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Wilo-EMU FA+T-Motor

6067561 · Book 1 of 2 · Ed.03-07/2015 WH

de Einbau- und Betriebsanleitungen Installation and operating instructionsfr Notice de montage et de mise en servicees Instrucciones de instalación y funcionamientoit Istruzioni di montaggio, uso e manutenzionenl Inbouw- en bedieningsvoorschriftensv Monterings- och skötselanvisning

Fig. 1: T 20.1 Fig. 1: T 49, T 50, T 50.1, T 56, T 57, T 63.1, T 63.2, T 72

Fig. 1: T 12, T 13, T 17, T 17.2, T 20 Fig. 1: T 24, T 30, T 34, T 42

Fig. 2

P-Typ M-Typ

S/N MFY

U Q IMø

I H OTS/E

IST Cos TPF max

P SF

F ISF IP

N MC

1 1

3

4

6

7

8

9

10

P-Typ M-Typ

S/N MFY

U Q IMø

I H OTS/E

IST Cos TPF max

P SF

F ISF IP

N MC

1

3

4

6

7

8

9

10

1

2

3

4

6

7

8

9

10

1

2

1

3

5

6

7

8

9

21

Fig. 3.1

Fig. 3.3

Fig. 3.2

Fig. 3.4

1

3

2x

4

2

Fig. 5 Fig. 6

1

5

66

33

4

2

S1

S1/S2

7a

7b

1

4

8

3

3 6

5

2

7

Fig. 4

1

1

5

9

6

3

4

2

S1

S1/S2

8

7b

7a

d

min

. 2 x

d

min

.0,

5 x

dm

in. 1

x d

A

dm

in.

0,3

x dB

Fig. 8Fig. 7

Fig. 11 Fig. 12Fig. 9 Fig. 10

M 3~

gn-y

eWVUPE DK

M 3~

gn-y

e

W1V1U1 U2V2W2PE DK

2120

250

V (A

C); 2

,5 A

; cos

φ =

1

2021 22

250

V (A

C); 2

,5 A

; cos

φ =

1

250

V (A

C); 2

,5 A

; cos

φ =

1m

ax. °

C

min

. °C

1110

DIN

440

82

1011 12

DIN

440

82

DIN

440

82

max

. °C

min

. °C

DK K21K20

s

Fig. 13: T 20 Fig. 13: T 20.1Fig. 13: T 17.2

Fig. 13: T 24 Fig. 13: T 30, T 34, T 42 Fig. 13: T 49, T 56

Fig. 13: T 12 Fig. 13: T 13 Fig. 13: T 17

DD

D

D

D-

D+

D-

D+

D- D+

D-

D+

D-D+

Fig. 13: T 50, T 50.1, T 57, T 63.1

Fig. 15: T 20.1 Fig. 15: T 50, T 50.1, T 57, T 63.1 Fig. 15: T 63.2, T 72

Fig. 13: T 63.2, T 72 Fig. 14

D-

D+

L-

L-

L

D-

D+

D*

L-

Fig. 16: T 50, T 50.1, T 57, T 63.1 Fig. 16: T 49/56 Fig. 16: T 63.2, T 72

F+F

F+

F+

F+

Fig. 17: T 24 Fig. 17: T 30, T 34, T 42 Fig. 17: T 49, T 56

S-

S-

S-

Fig. 17: T 50, T 50.1, T 57, T 63.1

Fig. 17: T 63.2, T 72

S-

S-

Fig. 18

1

2

3

4

Fig. 19

1

5

4

3

2

3

Installation and operating instructions Wilo-EMU FA + T-Motor 45

English

1. Introduction 461.1. About this document 461.2. Personnelqualifications 461.3. Copyright 461.4. Subject to changes proviso 461.5. Warranty 46

2. Safety 472.1. Instructions and safety instructions 472.2. General safety 472.3. Electrical work 482.4. Safety and monitoring devices 482.5. Conduct during operation 482.6. Operatingfluid 492.7. Fluids 492.8. Sound pressure 492.9. Standards and guidelines used 492.10. CE marking 49

3. Product description 493.1. Intendeduseandfieldsofapplication 493.2. Set-up 503.3. Monitoring devices 513.4. Operation in an explosive atmosphere 513.5. Operating modes 513.6. Type key 523.7. Technical data 523.8. Scope of delivery 523.9. Accessories 52

4. Transport and storage 524.1. Delivery 524.2. Transport 524.3. Storage 534.4. Return delivery 53

5. Installation 535.1. General 535.2. Installation methods 535.3. Installation 545.4. Dry-running protection 575.5. Electrical connection 585.6. Motor protection and activation types 60

6. Commissioning 606.1. Electrical system 616.2. Rotation control 616.3. Level control 616.4. Operation in potentially explosive areas 616.5. Commissioning 616.6. Conduct during operation 62

