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Summary of Contents for Wilo EMU KPR
- Page 1 Pioneering for You Wilo-EMU KPR en Installation and operating instructions 6097571 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, moisture sensors report a fault or switch 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 Explosion protection in accordance with the CSA standard for zone 1 General information Certification and classification Explosion symbol and coding “Flameproof enclosures" protection type Special conditions External sealing room monitoring Operation and installation types Maintenance and repair work, alterations to the construction Explosion protection in accordance with the FM standard General information Certification and classification...
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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 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 Axial machines are suspended directly in the discharge pipe. They are used to pump large amounts of pure, river, raw and cooling water, pre-cleaned waste water or activated sludge up small application elevations. - Page 18 The propeller is fastened on the rotor shaft of the motor and is driven directly. The propeller blade angle can be adjusted using a setting washer. Guide housing Propeller Stationary wear ring Intake funnel Fig. 3-1: Propeller wheel WILO SE 3.0...
- Page 19 Product description Machine structure Electrical supply cable Base packet Motor housing Bearing casing Rotor (motor shaft + package) Block seal cartridge Sealing chamber Guide blade Top edge Propeller hub Guide housing Stationary wear ring Propeller blade Intake funnel Fig. 3-2: Machine structure E:\shares\Baprod\BA\subtec_m\sewage\us\kpr\product.fm...
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Page 20: Type Designation
Service factor Protection class Current at service factor Operating mode (s = wet / e = dry) Motor wiring Cos ϕ Cosine phi Max. submersion IMø / S Impeller diameter/number of levels Table 3-2: Name plate key WILO SE 3.0... -
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 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 SE 3.0...
- Page 25 Installation Installation 1 Lower the pump into the steel pipe or concrete pit. 2 Ensure that the pump lies correctly on the support ring and is centered on the tapered ring. 3 The round cord ring on the guide housing seals the intake and discharge sides apart from each other after the centering process.
- Page 26 Installation Fig. 5-2: Installation in pipes in covered intake chambers and pipe overflow models WILO SE 3.0...
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Page 27: Dry-Run Protection
Installation Dry-run protection The machine must always be immersed up to the top edge of the propeller hub. For optimum reliability, we recommend installing a dry-run protection system. Correct running is ensured by float switches or electrodes. The float switch / electrode is fastened in the pit and switches off the machine when the water level falls below the minimum coverage level. -
Page 29: 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 30: 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 SE 3.0... -
Page 31: 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 33: 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 34: Lubricants
- Checking the insulation resistance two years, whichever is earlier - Changing the lubricant in the sealing room/chamber - Emptying the leakage chamber (not present in all models) - Functional inspection of all safety and control devices WILO SE 3.0... -
Page 35: Maintenance Tasks
Maintenance - Coating check and touch-up as required - General overhaul 15,000 operating hours or af- ter five years, whichever is If it is used in highly abrasive or corrosive material, the maintenance earlier intervals should be reduced by 50%! Maintenance tasks Overview of the individual maintenance intervals: The current consumption and voltage is to be monitored periodically during all 3 phases. -
Page 36: Changing The Lubricant
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. WILO SE 3.0... -
Page 37: Repairs
Maintenance Sealing chamber on oil filler screw and oil drain screw (D+, D-) Fig. 7-1: Position of the screw plugs Repairs The following repairs can be carried out on this machine: - Changing the propeller - Changing the stationary wear rings When carrying out repair work, the following information should always be observed: - Round sealing rings as well as existing seals should always be replaced. -
Page 38: Torque Values
Overview of the correct torques for dacromet-coated screws with Nord-Lock screw fixing Thread Tensile strength 10.9 kp m 0.94 15.0 1.53 36.8 3.75 73.6 7.50 126.5 12.90 316.3 32.24 621.0 63.30 1069.5 109.02 1610.0 164.12 Table 7-2: Dacromet-coated screws with Nord-Lock screw fixing WILO SE 3.0... - Page 39 Maintenance Thread Tensile strength 10.9 kp m 2127.5 216.87 Table 7-2: 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 0.76 230.0 23.45 18.5 1.89 285.0...
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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 And Possible Solutions
Troubleshooting and possible solutions Troubleshooting and possible solutions 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. -
Page 44: Fault: Machine Runs But Does Not Pump
Signs of wear Replace worn parts Defective hose or pipeline Replace defective parts Inadmissible levels of gas in the pumped liquid Contact the factory 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 and possible solutions Cause Solution Have a specialist inspect the connection and Two-phase operation correct it as necessary Check the supply and capacity of the system, Excessive decrease in the water table during and inspect the level control settings and operation functionality Table 9-4: The machine runs, but not at the stated operating levels... -
Page 46: Further Steps For Troubleshooting
- On-site support from customer service - Inspection or repair of the machine at the factory Please note that you may be charged for some services provided by our customer support. For more details, please contact customer service. WILO SE 3.0... -
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: Explosion Protection In Accordance With The Csa Standard For Zone
Explosion protection in accordance with the CSA standard for zone 1 Explosion protection in accordance with the CSA standard for zone 1 This chapter contains special information for owners and operators of machines which have been General information built and certified for use in environments where explosions may occur. It expands on and therefore supplements the standard instructions for these machines. -
Page 50: External Sealing Room Monitoring
Table B-1: Sealing change for explosion-proof motors The symbols in the table have the following meanings: -- = not present or replacement not possible without endangering explosion protection OK = replacement possible without endangering the explosion protection WILO SE 3.1... -
Page 51: Explosion Protection In Accordance With The Fm Standard
Explosion protection in accordance with the FM standard Explosion protection in accordance with the FM standard This chapter contains special information for owners and operators of machines which have been General information built and certified for use in environments where explosions may occur. It expands on and therefore supplements the standard instructions for these machines. -
Page 52: Maintenance And Repair Work, Alterations To The Construction
The symbols in the table have the following meanings: -- = not present or replacement not possible without endangering explosion protection OK = replacement possible without endangering the explosion protection = cartridge replacement possible, mechanical shaft seal cannot be removed WILO SE 3.1... -
Page 53: Signs Used
Explosion protection in accordance with the FM standard Signs used The following signs are attached to the machine. The type plate is attached to the motor casing. This sign contains the technical data. Type plate P-Typ M-Typ IMø Cosp CLASS I, DIV. 1, GROUPS C, D CLASS II, DIV. -
Page 55: Explosion Protection In Accordance With The Atex Standard For Zone
Explosion protection in accordance with the Atex standard for zone 1 Explosion protection in accordance with the Atex standard for zone 1 This chapter contains special information for owners and operators of machines which have been General information built and certified for use in environments where explosions may occur. It expands on and therefore supplements the standard instructions for these machines. -
Page 56: Special Conditions
Repairs and alterations to the construction which are not listed in this operating and maintenance construction handbook or which may impair explosion protection may only be performed by the manufacturer or by service dealers certified by the manufacturer. WILO SE 3.1... - Page 57 Explosion protection in accordance with the Atex standard for zone 1 Repair The spark-proof gaps may only be repaired according to the manufacturer's design specifications. It is not permitted to carry out repairs according to the values in tables 1 and 2 and DIN EN 60079-1.
- Page 58 Signs used The following signs are attached to the machine. Type plate The type plate is attached to the motor casing. This sign contains the technical data. P-Typ M-Typ IMø Cosp Excl Exno 0102 Fig. D-1: Type plate WILO SE 3.1...
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Page 59: 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 60: 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 64 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...
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