferably on a mounting pad, and anchored
according to Hydraulic Institute standards. In-line pumps can be suspended in piping system provided pipe
supports are installed on near each side of the pump.

Cast iron stands are available, at extra cost, if desired. These stands must be anchored to the floor and levelled
with suitable bolts to secure the pump assembly to the pad or floor.

E- SUCTION PIPING ARRANGEMENT

Suction piping should be as direct as possible, and ideally the length should be at least 10 times the pipe
diameter. At no point should suction piping be smaller in diameter than the pump suction opening. Use an
eccentric reducer, with the eccentric side down (Fig. 2) when reducing the pipe diameter to the diameter of
suction opening. Avoid any high points, such as pipe loops (Fig.1) that may create air pockets and throttle
the system or produce erratic pumping.

Figure 2

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F- GENERAL PIPING ARRANGEMENT

Install an isolating valve in the suction and discharge line to isolate the pump during shutdown and
maintenance, and facilitate pump removal. Globe valves should not be used particularly when NPSH is
critical. AVOID any high points in discharge piping that may entrap air or gas and thus affect pump operation.

Both suction and discharge piping should be independently supported and properly aligned so that no strain is
transmitted to the pump when flange bolts are tightened. Do not spring or force piping when making any
connections!

Properly sized pressure gauges can be installed in gauge taps on pump suction and discharge nozzles. Gauges
enable the operator to monitor pump performance. Gauge cocks are recommended for use with pressure
gauges, to protect gauges from constant wear and vibration when not in use. Clean and purge suction piping in
new installations before installing and operating pump. Pipe scale, welding slag and other abrasives can cause
rapid seal failure and void warranty.

CAUTION: Do not run the pump dry or against a closed valve! Dry operation will cause
mechanical seal failure within minutes.

Gauge Installation

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G- ALIGNMENT OF VERTICAL IN-LINE PUMPS
Before completing installation, check that the piping is aligned with the pump flanges. Make sure that no
strain is applied on either flange to avoid noise and vibration.

Now that pump alignment is verified place nuts on anchor bolts and tighten them enough to keep the pump
assembly secure to the concrete pad or floor.

H- MECHANICAL AND ELECTRICAL INSTALLATION

Isolating valves must be installed at the suction and discharge of each pump. A check valve should be installed
at the discharge of the pump. Hard wire the motor according to the Electrical code and the local authority.

Mount the control panel or motor starter(s) in close proximity to the pump to provide convenient control and ease
of installation.

Wire panel or starter(s) to motor(s) and pilot device(s): Wires to each motor must be sized for at least 125% of
the motor nameplate full load amps. AWG #16 Type THW stranded wire is recommended for wiring of pilot
devices (float switches).

Check incoming power source to ensure that it is the same as the voltage and phase of the
motor. Verify that the starters are suitable to operate the pump motors on voltage and phase that is available.

I- PRIMING

type IL or ILS pumps are not self-priming and must be completely filled with liquid before starting.

If the pump
connect thewill
lineoperate with
prior to a positive suction head, prime by opening the suction valve and allowing liquid
start-up
to enter the pump casing. Disconnect the recirculation line at the seal and bleed completely of all air,
If
re-pump has a suction lift, priming must be accomplished by other methods. The use of foot valves or ejectors, or
manual filling of the pump casing and suction line with liquid are possible methods suggested for this purpose.

J- PRE-START UP CHECKLIST

 Make sure all wiring connections are completed and that they match the wiring diagram

 Make sure rotation is clockwise as viewed from the back of the motor.

 Check voltage, phase, and line circuit frequency with the motor nameplate

 If the motor has been in storage for an extended period of time, refer to motor instructions before
starting

 Turn rotating element by hand to make sure it rotates freely.

 Tighten plugs in gauges and drain taps. If pump is fitted with pressure gauges, keep gauge cocks closed
at this time.

 Check suction and discharge piping for leaks and tighten all flange bolts.

 Make sure all isolating valves at the suction are fully open.

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J- PRE-START UP CHECKLIST
 The discharge gate valve should be closed before starting pump.

 The coupling guard (Type ILS & ILOS) must now be put back in place.

 If the pump is fitted with oil-lubricated bearings, check that the oil level is adequate in the lubrication
reservoir.

 If the pump is supplied with a micron filter it should be installed at this time.

K- PUMP START UP
 Make sure that the suction and discharge piping is flushed and cleaned before starting pump; pipe
scale, dirt, and slag may damage pump mechanical seal or plug impeller.

