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Related Manuals for Wilo EMU FA+HC20.1 Series
Summary of Contents for Wilo EMU FA+HC20.1 Series
- Page 1 Wilo-EMU FA... + HC20.1... Installation and operating instructions Order no.: template serial no. TMPHC20X...
- Page 2 WILO EMU GmbH Heimgartenstr. 1 95030 Hof 3309 95003 Hof Telefon: +49 9281 974-0 Telefax: +49 9281 96528 Email: info@wiloemu.de Internet: www.wiloemu.com E:\shares\Baprod\BA\subtec_m\sewage\us\title-wilo.fm WILO EMU 3.0...
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Page 3: Table Of Contents
Table of Contents Introduction Preface Structure of the manual Personnel qualification Illustrations Copyright Abbreviations and technical terms Manufacturer's address Rights of alteration Safety Instructions and safety information Guidelines used and CE certification General safety Electrical work Electrical connection Ground connection Operating procedure Safety and control devices Operation in an explosive atmosphere... - Page 4 Fault: The machine does not run smoothly and is noisy Fault: Mechanical shaft seal leaks, sealing chamber monitor reports fault and switches the machine off Further steps for troubleshooting List of machine operators and maintenance List of machine operators WILO EMU 3.0...
- Page 5 Maintenance and inspection log Assembly Sheet For the Anchor Bolts General product information Scope of proper use Transport and storage Setting the anchor bolts Operation with a static frequency converter Selecting the motor and converter Minimum speed for submersible pumps (well pumps) Minimum speed for waste water and sewage pumps Operation...
- Page 6 R2 and DN36… to DN250… suspension unit installation DN300 … to DN600… suspension unit installation Startup E-10 Data Sheet - Electrical Connection Safety notes Insulation resistance Monitoring equipment Wire designation of the connection lead EC declaration of conformity WILO EMU 3.0...
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Page 7: Illustrations
Introduction Introduction Preface Dear Customer, Thank you for choosing one of our company’s products. You have purchased a product which has been manufactured to the latest technical standards. Read this operating and maintenance manual carefully before you first use it. This is the only way to ensure that the product is safely and eco- nomically used. - Page 8 At the rated load, a constant temperature is reached that does not increase ing mode (con- even in prolonged operation. The operating equipment can operate uninter- tinuous ruptedly at the rated load without exceeding the maximum permissible tem- operation) perature. Table 1-2: Terms WILO EMU 3.0...
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Page 9: Manufacturer's Address
The level control is designed to switch the product on or off depending on Level control the filling level. This is made possible by installing a float switch. Table 1-2: Terms Manufacturer's address WILO EMU GmbH Heimgartenstr. 1 DE - 95030 Hof Tel.: +49 9281 974-0... -
Page 11: Safety
Safety Safety This chapter lists all the generally applicable safety instructions and technical information. Further- more, every other chapter contains specific safety instructions and technical information. All instructions and information must be observed and followed during the various phases of the prod- uct's lifecycle (installation, operation, maintenance, transport etc.). -
Page 12: Guidelines Used And Ce Certification
The technical specifications must be strictly adhered to. If the machine has been switched off by a protective device, it must not be switched on again until the error has been corrected. WILO EMU 3.0... -
Page 13: Electrical Connection
Safety Beware of electrical current Incorrectly performed electrical work can result in fatal injury! This work may only be carried out by a qualified electrician. Beware of damp Moisture penetrating cables can damage them and render them useless. Never immerse cable ends in the pumped fluid or other liquids. -
Page 14: Operation In An Explosive Atmosphere
- With products which have been operated with a lubricant or cooling fluid (such as oil), this can escape into the pumped fluid if the mechanical shaft seal is defective. Danger - explosive fluids It is absolutely prohibited to pump explosive liquids (e.g. gasoline, kerosene, etc.). The products are not designed for these liquids! WILO EMU 3.0... -
Page 15: Warranty
Safety Warranty This chapter contains the general information on the warranty. Contractual agreements have the highest priority and are not superseded by the information in this chapter! The manufacturer is obliged to correct any defects found in the products it sells, provided that the following requirements have been fulfilled: General information - The defects are caused by the materials used or the way the product was manufactured or... -
Page 17: Product Description
Product description Product description The machine is manufactured with great care and is subject to constant quality controls. Trouble- free operation is guaranteed if it is installed and maintained correctly. Proper use and fields of Submersible motor pumps are used in pumping stations and sewage treatment plants and many other installations to dispose of communal and industrial waste water. - Page 18 Details of the safety and monitoring devices used and how to connect these can be found in the “Electrical connection plan” data sheet. WILO EMU 3.0...