7. Decommissioning/disposal 627.1. Temporary decommissioning 627.2. Decommissioning for maintenance work

or storage 637.3. Return delivery/storage 63

7.4. Disposal 63

8. Maintenance and repair 638.1. Operatingfluid 648.2. Maintenance intervals 648.3. Maintenance work 658.4. Repairs 67

9. Troubleshooting and possible solutions 69

10. Appendix 7010.1. Tightening torques 7010.2. Operation with frequency converters 7110.3. Ex-approval 7110.4. Spare parts 73

46 WILO SE 07-2015 V05 DIN A4

English INTRODUCTION

1. Introduction

1.1. About this documentThe language of the original operating instruc-tions is German. All other languages of these instructions are translations of the original oper-ating instructions.This manual is divided into individual sections, which are listed in the table of contents. Each section has a heading which clearly describes its content.A copy of the EC declaration of conformity is a component of these operating instructions.Ifatechnicalmodificationismadeonthedesignsnamed there without our agreement, this decla-ration loses its validity.

1.2. Personnel qualificationsAll personnel who work on or with the pump must bequalifiedforsuchwork;electricalwork,forexample,mayonlybecarriedoutbyaqualifiedelectrician. All personnel must be of legal age.Operating and maintenance personnel must also observe national accident prevention regulations.It must be ensured that personnel have read and understood the instructions in this operating and maintenance handbook; if necessary, this manual must be ordered from the manufacturer in the required language.This pump is not intended for use by persons (in-cluding children) with limited physical, sensory or mental capacities or without the relevant experi-ence or knowledge, unless they are supervised by a person responsible for their safety and receive instructions from this person on how to use the pump.Children must be supervised in order to ensure that they do not play with the pump.

1.3. CopyrightThis operating and maintenance manual has been copyrighted by the manufacturer. The operating and maintenance manual is intended for use by installation, operating and maintenance person-nel. It contains technical regulations and draw-ings which may not be reproduced or distributed, either in whole or in part, or used for purposes of competition without the express consent of the manufacturer or shared with others. The illustra-tions used may differ from the original and are only intended as an exemplary representation of the pumps.

1.4. Subject to changes provisoThe manufacturer reserves the right to make technicalmodificationstounitsorcomponents.This operating and maintenance manual refers to the pump shown on the title page.

1.5. WarrantyIn terms of the warranty, the current version of the "General Terms and Condition of Business" is applicable.Youcanfindthesehere: www.wilo.com/legal

Any deviations must be contractually agreed and shall then be given priority.

1.5.1. GeneralThe manufacturer is obliged to correct any de-fects found in the pumps it sells, provided that the defects meet one or more of the following requirements:

• The defects are caused by the materials used or the way the product was manufactured or designed.

• The defects were reported in writing to the manufacturer within the agreed warranty period.

• The pump was used only as prescribed.• All monitoring devices are connected and were

tested before commissioning.

1.5.2. Warranty periodThe length of the warranty period is set out in the "General Terms and Conditions of Business".Any deviations must be contractually agreed.

1.5.3. Spare parts, attachments and modificationsOnly genuine spare parts from the manufacturer may be used for repairs, replacements, attach-mentsandmodifications.Unauthorizedadd-onsandmodificationsortheuseofnon-originalspareparts can seriously damage the pump and/or injure personnel.

1.5.4. MaintenanceThe prescribed maintenance and inspection work should be carried out regularly. This work mayonlybecarriedoutbyqualified,trainedandauthorised personnel.

1.5.5. Damage to the productDamage and malfunctions that endanger safety must be eliminated immediately by trained per-sonnel. The pump may only be operated if it is in perfect working order.In general, repairs should only be carried out by Wilo customer service.

1.5.6. DisclaimerNo warranty claims will be accepted or liability will be assumed for pump damage if any of the followingitemsapply:

• The manufacturer deems that information pro-videdbytheoperatororcustomerisinsufficientor incorrect

• Non-compliance with safety instructions and workinginstructionsasspecifiedinthisoperatingand maintenance manual

• Improper use• Incorrect storage and transport• Improper assembly/dismantling• Insufficientmaintenance• Incorrect repairs• Inadequate construction site or construction work• Chemical,electrochemicalandelectricalinflu-

ences• Wear


SAFETY English

This means the manufacturer’s liability excludes all liability for personal injury, material damage or financiallosses.

2. SafetyThis section lists all the generally applicable safety instructions and technical information. In addition,alltheothersectionscontainspecificsafety instructions and technical information. All instructions and information must be observed and followed during the various phases of the pump’s life cycle (installation, operation, mainte-nance, transport etc.)! The end-user is respon-sible for ensuring that all personnel follow these instructions and guidelines.

2.1. Instructions and safety instructionsThis manual uses instructions and safety instruc-tions for preventing injury and damage to prop-erty. To clearly identify them for personnel, the instructions and safety instructions are distin-guishedasfollows:

• Instructions appear in bold and refer directly to the preceding text or section.

• Safety instructions are slightly indented and bold and always start with a signal word.• Danger

Serious or fatal injuries can occur!• Warning

Serious injuries can occur!• Caution

Injuries can occur!• Caution (instruction without symbol)

Substantial property damage can occur. Irrepa-rable damage is possible!