 Start pump, immediately after pump motor reaches full operating speed, slowly open discharge gate
valve until system flow is achieved.

 Check discharge piping for leaks.

 Open gauge cocks and record pressure readings for future reference.

 Check and record voltage, amperage per phase, and kilowatts if wattmeter is available

 Verify that pump is performing in accordance with parameters specified on performance curve.

L- LUBRICATION (MOTOR)
Speed HP-Motor OPERATING CONDITIONS

Standard Severe Extreme

1750 and 1/3 – 7.5 3 yrs 1 yr 6 months

Below 10 - 40 1 yr 6 months 3 months
50 - 150 1 yr 6 months 3 months
200 - plus 1 yr 6 months 3 months

Above
1750 All HP 6 months 3 months 3 months

Standard Conditions

Operation of 8 hours

Severe Conditions

Continuous 24 hours a day operation, shock loading or vibration, 100 – 150°F (38 - 66°C) ambient
temperature.

Extreme Conditions

Continuous operation 24 hours a day, heavy shock or vibration, dirt or dust in the air, extreme ambient
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temperature.

L- LUBRICATION (PUMP)

Most WILO pumps are supplied with life-lubricated bearings do not require additional lubrication. To
lubricate regreasable bearings, remove grease plug and add clean ball bearing grease as recommended
below.

Too much grease can cause premature bearing failure, do not over-grease.
MANUFACTURER LUBRICANT
SHELL DOLIUM R
EXXON POLYREX
TEXACO POLYSTAR

If pump is equipped with regreasable bearings follow these instructions:

To lubricate regreasable bearings, remove grease drain plug (if any) and filler plug. Add clean ball bearing
lubricant until grease appears at drain hole or along shaft. On units with drain hole, all old grease can be purged
out ahead of new. In such cases, the drain should be left unplugged for several minutes during pump operation
to allow excess grease to be forced out.

Do not lubricate with lithium-based grease, equipment damage will result.

M- PREPARATIONS FOR DISASSEMBLY

Turn off power, lock-out electrical breaker and provide appropriate “Do Not Operate” or equivalent signage
prior to any work on equipment. Verify all power is off at pump using appropriate electrical instrumentation.

Only qualified and trained personnel should perform work.

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N- PUMP EXPLODED VIEW - TYPE IL

Refer to catalogue number and serial number when ordering spare parts

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O- DISASSEMBLY OF PUMP - TYPE IL
 Isolate the pump;.

 Remove casing bolts 8B from backplate 2K, lift motor assembly

 Remove and discard gasket 11A, new gasket should be used at re-assembly

 Remove impeller cap screw (8A) and impeller washer 10A from end of motor shaft

 Remove impeller (3A) from the shaft (6A) using a gear puller to prevent damage

 Remove and discard spring and retainer from seal assembly, and pull assembly from shaft sleeve
A(5a) a twisting motion may be necessary to loosen bellows.

 Unscrew bolts (8D), remove back plate (2K) and seal housing (26P)

 Separate seal insert (26P) from inner face of back ring

 Remove and discard gasket 11F from backplate

 Place seal housing on a flat surface and press out seal seat and spring (14A)

 Unscrew bolts from upper plate and separate bracket from base of motor

 Remove impeller key (12A)

 To separate shaft sleeve from motor shaft, apply torch heat along sleeve exterior and remove while hot.

 Remove water slinger (13G) from motor shaft. Slinger is press fit and will need to be pried loose with a
twisting motion.

 To replace mechanical seal follow instructions below

 To replace casing wear ring follow instructions below

 If pump is mounted on a cast iron stand, remove by unscrewing 3 bolts secure base of pump to upper
rim of stand.

 To reassemble pump, use the reverse procedure used for disassembly

P- MECHANICAL SEAL REPLACEMENT

 New seal is shipped completely assembled; do not use any existing components

 Clean and lightly oil shaft sleeve (5A) at this time

 Press new seal seat squarely into insert (26P) light oil may be applied to seal’s rubber cup to ease
installation. Avoid direct contact of metallic abrasive object with seal face, wipe clean.

 Remove spring from new seal assembly and slide assembly manually onto sleeve by applying even
pressure at base of bellows.

 Contacting surface of bellows and new seal head is coated with a bonding agent that adheres to shaft
sleeve in minutes. Make sure sealing faces of head and seat fit snugly and bellows are properly
compressed (see figure 3). Once in place, seal head cannot be removed without impairing adhesive
properties of bellows.

