Table of Contents
Troubleshooting
Related Manuals for Wilo EMU D
Summary of Contents for Wilo EMU D
- Page 1 Pioneering for You Wilo-EMU D, DCH, K, KD, KM, NK, SCH Wilo-Sub TWI 8/TWI 10 Wilo-Actun ZETOS-K + NU...T/U...T-Motor (Trinkwasser/drinking water) en Installation and operating instructions 6094323 01-05/2007 Wilo Hof...
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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 Maintenance and inspection log WILO SE 3.0...
- Page 5 Operation using a static frequency converter Standard equipment from well-known manufacturers Special equipment from well-known manufacturers Selection of motor and converter Minimum speeds for submersible pumps (well pumps) Operation Maximum voltage peaks and rise speed Motor protection Operation at over-frequency Efficiency Relevant motor specifications for FC operation Anti-vortex plate...
- Page 6 Notes on using water guide shrouds General product information Various models of the water guide shroud WILO SE 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 SE 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 SE Nortkirchenstr. 100 DE - 44263 Dortmund Tel.: +49 231 4102-0... -
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 SE 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 SE 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 General product infor- 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. The machine is supplied as an mation enclosed and compact unit. - Page 18 “Electrical connection plan” data sheet. Power supply line Discharge port End guide housing Guide housing Intake port Sieve Stator Lower section Fig. 3-1: Machine structure WILO SE 3.0...
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Page 19: Cooling
Product description Cooling Motors of this type are cooled by the pumped fluid circulating around it. The heat is carried out- ward directly via the motor casing and the stator casing to the pumped liquid. Type designation The type code provides information about the design of the machine. Example pump: NK 86 X (S)-8 Internal product designation (TWI..., NK..., K..., KD..., D..., KM..., KP..., DCH..., NK 86... -
Page 21: Transport And Storage
Transport and storage Transport and storage Delivery On arrival, the delivered items must be inspected for damage. Also check 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 22: Return Delivery
The packaging must protect the product against damage. If you have any questions please contact the manufacturer. WILO SE 3.0... -
Page 23: 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 24 2 Using a suitable funnel, fill pure, cold, drinking water (not distilled) into one of the threaded openings. The other opening acts as a vent when filling the motor. The correct water level is when the fluid is just below the threaded opening. WILO SE 3.1...
- Page 25 Installation 3 Before screwing in the screw plugs (1) and (2), wait approximately 30 minutes until all the air has escaped from the motor. Top up again with pure, cold drinking water (not distilled) if necessary. 4 Screw in the plugs (1) and (2) with the sealing ring tightly. 1 Unscrew the plugs (1) and (2) with the sealing ring.
- Page 26 Machines of this type must always be submerged during operation to attain the necessary cooling. Note the minimum immersion level. Never let the machine run dry. We recommend that dry-run protection be installed. If fluid levels deviate dramatically, a dry-run protection or level control must be installed. WILO SE 3.1...
- Page 27 Installation Vertical installation With this type of installation, the machine is installed directly on the rising pipe. Therefore, this determines the installation depth. Do not place the machine on the bottom of the pit, since this (optionally with water guide causes tension and mud accumulation.
- Page 28 Keep the lifting gear taut, take off the support clamp, and fasten the cable slightly above and WILO SE 3.1...
- Page 29 Installation below the bell with a cable clip. For heavy, large-diameter cables, it is advisable to attach a cable clip every 2-3m. If several cables are used, each must be fastened separately. Lower the rising pipe slightly so that the bell is in the well, put the support clamp back on below the top bell and lower the rising pipe until the support clamp touches the two pieces of square timber.
- Page 30 The connected pipeline must be self-supporting, i.e. it may not be supported by the machine. Pressure vessel Water tank Operating area Pipe system Intake Mounting supports Filter Machine Fig. 5-4: Horizontal installation in a pumping station WILO SE 3.1...
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Page 31: Removal
Installation During assembly, make sure the pipes carry their own weight and that Horizontal installation in a basin/ tank they and the foundations are strong enough. The pipe system and the machine are fitted separately. If installed horizontally, the machine is supported on two bearing brackets. The exact position can be found on the planning documentation. -
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 - Motor full, or motor filling level correct If the machine has not been operated for some time, check these speci- fications again and rectify any faults you find. -
Page 34: Electrical System
Motor protection should be set to the rated current when fully loaded. At partial load, we recom- mend that motor protection is set 5% above the measured current at the operating point. The maximum start-up time at reduced voltage (approx. 70%) is 3 seconds. WILO SE 3.0... -
Page 35: After Starting
Startup The machine can be operated on frequency transformers. Operation with frequency transformers Observe the data sheet in the appendix of this manual. The rated current is briefly exceeded during the start-up procedure. Once this process has ended, After starting the operating current should no longer exceed the rated current. -
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: Glycol Overview
None Phosphate None None None Silicate None None None Water hazard class FDA approval HT1 approval Afssa approval Remarks For medical use Table 7-1: Technical Data – Glycol Overview Maintenance intervals Overview of the maintenance intervals needed: WILO SE 3.0... -
Page 39: Maintenance Tasks
Maintenance Monthly - Monitoring the current consumption and voltage - Checking the used relays for posistors, sealing room monitor, etc. - Checking the insulation resistance Every six months - Visual inspection of the power supply cable - Visual inspection of accessories, e.g. pressure shroud, etc. - Functional inspection of all safety and monitoring devices and auxiliary hoisting gear Yearly Maintenance tasks... - Page 40 Maintenance Please consult the appropriate operating manual for details on inspecting the safety and monitor- ing devices on the auxiliary lifting gear. WILO SE 3.0...