• Safety instructions that refer to personal injury appear in black and are always accompanied by a safety symbol. Danger, prohibition or instruction symbols are used as safety symbols.Example:

Dangersymbol:Generalhazard

Danger symbol, for example, electrical current

Symbol for prohibited action, e.g. No entry!

Instruction symbol, for example, wear protec-tive clothing

The safety symbols used conform to the generally applicable directives and regulations, such as DIN and ANSI.

• Safety instructions that only refer to mate-rial damage are printed in grey, without safety symbols.

2.2. General safety• When installing or removing the pump, never

work alone in rooms and sump. A second person must always be present.

• The pump must always be switched off before any work is performed on it (assembly, disman-tling, maintenance, installation). The pump must be disconnected from the electrical system and secured against being switched on again. All rotating parts must have come to a stop.

• The operator should inform his/her superior im-mediately should any defects or irregularities occur.

• The end-user must shut down the equipment im-mediately if defects occur that represent a safety risk.Theseinclude:• Failure of the safety and/or monitoring devices• Damage to important parts• Damage to electrical equipment, cables, and

insulation.• Tools and other objects should be kept in their

designated places so that they can be found quickly.

• Sufficientventilationmustbeprovidedinen-closed rooms.

• When welding or working with electronic devices, make sure there is no risk of explosion.

• Onlyuseliftinggearwhichislegallydefinedassuchandofficiallyapproved.

• The lifting gear must be kept safely and must be suitable for the conditions of use (weather, hook-ing unit, load, etc.).

• Mobile equipment for lifting loads should be used in such a way that it is guaranteed to remain stable during operation.

• When using mobile equipment for lifting non-guided loads, take action to prevent tipping, shifting, sliding, etc.

• Measures should be taken to ensure that no person is ever directly beneath a suspended load. Furthermore, it is also prohibited to move suspended loads over workplaces where people are present.

• If mobile equipment is used for lifting loads, a second person should be present to coordinate the procedure if required (for example, if the operator’sfieldofvisionisblocked).

• The load to be lifted must be transported so that no-one will be injured if there is a power failure. Furthermore, if such work is being carried out outdoors, it must be cancelled if the weather conditions worsen.These instructions must be strictly observed. Non-observance can result in injury or substan-tial material damage.

48 WILO SE 07-2015 V05 DIN A4

English SAFETY

2.3. Electrical work

ELECTRICAL hazard! Incorrectly performed electrical work can result in fatal injury! This work may only be carried out by a qualified electrician.

BEWARE of moisture! Moisture penetrating the cable will damage both the pump and the cable. Never immerse the cable end in fluid and always protect it from moisture. Unused wires must be insu-lated!

The pumps are operated with alternating or three-phase current. The governing national directives, standards and regulations (e.g. VDE 0100) as well as the requirements of the local energy supply company must be observed.The person operating the pump must know where it is supplied with power and how to cut off the supply. A motor protection switch must be installed by the customer for three-phase AC motors. It is advisable to install a residual-current device (RCD). If there is a possibility that people can come into contact with the pump and the fluid(forexampleonconstructionsites),theconnection must be equipped with an additional residual-current device (RCD).The section entitled ‘Electrical connection’ must be observed when connecting the product. The technicalspecificationsmustbeobservedstrictly.The pumps must always be grounded.If the pump has been switched off by a protec-tive device, it must not be switched on again until the error has been corrected.

When the pump is connected to the electrical control panel, particularly when electronic devices such as soft start-up control or frequency con-verters are used, the switchgear manufacturer’s specificationsmustbefollowedtocomplywiththe electromagnetic compatibility (EMC) require-ments. Special separate shielding measures (e.g. shieldedcables,filters,etc.)maybenecessaryforthe power supply and control cables.Connections may only be made providing the switchgear meets the harmonised EU standards. Mobile radio equipment may cause malfunc-tions in the system.

BEWARE of electromagnetic radiation! Electromagnetic radiation can pose a fatal risk for people with cardiac stimulators. Put up appropriate signs and make sure anyone affected is aware of the danger!

2.4. Safety and monitoring devicesThemotormaybefittedwiththefollowingmonitoringdevices,dependingonconfiguration/customerrequestandmotorsize:

• Motor compartment monitoring

• Thermal motor monitoring as temperature limit function (1-circuit temperature monitor) or temperature control and limit function (2-circuit temperature monitor)

• Monitoring of the sealing chamber• Monitoring of the leakage chamber• Thermal motor bearing monitoring• Monitoring of the terminal room

For precise information about which monitor-ingdevicesarefitted,pleaserefertoyourorderconfirmationorthetechnicaldatasheet.These monitoring devices must be connected by an electrician and checked to ensure that they function correctly before commissioning.Personnel must be informed about the installed systems and how they work.

CAUTION! Never operate the pump if the monitoring devices have been removed or damaged, or if they do not work.