 Place spring and retainer into position and re-assemble impeller washer and cap screw REVERSING
THE PROCEDURE OUTLINED ABOVE.

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 FIGURE 3

Q- WEAR RING REPLACEMENT

 To remove case wear ring (4A), drill two holes (slightly smaller than width of ring) into the edge of wear ring.
After holes are drilled, use a chisel to completely sever holes, break ring in two halves to remove.

 To reassemble, press fit the new wear ring squarely into volute. Make sure cavity is cleaned properly
before inserting new wear ring. Ring may be tapped into place.
Make sure that it is completely inserted into cavity.

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R- PUMP EXPLODED VIEW - TYPE IS

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S- PUMP DISASSEMBLY TYPE IS
 Turn off power to the motor

 Close all isolating valves and drain pump

a) SEAL REPLACEMENT
1- Remove coupling guard and unscrew tubing connector (4) from seal cap (30) and volute (3)

2- Remove coupling the four set screws (25) and jam nuts (26)

3- Pry open the two halves of the spacer coupling (24), also remove the two split rings (40) and set aside

4- Remove the 4 seal cap nuts (32) and slide the seal cap (30) and O’ring (18) along the pump shaft (12) and
remove them through the gap left by the spacer coupling removal

5- Remove and discard mechanical seal seat and head (28) from seal cap, then clean the inside of the seal cap
properly.

6- Clean and lightly oil the pump shaft (22) making sure no sharp edges or corners exist to damage the bellows
of the new seal.

7- Press new seal seat squarely into cap. Light oil may be applied to seal’s rubber cup to ease installation. Avoid
direct contact of metallic abrasive object with seal face, wipe clean after installation.

8- Place seal spring and retainer into position and slide new seal head onto shaft by applying even pressure. Do
not compress seal spring to its maximum but rather press seal assembly onto shaft (22) until the carbon
face is slightly below the small level of the shaft.

9- Slide seal cap (30) and O’ring (18) until studs (31) protrude through the four holes in the seal cap. Tighten the
four seal cap nuts (32) evenly going diagonally from one to the other.

10- Lightly grease the split rings (40) and fit them in the shaft grooves, slide coupling key (23) in the shaft keyways
.
11- Install keyed half of the spacer coupling (24) by lining up motor split ring and coupling key with the keyways in
the coupling half. Then with a screwdriver, gently pry upwards shaft (22) until lower split ring (14) slips into
coupling keyway.

12- Install other half of spacer coupling (24) and tighten socket screws (25) and jam nuts (26) diagonally until
evenly snug.

13- Reconnect tubing connector (4)

14- Reinstall coupling guard.

b) PUMP DIASSEMBLY – TYPE IS

 Follow steps 1 through 6 in the seal replacement procedure A)
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 Remove four motor screws (31) and nuts (32) then lift motor with chain block

 Unscrew six bracket screws (13) and remove bracket (12)

 Remove and discard gasket (11), new gasket should be used at re-assembly

 Using a chisel and a hammer, push out guide ring (20)

 Remove eight volute screws (10) and pull of backplate (9) and volute gasket (8)

 Remove and discard spring and retainer from seal assembly, and pull assembly
from shaft sleeve A(5a) a twisting motion may be necessary to loosen bellows.

 Unscrew bolts (8D), remove back plate (2K) and seal housing (26P)

 Separate seal insert (26P) from inner face of back ring

 Remove and discard gasket 11F from backplate

 Place seal housing on a flat surface and press out seal seat and spring (14A)

 Unscrew bolts from upper plate and separate bracket from base of motor

 Remove impeller key (12A)

 To separate shaft sleeve from motor shaft, apply torch heat along sleeve exterior
and remove while hot.

 Remove water slinger (13G) from motor shaft. Slinger is press fit and will need to be pried loose with a twisting
motion.

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P EXPLODED VIEW - TYPE IS

U- PUMP DISASSEMBLY - TYPE IX

 Turn off power to the motor
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U- PUMP DISASSEMBLY - TYPE IX
 Turn off power to the motor

 Close all isolating valves and drain pump

a) SEAL REPLACEMENT

1- Remove coupling guard and unscrew tubing connector (4) from seal cap (30) and volute (3)

2- Remove coupling the four set screws (25) and jam nuts (26)

3- Pry open the two halves of the spacer coupling (24), also remove the two split rings (40) and set aside

4- Remove the 4 seal cap nuts (32) and slide the seal cap (30) and O’ring (18) along the pump shaft (12) and
remove them through the gap left by the spacer coupling removal

5- Remove and discard mechanical seal seat and head (28) from seal cap, then clean the inside of the seal cap
properly.