- Page 19 Product description Machine structure Handle Motor housing (surrounded by cooling jacket) Power supply line Name plate Discharge port Bearing casing Pump housing Fig. 3-2: Machine structure E:\shares\Baprod\BA\subtec_m\sewage\us\hc\product.fm...
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Page 20: Type Designation
Table 3-1: Type designation Cooling The motor is cooled by the internal cooling circuit in the cooling jacket. This is hermetically sealed and filled with the manufacturer's filling P35. The circulation is carried out by an impeller which is WILO EMU 3.0... -
Page 21: Name Plate
Impeller diameter/number of levels Table 3-2: Name plate key Technical data Unit Year of manufacture: 2008 Order no.:: template Machine number: TMPHC20X Product description: Wilo-EMU Pump type: FA... Version: Model: Impeller diameter: - / corrected: - Downstream device: Motor type: HC20.1... Version:... - Page 22 1.00 Operating mode: Wet installation: Dry installation: Explosion coding: Explosion number: Tabelle 3-5: Filling quantity/lubricant Motor chamber: Sealing room: Esso Marcol 82 (White oil) Cooling system: Esso Marcol 82 (White oil) Table 3-6: Coatings Pump: Tabelle 3-7: WILO EMU 3.0...
- Page 23 Product description Rotor: Tabelle 3-7: Power supply connection Connector: Relay: Power cable length: 10.00 m Power cable 1 Number: Type: Size: Power cable 2 Number: Type: Size: Power cable 3 Number: Type: Size: Trip line Number: Type: Size: Sealing chamber monitor Number: Type: Size:...
- Page 24 Max. pump fluid tempera- 40 °C ture: Dimensions: see dimension sheet/catalogue Weight: see dimension sheet/catalogue Sound pressure: system-dependent Tabelle 3-9: *Valid for standard conditions (pumped fluid: pure water. Density: 1kg/dm Viscosity: 1*10 m²/s, temperature: 20°C, pressure: 1.013bar) WILO EMU 3.0...
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Page 25: Transport And Storage
Transport and storage Transport and storage Delivery On arrival, the delivered items must be inspected for damage and a check made that all parts are present. If any parts are damaged or missing, the transport company or the manufacturer must be informed on the day of delivery. -
Page 26: Returning To The Supplier
The packaging must protect the product against damage. If you should have any questions please contact the manufacturer. WILO EMU 3.0... -
Page 27: Installation
Installation Installation In order to prevent damage to the machine or serious injury during installation the following points must be observed: - Installation work – assembly and installation of the machine – may only be carried out by qualified persons. The safety instructions must be followed at all times. - The machine must be inspected for transport damage before any installation work is carried out . - Page 28 Installation work for the machine and its accessories is performed directly on the edge of the basin. Carelessness or wearing inap- propriate clothing could result in a fall. There is a risk of fatal injury! Take all necessary safety precautions to prevent this. WILO EMU 3.0...
- Page 29 Installation Wet installation with a A suspension unit must be installed for wet installation. This must be ordered separately from the manufacturer. The pipeline system on the discharge side is connected to this. The connected pipe- suspension unit line must be self-supporting, i.e. it should not be supported by the suspension unit. The operating area must be laid out so that the suspension unit can be installed and operated without difficulty.
- Page 30 The housing parts can heat up to well above 40°C. There is a danger of burns. After switching it off, let the machine cool down to ambient temperature. Machine room Collector tank Slider Discharge side pipeline Machine Minimum level Intake side pipeline Fig. 5-2: Dry installation example WILO EMU 3.0...
- Page 31 Installation Portable installation The machine is fitted with a pump pedestal for this type of installation. It is fitted to the intake port and ensures that the machine is in a secure position on a firm base. This installation type makes optional positioning in the operating area possible.