2.5. Conduct during operationWhen operating the pump, always follow the locally applicable laws and regulations for work safety, accident prevention and handling elec-trical machinery. To help ensure safe working practice, the responsibilities of employees should beclearlyspecifiedbytheoperator.Allpersonnelare responsible for ensuring that regulations are observed.The pump is equipped with moving parts. During operation, these parts rotate in order to pump the fluid.Certainsubstancesinthefluidcanresultinvery sharp edges forming on the moving parts.

WARNING: rotating parts! The rotating parts can crush and sever limbs. Never reach into the hydraulics or touch the rotating parts when the machine is in opera-tion.

• Before performing maintenance or repairs, switch off the pump, disconnect it from the mains and secure it against being switched on again without authorization.

• Allow the rotating parts to come to a stand-still!


PRODUCT DESCRIPTION English

2.6. Operating fluid

BEWARE of high pressure! If there is a defect, it is possible for there to be a high pressure of several bar in the sealing chamber and leakage chamber. This pressure is dissipated through any orifices open dur-ing maintenance work! Screw plugs opened carelessly can behave like projectiles. To avoid injuries, always comply with the following instructions:

• Always comply with the prescribed sequence of work steps.

• Slowly unscrew the screw plugs, but do not unscrew them completely.

• As soon as the pressure escapes (visible whis-tling or hissing of air), stop turning the screw plug any further. Wait until the pressure has fully dissipated.

• Always wear appropriate protective clothing/equipment!

BEWARE of burns! Operating fluids can also spray out when the pressure is escaping. Danger of scalds! Only open the screw plugs once the motor has cooled down to ambient temperature. Always wear appropriate protective clothing/equip-ment!

2.7. FluidsEachfluiddiffersinrespectofcomposition,cor-rosiveness, abrasiveness, dry matter content and in many other aspects. Generally, our pumps can be used for many applications. Please note that if requirements change (density, viscosity or general composition), this can also affect many param-eters of the pump.When using or replacing the pump in a different fluid,observethefollowingpoints:

• Thefluidcanbecontaminatedbyoilfromthesealing chamber if the mechanical shaft seal is defective.Use with drinking water is not permitted!

• Pumps that have been operated in dirty waste water must be cleaned thoroughly before being usedforotherfluids.

• Pumps that have been operated in sewage water containingfaecesand/orfluidsthatarehazardousto health must be decontaminated before being usedwithotherfluids.Clarification must be sought as to whether the pump can be used at all with another fluid.

2.8. Sound pressureDepending on the size and performance (kW) of the pump, it has a sound-pressure level of approximately 70 dB (A) to 110 dB (A) during operation.However, the actual sound-pressure level depends on several factors. These include, for example,theinstallationdepth,installation,fixa-

tion of accessories and piping, the duty point, immersion depth, etc.We recommend that the end-user takes an ad-ditional measurement at the workplace once the pump is running at its duty point and under all operating conditions.

CAUTION: Wear ear defenders! According to applicable laws and regula-tions, ear protection must be worn if the sound-pressure level is 85 dB(A) or more! The end-user must make sure that this is complied with!

2.9. Standards and guidelines usedThe pump is subject to various European direc-tives and harmonised standards. See the EC declaration of conformity for precise information about these.In addition, various standards are used as a basis for operating, assembling and dismantling the pump.

2.10. CE markingThe CE marking is attached to the rating plate.

3. Product descriptionThe pump is manufactured with great care and is subject to constant quality controls. Trouble-free operation is guaranteed if it is installed and maintained correctly.

3.1. Intended use and fields of application

ELECTRICAL hazard When using the pump in swimming pools or other basins that can be entered, there is a risk of electrocution. Note the following:

• Use is strictly forbidden if there are people in the basin!

• If there are no people in the basin, protec-tive measures must be taken according to DIN VDE 0100-702.46 (or the appropriate national regulations).

DANGER - explosive fluids! It is strictly prohibited to pump explosive flu-ids (gasoline, kerosene, etc.). The pumps are not designed for these fluids!

Wilo-EMU FA… submersible motor pumps with T motor are suitable for intermittent and continu-ousdutywith:

• Wastewater and sewage• Sewage containing faeces• Municipal and industrial sewage• Sludgeswithupto8%drymatter(dependingon

type)from pump chambers and tanks.The submersible pumps must not be used for pumping:

• Drinking water

50 WILO SE 07-2015 V05 DIN A4

English PRODUCT DESCRIPTION

• Fluids containing hard components such as stone, wood, metal, sand etc.

• Highlyflammableandexplosivefluidsinpureform.The intended use includes complying with these instructions. Any other use is considered to be outside the intended use.

3.2. Set-upWilo-EMU FA pumps with T motor are submers-ible sewage pumps that can be operated vertically in stationary wet well installation and, depend-ing on the motor size, in portable wet well and stationary dry well installation.Differentdesignsresultfromtheconfigurableop-tions for installation type, hydraulics and motor.