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Page 41: 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 42: Restarting After An Extended Period Of Storage
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 SE 3.1... -
Page 43: 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 44: 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 SE 3.0... -
Page 45: 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 46: 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 47: 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 48: Maintenance And Inspection Log
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 SE 3.0... -
Page 49: B Operation Using A Static Frequency Converter
– Remote control – etc. manufacturers Selection of motor Every submersible motor from the Wilo product series can be used. In the case of a rated voltage exceeding 415 V, the factory should be consulted. Because of the additional heating caused by and converter harmonics, the rated power of the motor should be around 10 % more than the power requirement of the pump. -
Page 50: Maximum Voltage Peaks And Rise Speed
(PT 100). Operation at Wilo submersible motors with a rated frequency of 50 Hz can be regulated up to 60 Hz. Motors with a rated frequency of 100 Hz can be accordingly regulated up to 120 Hz. -
Page 51: Relevant Motor Specifications For Fc Operation
Operation using a static frequency converter Relevant motor specifications for FC operation Max. voltage Max. voltage peaks at Num- Ramp time rise rate at the Motor nominal (S1) the motor Construction ber of motor terminals type [Hz] [Hz] terminals poles [Hz] [V/?s] encapsulated,... -
Page 53: C Anti-Vortex Plate
Anti-vortex plate Anti-vortex plate General product infor- The anti-vortex plate can be used for horizontally installed machines. It is fitted above the suction strainer. It is fastened to the motor and pump housing by means of two metal brackets. The anti- mation vortex plate prevents air from being sucked in. -
Page 55: D Instructions For Filling The Nu4 / Nu5 / Nu7 Motors
Instructions for filling the NU4 / NU5 / NU7 motors Instructions for filling the NU4 / NU5 / NU7 motors The procedures for filling, draining and checking fluid levels for these motors differ from our other General product infor- motors. The steps for this procedure are described in this chapter. mation Only motors that are completely and correctly filled guarantee problem- free operation. - Page 56 5 To bleed, push in the valve briefly with the test pin until the water with no bubbles emerges. Be careful to avoid excess pressure. 6 Keep injecting water until the diaphragm spacing (D) is reached. 7 Replace the filter (C). Test pin with test size “D" Fig. D-2: Checking and correcting the fluid level WILO SE 3.0...
- Page 57 Instructions for filling the NU4 / NU5 / NU7 motors Motor type Test size (D) Tolerance 4“ 234… 10 mm +/- 2mm 6“ 236… 59 mm +/- 2mm 6“ 236… (AISI 316 SS) 19 mm +/- 2mm 8“ 239… (93kW…150kW) 38 mm +/- 2mm 8“...
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Page 59: Instructions On Filling The Nu 611 And Nu 811 Motors
Instructions on filling the NU 611 and NU 811 motors Instructions on filling the NU 611 and NU 811 motors The procedures for filling, draining and checking fluid levels for these motors differ from our other General product motors. The steps for this procedure are described in this chapter. information Only motors that are completely and correctly filled guarantee problem- free operation. - Page 60 Draining the motor 1 Lay the motor horizontally and remove the screw (1). 2 The motor fluid flows out. 3 Slightly raise the motor to allow the remaining fluid to drain out. Screw (1) Fig. E-2: Draining the motor WILO SE 3.0...
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Page 61: F Use As A Sprinkle Pump
Use as a sprinkle pump Use as a sprinkle pump Proper use and fields of These machines are used in sprinkler fire extinguishing systems in buildings. The units are designed for this use and have been tested and certified by a named authority. application Only machines which are suitably certified (VdS, PAWUS etc.) may be used as sprinkler pumps. - Page 62 Use as a sprinkle pump Type plate The type plate is attached to the motor casing. This sign contains the technical data. P-Typ M-Typ IMø Cosp IMø Mat.Ph Fig. F-1: Type plate WILO SE 3.1...
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Page 63: G Notes On Assembling Large Pure Water Machines
Notes on assembling large pure water machines Notes on assembling large pure water machines Because of the danger of inadmissibly large bending of longer machines, they have to be dis- patched and supplied on transport rails. The transport rail may only be removed when the machine is in the vertical installation position. The transport rail must also be re-attached if the machine is moved to a horizontal position. -
Page 65: Filling Instructions For U21
Filling instructions for U21… motor series Filling instructions for U21… motor series General product infor- These motors are equipped with a cooling circuit to ensure better cooling. To balance the volume in the cooling circuit, two relief diaphragms have been fitted on the motor. For this reason, the motors mation must be filled with s special device before installation and commissioning. - Page 66 Filling instructions for U21… motor series Relief diaphragm Relief diaphragm Fig. H-1: Filling the U21… motor series WILO SE 3.0...
- Page 67 Notes on using water guide shrouds Notes on using water guide shrouds General product infor- A water guide shroud is used to prevent air intake or vortexes forming in the pumped liquid. The water guide shroud can be used to in machines installed vertically or horizontally. Depending on the mation construction of the water guide shroud, it must be dismantled before filling the motor or may remain installed during this.
- Page 68 3 Install the machine again. 4 Install and commission the machine in accordance with chapters 5 and 6 of the operating and maintenance handbook. Flange Flange Water guide shroud Fig. I-2: Filling the vertical water guide shroud after dismantling WILO SE 3.0...
- Page 69 Notes on using water guide shrouds If the water guide shroud is in- The motor is filled using two supply lines. They are fixed to the motor and the flange. stalled vertically, it is possible Draining the motor is only possible if the machine is removed from the to fill the motor without the water guide shroud.
- Page 72 Local contact at www.wilo.com/contact WILO SE Wilopark 1 44263 Dortmund Germany T +49 (0)231 4102-0 F +49 (0)231 4102-7363 wilo@wilo.com Pioneering for You www.wilo.com...