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Page 32: Dry-Run Protection
Make sure the power supply cable does not become damaged. Beware of poisonous substances! Machines which pump fluids hazardous to health present a fatal risk. These machines must be decontaminated before any other work is carried out. Wear the necessary protective clothing/ equipment when doing so. WILO EMU 3.0... -
Page 33: Startup
Startup Startup The "Startup" chapter contains all the important instructions for the operating personnel for start- ing up and operating the machine safely. The following specifications must be adhered to and checked: - Type of installation - Operating mode - Minimum water coverage / max. submersion If the machine has not been operated for some time, check these speci- fications again and rectify any faults you find. -
Page 34: Direction Of Rotation
The machine can be operated on frequency transformers. transformers Observe the data sheet in the appendix of this manual. Activation types with plugs / relays Units with plugs Connect the plug to the socket provided and press the On/Off switch on the relay. WILO EMU 3.0... -
Page 35: After Starting
Startup Please observe the relay manual. Units with relays After starting The rated current is briefly exceeded during the start-up procedure. Once this process has ended, the operating current should no longer exceed the rated current. If the motor does not start immediately after the machine is switched on, it must be switched off immediately. -
Page 37: Maintenance
Maintenance Maintenance The machine and the entire system must be inspected and maintained at regular intervals. The time limit for maintenance is set by the manufacturer and applies to the general conditions of use. The manufacturer should be consulted if the system is to be used with corrosive and/or abrasive pumped liquids, as the time limit between inspections may need to be reduced. -
Page 38: Lubricants
P35 is in water pollution category 1 according to VwVwS 1999. When disposing of the fluid, observe DIN 52 900 (concerning propane diole and propylene glycol). Other concentrates may not be used as this can lead to faulty operation or destruction of the motor. WILO EMU 3.0... -
Page 39: Maintenance Intervals
Maintenance Glycol Overview Technical data: Production Status Product used Possible alternatives stopped Product name Thermofrost Zitrec Pekasol L Propylene glycol LEU Energie Prokühlsol Company Fauth & Co. KG GmbH & Co. KG GmbH Monopropylene Propane-1,2- Propane-1,2- Basis Propane-1,2-diol glycol diol diol Color None... -
Page 40: Maintenance Tasks
Monitoring devices are temperature sensors in the motor, sealing room monitors, motor protection relays, overvoltage relays, etc. ty and control devices Motor protection and overvoltage relays and other trip elements can generally be triggered manu- ally for test purposes. WILO EMU 3.0... -
Page 41: Changing The Lubricant
Maintenance To inspect the sealing room monitor or the temperature sensor, the machine must be cooled to ambient temperature and the electrical supply cable of the monitoring device in the switch cabinet must be disconnected. The monitoring device is then tested with an ohmmeter. The following val- ues should be measured: Bi-metal sensor: Value = “0”... - Page 42 3 Fill lubricant by means of the opening in the filling plug (D+). Comply with the specified lubricants and filling quantities. 4 Clean the filling plug (D+), fit with a new sealing ring and screw it in again. Fig. 7-1: Position of the screw plugs WILO EMU 3.0...
- Page 43 Maintenance 1 Slowly remove the screw plug (L) from the leak chamber and drain the collected fluid. Emptying the leak chamber 2 Clean the screw plug (L), fit with a new sealing ring and screw it in again. The coolant should only be changed when the motor is cold. If the motor is still warm or hot, an Changing the coolant incorrect filling level is displayed, as the coolant expands under heat.
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Page 44: Repairs
(see table). 8 Place the pump unit on the sealing housing and fasten it with hexagon nuts (1). 9 It must be possible to turn the impeller by hand. WILO EMU 3.0... - Page 45 Maintenance Bearing casting (5) Hex nut (1) Impeller (4) Cylinder screw (3) Pump housing (2) Fig. 7-3: Changing the impeller - version 1 E:\shares\Baprod\BA\subtec_m\sewage\us\hc\maintenance.fm...
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Page 46: Torque Values
Table 7-3: Dacromet-coated screws with Nord-Lock screw fixing Overview of the correct torques for rustproof screws without screw fixing: Thread kp m Thread kp m 0.56 135.0 13.76 Table 7-4: Rustproof screws without Nord-Lock screw fixing 7-10 WILO EMU 3.0... - Page 47 Maintenance Thread kp m Thread kp m 0.76 230.0 23.45 18.5 1.89 285.0 29.05 37.0 3.77 415.0 42.30 57.0 5.81 565.0 57.59 Table 7-4: Rustproof screws without Nord-Lock screw fixing E:\shares\Baprod\BA\subtec_m\sewage\us\hc\maintenance.fm 7-11...
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Page 49: Shutdown
Shutdown Shutdown This chapter provides an overview of the various ways to shut down the machine. For this type of shutdown, the machine remains installed and is not cut off from the electricity sup- Temporary shutdown ply. For temporary shutdown, the machine must remain completely submerged so that it is pro- tected from frost and ice. - Page 50 Once this work has been completed, the machine can be installed (see “Installation”) and connected to the electricity supply by a specialist. See “Startup” a for instructions on restarting. Only restart the machine if it is in perfect condition and ready for opera- tion. WILO EMU 3.0...