Fig. 1: Description of units

1 Cable 6 Hydraulics housing

2 Handle 7 Suction connection

3 Motor housing 8 Pressure connection

4 Seal housing with seal-ing chamber 9 Attachment point for

chains with shackle5 Bearing housing 10 Rating plate

3.2.1. HydraulicsRotodynamic hydraulics with horizontal pressure connectionandflangeconnection.Variousimpel-lershapesareusedastheimpeller:

• Vortex impellers (W)• Vortex impeller with mechanical turbulator (WR)• Single-channel impellers (E)• Multi-channelimpeller:

• Z = Two-channel• D = Three-channel• V = Four-channel

• SOLID impellers• T = Shut SOLID impeller• G = Half open SOLID impellerThefollowingcomponentsarealsofitted,de-pendingontype:

• Inspection cover Opening on hydraulics housing for clearing block-ages in the hydraulics.

• Impeller wear ring Theimpellerwearringcanbefittedtochannelimpellers and determines the gap between the suction area and the impeller. The larger the gap, the lower the output, or else there is a danger of clogging.

• Casing wear ring Thecasingwearringisfittedinthesuctionarea of the hydraulics and determines the gap between the suction area and the impeller. The larger the gap, the lower the output, or else there is a danger of clogging.The casing and impeller wear rings are subject to increased wear, which means they are exchange-ableandthusensureslongandefficientoperationof the hydraulics.

The pump is not self-priming, in other words, the fluid must flow in either automatically or with supply pressure.

3.2.2. MotorThree-phase current dry motors are used as the motors.Themotoriscooledbythefluidaroundit.Thewasteheatistransferreddirectlytothefluidvia the motor housing. For sizes up to 49 and also for size 56, the roller bearings are permanently lubricated and therefore maintenance-free. For size 50, the lower bearing requires regreasing. For size 72, the upper and lower bearings require regreasing.If the motor is immersed up to the top edge of the motor housing, it can be used in continuous duty ‘S1’. If the motor is not immersed, it may be able to be used in continuous duty or in short-time duty ‘S2’, depending on its size and power class.The operating mode for non-immersed opera-tion must also be observed in the case of dry well installation.For exact specifications about the operating mode, refer to the rating plate or the enclosed data sheet.

In the case of motors with high power, the waste heat generated can cause water to condense in the motor. Motors of size 24 and higher are therefore equipped with a separate leakage chamber for the condensation water. The con-densation water can be drained when the motor compartment monitoring is tripped.

DANGER in explosive atmospheres! In the case of Ex-rated motors, the design of some of the motors means that condensa-tion water cannot be drained off because the drainage screw would not be in compliance with the spark-proof area.

The connection cable is longitudinally watertight and has bare cable ends. The standard length is 10 mandadaptedspecificallyfortheorder.

3.2.3. SealBetween the motor and hydraulics, there is the seal housing or bearing housing with the seals onthefluidsideandmotorside.Thesealcanbeimplementedindifferentways:

• Variant‘H’:rotaryshaftsealonthemotorside,mechanicalsealonthefluidside

• Variant‘G’:oneseparatemechanicalsealeachonthemotorandfluidsides

• Variant‘K’:twomechanicalsealsinasealcar-tridgeItispossibletotellwhichsealvariantisfittedbyreferring to the motor designation on the rating plate,theorderconfirmationorthetechnicaldatasheet.Between the two seals, there is a sealing chamber filledwithpotentiallybiodegradablewhiteoil.This accommodates the leakage of the seal on thefluidside.


PRODUCT DESCRIPTION English

Motor types with the bearing housing also have a leakage chamber, which is normally empty. This accommodates the leakage of the seal on the motor side.

3.3. Monitoring devicesThe monitoring devices vary depending on the motorsizeandconfiguration.Foronoverviewofthemonitoringdevicesfitted,refertotheorderconfirmationaswellastheseparatetechnicaldata sheet.All the monitoring devices fitted must always be connected!

The following monitoring devices are possible for Tseriesmotors:

• Motor/terminal compartment monitoring The motor/terminal compartment monitoring signals water ingress into the motor compartment or terminal board, respectively.

• Thermal motor monitoring: The thermal motor monitoring protects the motor winding from overheating. The monitoring sys-tem used can either be 1-circuit monitoring (limit only) or 2-circuit monitoring (control and limit). Bimetallic strips are used for this as standard. The motors can be equipped with PTC sensors as an option.

• Sealing chamber monitoring: The sealing chamber is monitored by a pencil electrode. This signals if there is water ingress into the sealing chamber through the mechanical sealonthefluidside.

• Leakage chamber monitoring: Theleakagechamberismonitoredbyafloatswitch. This reports any water ingress into the leakage chamber through the mechanical seal on the motor side.

• Thermal motor bearing monitoring: The thermal motor bearing monitoring protects the motor bearings from overheating. Pt100 sen-sors are used as sensors.

