When equipment fails, its owner, who for one reason or another does not have time to deliver the broken unit to service center, independently determines the cause of the breakdown, calls a lone mechanic he knows, reports the malfunction and asks him to come to repair or replace the part. Perhaps such repairs can restore the functionality of the equipment, but for how long? It is likely that after some time the unit will fail again, and this time due to another breakdown. What's the matter? In the absence of comprehensive diagnostics, which allows not only to determine the specific cause of the malfunction, but also to assess the general condition of the equipment. And if the owner does not realize the importance of diagnostics in time, then he will continue to waste money, scolding equipment manufacturers for poor quality of its manufacture and feeling sorry for himself.
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Reading time: 6 minutes.
Forced movement of water in water supply and heating systems is provided using pumps. Reliable and effective work pump, when heating premises, supplying cold and hot water will provide all household needs, and in some cases, industrial needs.
Normal operation of the Wilo pump is possible only if the operating rules are followed, timely maintenance (preventive maintenance), high-quality diagnostics and repairs.
Operational Requirements
To avoid premature repairs Wilo pumps, the following should be adhered to:
- exclude work for idling(in the absence of water in the system);
- do not block the water flow when the pump is on;
- set the operating mode in accordance with the minimum and maximum capabilities of the equipment;
- follow the manufacturer's recommendations for permissible pressure in system;
- do not allow the coolant approaching the pump to heat up above 65 °C;
- avoid long periods of downtime;
- use filters to purify water circulating in the system.
If these rules are followed, the turned on pump will produce a uniform sound and maintain a stable pressure, which is evidence of its normal operation. Most pumps operate without repair for 5 years or more, until the main elements are completely worn out, provided that all operating rules have been followed.
Prevention
In order to avoid the need for repairs to the Vilo pump, it is necessary to carry out periodic preventive work. You can carry out simple maintenance of the device yourself, without resorting to the services of specialists. To do this, inspect the pump at least 4 times a year and, if necessary, clean it. As practice shows, cleaning is necessary after 2-3 years of operation, depending on the quality of the coolant and the general conditions under which heating and water supply systems operate.
When inspecting the equipment, be sure to pay attention to the following points:
- no leaks at connections;
- grounding performance;
- absence of extraneous sounds during operation of the device (clanging, knocking);
- no vibration;
- pressure in the system in accordance with technical standards;
- dry and clean device body.
Wilo pumps, in most models, are reliable and do not require regular repairs. But prevention, provided that guarantee period expired, you can do it yourself.
For this you will need:
- spanner;
- Phillips screwdriver;
- flat screwdriver;
- cleaning brush.
Before dismantling the pump, water is drained from the system or the area is closed to dry disconnect the device. After which the pump is removed, and the following steps are performed:
Having completed these steps, the main disassembly is completed and the internal surfaces of the shell, impeller and rotor are cleaned of scale or dirt deposits.
Surfaces are cleaned using a stiff polymer brush with a small amount of cleaning agent containing hydrochloric acid.
In case of severe (sticky) contamination, it is permissible to use zero grade sandpaper.
The main malfunctions of Wilo pumps are wear of the support bearings. If such a factor is identified, it is difficult to replace them with your own hands, so it is better to contact a service center.
Before reassembly, all gaskets and seals are checked for cracks or tears. But since the pump has already been disassembled, it is advisable to replace them with new ones.
Basic problems and methods for resolving them
In cases where vibration appears during operation of the device, extraneous noise occurs, or the pressure in the system changes, you should determine the cause and, if possible, troubleshoot the problem yourself.
When turned on, the pump hums, but the shaft does not rotate:
- The shaft jammed due to prolonged downtime. Remove the protective cap on the motor housing and rotate the shaft using a flat-head screwdriver;
- if foreign objects get in, disassemble the pump and clean the impeller, after which replacing the cleaning filter, which is installed in front of the device;
- problems with power supply (insufficient voltage in the network).
When turned on, the device does not work:
- there is no voltage in the network. Electrical wiring and protective automation are checked;
- The fuse has blown. Replaced with a new one.
Automatic shutdown of the device after a short period of operation:
- accumulation limescale in the stator cup. The glass and rotor of the electric motor are cleaned.
The pump makes a lot of noise when running:
- dry operation with air in the system. Release the air and make sure the pump shell is filled with liquid;
- cavitation. The pressure in the fluid supply line must be increased.
Excessive pump vibration:
- critical condition of support bearings due to severe wear. The bearings should be replaced.