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Page 51: Troubleshooting
Troubleshooting Troubleshooting In order to prevent damage or serious injury while rectifying machine faults, the following points must be observed: - Only attempt to rectify a fault if you have qualified staff. This means each job must be carried out by trained specialist staff, for example electrical work must be performed by a trained electrician. -
Page 52: Fault: Machine Runs But Does Not Pump
Replace defective parts Inadmissible levels of gas in the pumped liquid Contact the factory Have a specialist inspect the connection and Two-phase operation correct it as necessary Table 9-4: The machine runs, but not at the stated operating levels WILO EMU 3.0... -
Page 53: Fault: The Machine Does Not Run Smoothly And Is Noisy
Troubleshooting Cause Remedy Check the supply and capacity of the system, Excessive decrease in the water table during and inspect the level control settings and operation function Table 9-4: The machine runs, but not at the stated operating levels Fault: The machine does not run smoothly and is Cause Remedy... -
Page 54: Further Steps For Troubleshooting
Further steps for trouble- If the items listed here do not help you rectify the fault, contact our customer service. They can help you as follows: shooting - Telephone or written help from customer service - On-site support from customer service - Checking and repairing the machine at the factory Note that you may be charged for some services provided by our customer support. -
Page 55: A List Of Machine Operators And Maintenance
List of machine operators and maintenance List of machine operators and mainte- nance All persons working on or with the product confirms with their signatures that they have received, List of machine operators read and understood this operating and maintenance manual. In addition, they obligate themselves to conscientiously follow the instructions provided. - Page 56 This list is to be shown on request to representatives of controlling organizations, government inspection teams and the manufacturer! Maintenance / Signature of the Date Signature Revision on person in charge Table A-2: Maintenance and inspection log WILO EMU 3.0...
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Page 57: Assembly Sheet For The Anchor Bolts
Once fitted, the anchor cannot be removed! Scope of proper use The anchor bolts supplied by WILO EMU GmbH may only be used for WILO auxiliary hoisting gear and accessories. These anchor bolts may only be used in normal reinforced or non-reinforced concrete in a strength class of min. - Page 58 (internal thread M16) Table B-2: Dimensions and tightening torque values 1 Drill the holes as shown in table 1 and the following drawing. Note: The quality of the fastening depends on how well the anchor bolts are correctly seated! WILO EMU 3.0...
- Page 59 Assembly Sheet For the Anchor Bolts 2 Carefully and thoroughly clean the holes using a brush and bellows. 3 Insert the grout cartridge carefully into the hole. Any air bubbles must face outwards. If the drilled hole is too deep or broken at the edges, you may need to use more than one grout cartridge.
- Page 60 Then bolt the part to the base and tighten it to the specified torque (see Table 1). To secure the nut, coat it with Loctite 2701 locking glue and re-tighten WILO EMU 3.0...
- Page 61 Assembly Sheet For the Anchor Bolts it to the specified torque at least three times in order to compensate for any movement due to setting. inst inst E:\shares\Baprod\BA\subtec_m\appendix\us\general\anchor_bolts.fm...
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Page 63: Operation With A Static Frequency Converter
However, the following points must be observed when operating the converter: Selecting the motor and Any standard WILO motor can be used. If the rated voltage is above 415 V, you must consult the manufacturer. Because of the additional heating caused by harmonics, the rated power of the converter motor should be around 10% more than the power requirement of the pump. -
Page 64: Emc
Operation up to 60 Hz A WILO submersible motor can be adjusted up to 60 Hz provided the motor has been rated for the pump’s higher power requirement. However, the rated power should be taken from the 50 Hz data sheets. -
Page 65: D Ceram C0 Data Sheet
Ceram C0 data sheet General information WILO products are used for many different pumped liquids and installation sites. We want our coat- ings to offer an even higher degree of protection against wear and corrosion. For this purpose, we mainly use our Ceram coatings. However, only an intact coating provides the best possible protec- tion. -
Page 66: Resistance
+20°C Toluene +20°C Water (cooling/industrial water) +50°C Xylene +20°C Table D-2: Resistance Total layer thickness: at least 400µm Key: 1 = resistant; 2 = resistant for 40 days; 3 = resistant against overflow, immediate cleaning rec- ommended WILO EMU 3.0... -
Page 67: Surface Preparation
Ceram C0 data sheet Surface preparation In order to achieve the best results with this product, proper preparation of the surface is of critical importance. The exact requirements change depending on the application, expected period of ser- vice and original surface condition. Make sure it is clean, dry and free of grease. -
Page 68: Material Needed
- Vessel for mixing the two components Working steps 1 Lift the WILO machine from the basin, place it on a secure surface and clean it. 2 Thoroughly clean the damaged area with suitable cleaning agent. 3 Roughen the surface around the damaged area. -
Page 69: E Assembling The Suspension Unit
Assembling the suspension unit Assembling the suspension unit Product description The suspension units consist of a coupling base with a coupling flange, guide and mounting ele- ments. The coupling base and the guide and mounting elements are assembled together to form the suspension unit. - Page 70 We differentiate between “with elbow" and “without elbow". Without elbow means that the cou- pling base has a horizontal connection to the pipeline system. With elbow means that a 90°-arch is integrated into the coupling base and a vertical connection to the pipeline system is available. WILO EMU 3.0...