3.4. Operation in an explosive atmospherePumps marked as explosion-protected are suit-able for operation in an explosive atmosphere. The pumps must meet certain guidelines for this type of use. Certain rules of conduct and guide-lines must be also followed by the operator.Pumps that have been approved for use in an explosive atmosphere must be marked as follows ontheratingplate:

• ‘Ex’ symbol• InformationonExclassification

For use in an explosive atmosphere, observe the further specifications in the appendix to this manual

INCORRECT use can result in danger! When used in an explosive atmosphere, the pump must have a corresponding approval. Also, the accessories must be approved for this application. Check the pump as well as all accessories before use to verify that they conform to this directive.

3.5. Operating modes

3.5.1. Operating mode S1 (continuous duty)The pump can operate continuously at the rated load without exceeding the permissible tempera-ture.

3.5.2. Operating mode S2 (short-time duty)Themaximumoperatingperiodisspecifiedinminutes, e.g. S2-15. The pause must last until the machine temperature no longer differs from the temperatureofthecoolantbymorethan2 K

3.5.3. “Non-immersed operation” modeThe “Non-immersed operation” mode describes the possibility of the motor being non-immersed in a wet well installation during the drainage pumping sequence and thus permits a lowering of the water level to the top edge of the hydraulics.Non-immersed operation is only possible with the followingmotors:T 12,T 13,T 17,T 20.1,T 24,T 30,T 34,T 42,T 50,T 50.1,T 57,T 63.1 To allow the pump to be operated with a non-immersedmotor,thefollowingmustbeobserved:

• When the motor is non-immersed, note and com-ply with the operating mode for non-immersed operation!

• If an operating mode is not documented for non-immersed operation, the motor mustbefittedwith 2-circuit temperature monitoring (tempera-turecontrolandlimitfunction):• An automatic restart can be initiated via the

temperature control function. For this to occur, thespecificationsforthemaximumswitchingfrequency and minimum switching break must be observed!

• When the temperature limit is reached, the unit must deactivate with restart interlock.

Before the motor can be used in permanent op-eration again, it must be completely immersed for at least 1 minute to ensure the necessary degree of cooling!

• During non-immersed operation, the maximum fluidtemperatureandambienttemperaturemustnot be exceeded. The max. ambient temperature isequivalenttothefluidtemperature.For the motor T 12, the following applies: Dur-ing non-immersed operation, the fluid tem-perature and ambient temperature must not exceed 30 °C.

52 WILO SE 07-2015 V05 DIN A4

English TRANSPORT AND STORAGE

3.6. Type key

Example: Wilo-EMU FA 10.82E + T 20.1-4/22KEx

Hydraulics definition

FA Sewage series

10 Nominaldiameterofpressureconnectione.g.:DN 100

82 Internalperformancecoefficient

E

Impeller shapeW = Vortex impellerWR = Vortex impeller with mechanical stirring apparatusE = Single-channel impellerZ = Two-channel impellerD = Three-channel impellerV = Four-channel impellerT = SOLID impeller, closedG = SOLID impeller, half open

Motor definition

T Dry motor

20 Size

1 Internalcodefigure

4 Number of poles

22 Package length in cm

K Sealing variant

Ex Ex-rated motor

3.7. Technical dataRefer to the following documents for the com-pletetechnicaldata:

• Catalogue sheet (for standard articles)• Orderconfirmation(forconfiguredarticles)• Attacheddatasheet(forconfiguredarticles)

3.7.1. Rating plateThe most important data can be found on the rating plate.

Abbreviations on rating plate

P type Hydraulics type

M type Motor type

S/N Serial number

Q Volumeflow

H Delivery head

n Speed

TPF max Max.fluidtemperature

IP Protection class

I Rated current

IST Starting current

P2 Nominal power P2

F Frequency

Cos φ Cos phi

SF Service factor

ISF Rated current with service factor

IMØ Impeller diameter

OTS Immersed operating mode

OTE Non-immersed operating mode

MFY Year of manufacture

3.8. Scope of delivery

Standard product• Pumpwith10 mcableandbarecableend• Installation and operating instructions

Freely configured products• Pump with cable length per customer request• Cable version (depends on type)

• With bare cable end• With plug• Withfloatswitchandbarecableend• Withfloatswitchandplug

• Mounted accessories, e.g. sealing chamber con-trol, pump support foot, etc.

• Installation and operating instructions

3.9. Accessories• Suspension unit• Pump support foot• External pencil electrode for sealing chamber

control• Level control devices• Versions in cast stainless steel or Abrasit and with Ceramcoatingforaggressiveandabrasivefluids

• Thermal motor monitoring with PTC sensors• Various monitoring devices• Fixing accessories and chains• Switchgear, relays and plugs

4. Transport and storage

4.1. DeliveryOn delivery, check immediately that the ship-ment is complete and undamaged. If any parts are damaged or missing, the transport company orthemanufacturermustbenotifiedonthedayof delivery. Claims made after this date cannot be recognised. Damage to parts must be noted on the freight documentation.