Reduced head and flow compared to manufacturer's specifications:
- power supply failure or phase change, which leads to a drop in power or reverse rotation of the impeller. Phase check ( three phase motors) and replacement of the capacitor (with single-phase power supply);
- the pipeline has great resistance to fluid movement (hydraulic resistance). Clean (replace) the filters, check the shut-off valves, and increase the diameter of the pipes if necessary.
Automatic pump shutdown external system protection:
- malfunction of the electrical components of the device. Check connection terminals (oxidation, short circuit), capacitor (replacement), control unit.
Repair
It is better to have your faulty pump repaired at a service center if the warranty period has not yet expired. Some models are non-separable or partially disassembled, which means renovation work in the form of replacing entire units or the entire device.
In the absence of a warranty and the possibility of disassembling the pump, minor repairs are carried out independently.
Based on the above symptoms, the causes of malfunctions are eliminated and repairs are carried out if the design of the pump allows for its disassembly.
Operating elements of the control unit that can cause pump failure and must be replaced:
- capacitor;
- connection block (terminals);
- speed controller.
Since the capacitor has a small capacitance, its performance can be checked using the C-meter, which is built into the multimeter. If a discrepancy with the nominal values is detected, this part should be replaced with a new one. It is important not to confuse the polarity of the connection and check the voltage matches. In normal single-phase electric motor capacitors are installed that are approved for connection to a network up to 450 V.
If the speed controller breaks down, it is replaced with a new one, observing correct connection terminals
The terminals should always be clean, dry, without signs of overheating or carbon deposits. If the above problems are identified, they should be replaced with new ones, similar ones or the same ones if possible.
During post-warranty operation, problems with the support bearings are possible. It is better to replace them in a specialized workshop.
To prevent scale formation on the impeller and silting of the stator cup, high-quality filters should be installed and the prepared liquid should be used in closed heating systems. If these conditions are met, the pump pumping liquid will operate in ideal conditions and will not cause problems with repairs for a long time.
Disassembly for repair of WILO circulation pumps with a “wet” rotor (video)
The heart of any heating system is the circulation pump, which is responsible for the forced movement of water in the system. To minimize energy costs and at the same time create comfortable temperature conditions in a living room, buy Wilo pumps.
Ensuring they are effective and reliable operation, service life extension occurs by observing operating rules, timely maintenance. If the owner ignores these requirements, equipment malfunctions will inevitably occur. Their elimination when the warranty period has expired is often done by hand.
1 Design and technical features
Vilo pumps significantly increase the efficiency of the heating system and the heat transfer of the coolant. Their use makes it possible to use pipes with a smaller cross-section when assembling the pipeline, which will reduce fuel consumption and reduce emissions. carbon dioxide, will allow you to achieve savings without loss of quality of operation. This is achieved through a properly thought out and designed design designed for continuous operation.
The Wilo pump consumes no more than 250 W per day, operation is silent, since there is no fan or similar technical elements that produce noise. There are two types of circulation equipment on sale - with a dry and wet rotor. The latter are used when installing heating systems, usually inside small buildings. The difference also lies in the power and volume of the pumped medium. The weakest model can do heating system more efficient on an area of 200 sq.m.
The powerful one is designed for heating buildings with an area of up to 1000 sq.m. Both units have the most simplified design and small dimensions. Specifications, relating to the pressure height, make it possible to lift water from 8 meters at a flow rate of 5 m3/h.
Distinctive features are the strength and corrosion resistance of the Wilo pump material. For example, the body is cast from cast iron, the shaft located inside it - of stainless steel. Its fastening is possible thanks to graphite bearings. The water supply speed is equipped with three-stage adjustment.
The permissible coolant temperature in household products should not exceed +110° C; for industrial products the temperature limit is increased. As for the operating pressure, units used in everyday life can withstand 10 Bar, and industrial ones - 16.
The operation of the system is controlled automatically. Some models of circulators have a thermostat. The functions of the mechanism are displayed on the liquid crystal display. You can also control the shaft rotation speed by manual switching. Connecting the device is simple and quick, which is facilitated by the presence of springy terminals. Voltage surges are not a problem for the pump, since the motor and rotor have a multi-stage protection system.
1.1 Operating requirements and prevention
To avoid premature repair of Wilo pumps, the manufacturer urges you to adhere to the following:
If these rules are observed, the pump will be characterized by maintaining a stable pressure, and the sound produced during operation will be uniform and quiet. Most pumps do not require repairs for 5 years from the moment they are put into operation. It is required only when the main components are completely worn out or force majeure circumstances cause the device to fail.