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Page 71: Assembling The Various Suspension Units
Assembling the suspension unit Fig. E-1: Model “with elbow" and “without elbow" Assembling the various Completely trouble-free operation can only be guaranteed if the unit is precisely installed. suspension units When installing the suspension units, remember that the guide elements must be entirely perpendicular and may not be twisted. - Page 72 Guide holder (1) Hexagon nut (12) Hexagon nut (9) Hammer head bolt (11) Holding rail (7) Hexagon socket bolt (8) Pipe extension (10) Fig. E-3: Installation of the guide holder for pipe mounting, Illustration of the pipe extension WILO EMU 3.0...
- Page 73 Assembling the suspension unit Fixing the guide elements - The guide element (13) is fixed by the rubber piece (14) to the appropriate holder for the guide element. - The rubber piece (14) on the guide holder (1) is compressed when the hexagon head bolt (15) is turned.
- Page 74 - Unscrew the top guide holder (1) and insert in the top guide element (13b). - Secure the guide holder (1) to the discharge port or the background structure and screw tight. - Fix the top guide element (13b) to the guide holder (1) by turning the hexagon head bolt (15). WILO EMU 3.0...
- Page 75 Assembling the suspension unit Guide holder (1) Hexagonal bolt (15) Guide element (13) Pipe extension (10) Guide element (13b) Guide element (13a) Discharge pipe (20) Guide element (13) Coupling base (18) Fig. E-5: Installing the suspension unit E:\shares\Baprod\BA\subtec_m\appendix\us\sewage\suspension_unit.fm...
- Page 76 - Screw on the cover cap (8) on the top part of the stud (7 short). To prevent contact corrosion, PVC washers can be inserted between the guide element and the guide holder on these suspension devices. WILO EMU 3.0...
- Page 77 Assembling the suspension unit Cover cap (8) Stud (7 short) Guide holder (1) / shaft mounting Guide element (4) Securing set 1 Clamp (2) Stud (10 long) Securing set 2 Guide holder (1) / pipe extension (9) Coupling flange (A) Flat seal Gasket (B) Stud (6)
- Page 78 If air is present in the pipeline system, this must be removed immediately using the bleeding system. Please observe the chapter entitled “Start-up” in this operating and maintenance manual. Fig. E-7: Coupling flange assembly E-10 WILO EMU 3.0...
- Page 79 Data Sheet - Electrical Connection Data Sheet - Electrical Connection Safety notes The motor must be connected only by an authorized electrician: The relevant local regulations must be observed when laying the cables and connecting the motor. The installation of motor protection equipment is mandatory.
- Page 80 20 bimetallic thermistor (break contact) 250V 2A cos j = 1 21 bimetallic thermistor beginning 22 bimetallic thermistor high temperature (break contact) 23 bimetallic thermistor low temperature (break contact) 24 temperature control Pt 100 beginning as per DIN 43760 B WILO EMU 3.0...
- Page 81 Data Sheet - Electrical Connection 25 temperature control Pt 100 end as per DIN 43760 B 26 leakage float (break contact) 250V 3A cos j = 1 27 motor overpressure switch (break contact) 250V 4A cos j = 1 28 thermal float (break contact) 250V 2A cos j = 1 29 sealing chamber control 30 bearing temperature control 31 bearing temperature control Pt 100 as per DIN 43760 B...
- Page 82 DATENBLATT - ELEKTRISCHER ANSCHLUSS Sicherheitshinweise: Der Anschluß des Motors darf nur von einer autorisierten Elektrofachkraft vorgenommen werden. Es sind bei der Leitungsverlegung und beim Anschließen des Motors die VDE- und die örtlichen Vorschriften zu beachten. Der Einbau eines Motorschutzes zwingend vorgeschrieben.
- Page 83 EC declaration of conformity...
- Page 85 Lithuania Serbia and Montenegro Taiwan WILO SALMSON WILO Lietuva UAB WILO Hrvatska d.o.o. WILO Magyarország Kft WILO Beograd d.o.o. WILO-EMU Taiwan Co. Ltd. Argentina S.A. 03202 Vilnius 10090 Zagreb 2045 Törökbálint 11000 Beograd 110 Taipeh C1295ABI Ciudad T +370 5 2136495...
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