4.2. TransportOnly the designated and approved sling gear, transport and lifting equipment are to be used for transportation.Thesemusthavesufficientload-bearing capacity to ensure that the pump can be transported safely. If chains are used they must be secured against slipping.Thepersonnelmustbequalifiedforthetasksandmust follow all applicable national safety regula-tions during the work.The pump is delivered by the manufacturer or shipping agency in suitable packaging. This nor-mally precludes the possibility of damage occur-ring during transport and storage. The packaging


INSTALLATION English

should be stored in a safe place for reuse if the product is frequently used at different locations.

4.3. StorageNewly supplied pumps are prepared so that they can be stored for at least 1 year. The pump should be cleaned thoroughly before it is put into tem-porary storage.The following should be taken into consideration forstorage:

• Placethepumponafirmbearingsurfaceandse-cure it against slipping and falling over. Submers-ible sewage pumps are stored horizontally.

DANGER due to falling over! Never set the pump down if unsecured. If the pump falls over, this may lead to injuries!

• The pumps can be stored at temperatures down to-15 °C.Thestoreroommustbedry.Werecom-mend a frost-protected room for storage with a temperaturebetween5 °Cand25 °C.

• Suction and pressure connections must be sealed securely to prevent contamination getting in.

• All power supply cables must be protected against kinking, damage and moisture ingress.

ELECTRICAL hazard! Damaged power supply cables can cause fatal injury! Defective cables must be replaced by a qualified electrician immediately.

BEWARE of moisture! Moisture penetrating the cable will damage both the pump and the cable. Never immerse the cable end in fluid and always protect it from moisture.

• The pump must be protected from direct sunlight, heat, dust, and frost.

• The impellers should be checked at regular inter-vals. This presents jamming of the bearings and it renewsthefilmoflubricationonthemechanicalseal.

BEWARE of sharp edges! Sharp edges can form on the impellers and hydraulic openings. There is a risk of injury! Wear the necessary protective clothing, such as protective gloves.

• If the pump has been stored for a long period of time, it should be cleaned of impurities such as dust and oil residue before commissioning. Check that the impellers move freely and check the housing coatings for damage.Prior to commissioning, the fill level in the seal-ing chamber should be checked and topped up, if necessary! Damaged coatings must be repaired immedi-ately. Only an intact coating fulfils its intended purpose.

Please note that elastomer parts and coatings become brittle over time. If the product is to be stored for longer than 6 months, we recommend checking these parts and replacing them as nec-essary. Consult the manufacturer for details.

4.4. Return deliveryPumps that are returned to the factory must be properly packaged. This means that impurities have been removed from the pump and that it has beendecontaminatedifusedwithfluidsthatarehazardous to health.For shipping, the parts must be packed in tear-proofplasticbagsofsufficientsizeinsuchamanner that they are tightly sealed and leak-proof. Furthermore, the packaging must protect the pump from damage during transportation. If you have any questions, please contact the manufacturer!

5. InstallationIn order to prevent damage to the product or seri-ous injury during installation, the following points mustbeobserved:

• Installation work – assembly and installation of thepump–mayonlybecarriedoutbyqualifiedpersons. The safety instructions must be followed at all times.

• The pump must be inspected for transport dam-age before any installation work is carried out.

5.1. GeneralFor design and operation of technical sewage sys-tems, observe the pertinent local regulations and directives for sewage technology (such as those of the German Association for Water, Wastewater and Waste).Note that pressure surges can occur, in particu-lar with stationary installations where water is pumped with longer discharge pipes (especially with steady ascents or steep terrain). This can result in the destruction of the pump/system.If you are using level control, make sure that the minimum water coverage is present. Air pockets in the hydraulic housing or piping system must be avoided at all costs and must be removed using a suitable ventilation system. Protect the pump from frost.

5.2. Installation methods• Vertical stationary wet well installation with

suspension unit• Vertical portable wet well installation with pump

support foot• Vertical stationary dry well installation

54 WILO SE 07-2015 V05 DIN A4

English INSTALLATION

Overview: Installation methods

MotorStationary Portable

Wet well Dry well Wet well

T 12 … T 17 x x x

T 20.1 x x x

T 20 … T 24 x o x

T 30 … T 34 x o -

T 42 … T 72 x - -

• x:Possible• -:Notpossible• o:Order-specific

A reduction in the power of the motor may permit dry well installation under certain circumstances.In this regard, always observed the operating mode specifications for immersed and non-im-mersed operation, as shown on the rating plate.

5.3. Installation

DANGER of falling! When installing the pump and its accessories, work is sometimes performed directly at the edge of the basin or pump chamber. Careless-ness or wearing inappropriate clothing could result in a fall. There is a risk of fatal injury! Take all necessary safety precautions to pre-vent this.

The following information should be taken into considerationwheninstallingthepump:

• Thisworkmustbecarriedoutbyaqualifiedperson and electrical work must be carried out by an electrician.

• The operating space must be clean, free of coarse solids, dry, frost-free and, if necessary, decontaminated. It must also be suitable for the particular pump.

• When working in pump chambers, a second per-son must be present for safety reasons. If there is a risk of poisonous or asphyxiating gases forming, the necessary precautions must be taken.