Prevention is another type of periodic measures, the implementation of which insures the pump and its elements from premature breakdowns. At the same time simple Maintenance carried out independently, without the intervention of a specialist. To do this, you should carry out at least 3-4 times annually visual inspection external and internal parts of the unit and clean it if necessary.
Practice shows that cleaning becomes mandatory after 2-3 years of operation. The quality of the coolant affects the cleaning procedures, General terms conditions under which the heating system operates.
For prevention, you need to prepare a Phillips and flathead screwdriver, a spanner wrench, and a cleaning brush. Inspection requires disassembly, during which you will find the main components of the hydraulic structure: housing, impeller, motor shaft, rotor, terminal box, air propeller and the engine itself. Pay attention to the following nuances:
- grounding performance;
- absence of leaks at joints;
- pressure value in accordance with technical standards;
- absence of vibration and extraneous sounds (knocking, clanging);
- condition of the case. It must be clean and dry;
- the pump should not get very hot;
- the amount of lubricant on bearings, flanges and moving parts must be sufficient;
Also make sure that the terminal box cables are free of moisture, that they are securely fastened, that the gaskets provide a seal, and that the connections to the main line are strong. Before dismantling the device, water is drained from the system, the area where it enters is blocked, after which the pump is removed.
The 6 bolts connecting the shell of the pump part and the motor housing are unscrewed with a spanner. When the shell is removed, you will have access to drainage holes. The impeller remains on the engine rotor. Using a narrow screwdriver flat type the shirt serving for the impeller and engine compartment is pulled off. The actions taken will remove the rotor shaft and impeller from the stator cup.
At this stage, the inner surface of the shell, rotor and impeller are cleaned of dirt deposits or scale. A stiff polymer brush and a small amount of cleaning agent will help with this. hydrochloric acid. It would be a good idea to check all seals and gaskets for cracks; if found, replace them with new ones.
Pump repairs are carried out only after disconnecting the power cable and draining the area. It should be said that wet rotor pumps are equipped with modules depending on required power and size. Restoring the functionality of these devices is easier - the faulty module is replaced with a new one.
If the warranty period has expired and the repair is minor, you can do it yourself; in case of a more serious malfunction, take your pump to a service center. Most often, repair work comes down to replacing entire components or the entire pump. The following working parts are subject to replacement: connection block, capacitor, speed controller, bearings.
2.1 Disassembling Wilo circulation pumps for repair (video)
2.2 The shaft does not rotate when the pump is on and there are characteristic sounds
The reasons are: oxidation of the shaft after long downtime or a foreign object entering Working wheel. In the first case, you need to repair the pump following these steps: drain the water, unscrew the screws that hold the electric motor and housing together. Remove the electric motor with rotor and impeller. Turn the last knot by hand. Low-power products require a screwdriver to unlock the shaft. There is a special notch for it at the end of the shaft.
In the second case, it is enough to dismantle the electric motor and remove the foreign object. To eliminate this situation in the future, install strainer in front of the pump. Problems with the power supply may also be a reason for shaft failure. Check the voltage in the network for compliance with the circulator's passport data, pay attention to the presence of phases and the correct connection in the terminal box.
2.3 When the temperature in the system rises above 40° C, a creaking sound appears
The reason is that the electric motor pulley hits the drain plug. The noise is eliminated by wearing an additional plastic gasket onto the plug; if necessary, the thread of the plug is ground. If the creaking appears again, it is advisable to saw off part of the pulley (with markings for a screwdriver) using a grinder. Approximately 3 mm should be cut off, and it is precisely the area that does not move along the bushing.
2.4 The unit stalls after a short period of operation
The “root of evil” lies in the scale formed in the submersible part of the rotor. To eliminate it, disassemble the electric drive, then clean the limestone deposits between the rotor and stator with a brush. To prevent scale from forming on the impeller and flooding the stator cup, install a filter.
2.5 The pump vibrates and is accompanied by noise
The reason lies in the wear of the bearings that ensure rotation of the impeller. Worn parts must be replaced. Since the bearings are pressed using a puller into seat, you will need wooden hammer. Using precise but gentle blows, drive the new bearings into the seat. The reason for vibration and loud noise can be low pressure in the system. Elimination involves increasing it at the inlet; do not forget that the liquid level in the coolant also needs to be increased.
2.6 The system has low water pressure
This problem occurs when the phases in three-phase pumps are incorrectly connected or the percentage of liquid viscosity is increased. For the first reason, it is enough to connect the equipment according to the instructions. In the second case, the repair is reduced to cleaning the filter of the nozzle, checking the good condition of the pipeline connected to the pump and adjusting the installation parameters in accordance with the equipment specifications.