6- Clean and lightly oil the pump shaft (22) making sure no sharp edges or corners exist to damage the bellows of
the new seal.

7- Press new seal seat squarely into cap. Light oil may be applied to seal’s rubber
cup to ease installation. Avoid direct contact of metallic abrasive object with seal face,
wipe clean after installation.

8- Place seal spring and retainer into position and slide new seal head onto shaft by applying even pressure. Do
not compress seal spring to its maximum but rather press seal assembly onto shaft (22) until the carbon face is
slightly below the small level of the shaft.

9- Slide seal cap (30) and O’ring (18) until studs (31) protrude through the four holes in the seal cap. Tighten the
four seal cap nuts (32) evenly going diagonally from one to the other.

10- Lightly grease the split rings (40) and fit them in the shaft grooves, slide coupling key (23) in the shaft keyways
.
11- Install keyed half of the spacer coupling (24) by lining up motor split ring and coupling key with the keyways in
the coupling half. Then with a screwdriver, gently pry upwards shaft (22) until lower split ring (14) slips into
coupling keyway.

12- Install other half of spacer coupling (24) and tighten socket screws (25) and jam nuts (26) diagonally until
evenly snug.

13- Reconnect tubing connector (4)

14- Reinstall coupling guard.

b) PUMP DIASSEMBLY – TYPE IX

 Follow steps 1 through 6 in the seal replacement procedure A)

 Remove four motor screws (31) and nuts (32) then lift motor with chain block

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  Unscrew six bracket screws (13) and remove bracket (12)

 Remove and discard gasket (11), new gasket should be used at re-assembly

 Using a chisel and a hammer, push out guide ring (20)

 Remove eight volute screws (10) and pull of backplate (9) and volute gasket (8)

 Remove and discard spring and retainer from seal assembly, and pull assembly
from shaft sleeve A(5a) a twisting motion may be necessary to loosen bellows.

 Unscrew bolts (8D), remove back plate (2K) and seal housing (26P)

 Separate seal insert (26P) from inner face of back ring

 Remove and discard gasket 11F from backplate

 Place seal housing on a flat surface and press out seal seat and spring (14A)

 Unscrew bolts from upper plate and separate bracket from base of motor

 Remove impeller key (12A)

 To separate shaft sleeve from motor shaft, apply torch heat along sleeve exterior
and remove while hot.

 Remove water slinger (13G) from motor shaft. Slinger is press fit and will need to be pried
loose with a twisting motion.

V- PUMP TROUBLE SHOOTING LIST

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 SYMPTOMS
1 - Pump does not deliver any liquid
2 - Pump stops delivering liquid after start up
3 - Pump does not deliver enough liquid
4- Pump does not produce enough pressure
5- Pump uses too much power
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POSSIBLE CAUSE
- Pump does not deliver any liquid
- Pump not properly bled of air
- Pump suction line not completely primed
- suction lift too high
- Fluid pumped contains too much entrained air
- Suction valve is closed or only partially open
- Suction strainer (if any) is clogged with debris
- Foot valve (if any) is clogged or undersized
- Pump driver speed is too low
- Pump rotation is wrong
-Total head is higher than rated pump head
- Impeller may be clogged with debris
- Impeller may be damaged
- Pump suction line not completely primed
- Fluid pumped contains too much entrained air
- Suction valve is closed or only partially open
- Suction strainer (if any) is clogged with debris
- Foot valve (if any) is clogged or undersized
- Impeller may be clogged with debris
- Impeller may be damaged
- Air or gases in liquid
- Pump driver speed is too low
- Total head is higher than rated pump head
- Suction lift is too high
- Impeller may be partially clogged with debris
- Impeller may be damaged
- Foot valve (if any) is clogged or undersized
- Pump wear ring excessively worn
- Pump driver speed is too low
- Air or gases in liquid
- Pump wear ring excessively worn
- Impeller may be damaged
- Impeller diameter is too small check design.
- Discharge head less than pump rating
- Liquid too heavy (viscosity, specific gravity)
- Wrong rotation
- Misalignment