• Depending on the ambient conditions in opera-tion, the unit consultant must select the chamber size and motor cooling time accordingly.

• Ensurethatliftingequipmentcanbefittedwithout any trouble, since this is required for assembly and removal of the pump. It must be possible to reach the pump safely in its operating and storage locations using the lifting equip-ment.Themachinemustbepositionedonafirmbearing surface. For transporting the pump, the lifting gear must be secured to the lifting eyelets provided or the handle. When using chains, they must be connected with a shackle to the lifting eyelets or the handle. Lifting gear must be tech-nically approved.

• Power supply cables must be laid out in such a way that safe operation and trouble-free as-sembly/dismantling are possible at all times. The pump must never be carried or dragged by the power supply cable. Check whether the cable

present is long enough for its cross-section and its installation type.

• When using switchgear, the corresponding protection class must be observed. In general, switchgearmustbeoverflow-proofandistobeinstalled outside potentially explosive areas.

• When used in an explosive atmosphere, it must be ensured that the pump and all accessories are approved for this purpose.

• Structural components and foundations must be ofsufficientstabilityinordertoallowtheproducttobefixedsecurelyandfunctionally.Theoperatoror the supplier is responsible for the provision of the foundations and their suitability in terms of dimensions, stability and strength!

• Ifthemotorhousingistobetakenoutofthefluidduring operation, the operating mode for non-immersed operation should be followed.To keep dry motors sufficiently cooled when they are not immersed, they must be flooded completely before being switched back on!

• Never let the pump run dry. The water level must never fall below the minimum. Therefore, we recommend installing a level control system or a dry-running protection system where there are great variations in the level.

• Useguideanddeflectorplatesforthefluidintake.If the water jet reaches the surface of the water, airwillbeintroducedintothefluid,whichcanaccumulate in the pipe system. This can result in inadmissible operating conditions and to deacti-vation of the entire system.

• Check that the available design documentation (installation plans, layout of the operating space, intake ratios) is complete and correct.

• Please observe all regulations, rules and legal requirements for working with and underneath heavy suspended loads. Wear appropriate protec-tive clothing/equipment.

• Please also observe the applicable national acci-dent prevention regulations and trade association safety provisions.

5.3.1. Attach lifting gear to the pump

Fig. 2: Attaching lifting gear correctly

1 Pump with one attachment point

2 Pump with two attachment points

Note the following points when attaching the liftinggear:

• Only use authorised lifting gear.• The lifting gear must have a corresponding bear-

ing capacity.• Use 1 or 2-line lifting gear depending on the at-

tachment points on the pump.• The lifting gear must be attached to the pump

using shackles.• Observe the installation and operating instruc-

tions for the lifting gear with regard to permitted use.



5.3.2. Unloading pumps delivered in horizontal posi-tionTo prevent excessive tension and bending forces being applied to the material, pumps are delivered lying horizontally on specially designed transport frames.

Fig. 3: Unloading units

1 Bearing surface

2 Transport frame

3 Hydraulics attachment point

4 Motor attachment point

The following points must be followed when unloadingandtransportingthesepumps:

1. Preparatory tasks• Set the pump and its transport frame down on afirmandhorizontalbearingsurface.

• Attach the 1st piece of lifting gear to the hy-draulics and to the 1st lifting device.

• Attach a 2nd piece of lifting gear to the attach-ment points on the motor and to the 2nd lifting device.

Only use approved straps or transport ropes made of steel as lifting gear. Chains may dam-age the housing parts and will not prevent slippage!

2. Lifting the pump• Slowly lift the pump with both lifting devices.• Make sure that the pump remains horizontal.• Remove the transport frame.

3. Bringing the pump upright• Use the two lifting devices to bring the pump

slowly into a vertical position.• Make sure that the housing parts do not touch

the ground. The minimal bearing surface gives rise to high point loads, which may cause dam-age to the housing parts.

4. Setting the pump down• Once the pump is upright, slowly lower it to the

ground.• The pump can now be prepared for the installa-

tion method to be used.Store the transport frame in a safe place for later transport use.

5.3.3. Maintenance work at initial commissioning or after lengthy storageOn initial commissioning or after a storage period of more than 6 months, the following mainte-nance work must be carried out before installa-tion:

• Rotate impeller• Check oil level in the sealing chamber

Rotate impeller1. Positionthepumphorizontallyonafirmsurface.

Make sure that the pump cannot fall over and/or slip!

2. Carefully and slowly reach into the hydraulics housing from below and rotate the impeller.

BEWARE of sharp edges! Sharp edges can form on the impellers and hydraulic opening. There is a risk of injury! Wear the necessary protective clothing, such as protective gloves.

Oil level check of sealing chamber (Fig. 13)The sealing chamber has either one common hole fordrainingandfillingthechamberortwosepa-rate holes, depending on the motor.

1. Placethepumpuprightonafirmsurface.Make sure that the pump cannot fall over and/or slip!

2. Removetheplasticcover(iffitted)andcarefullyand slowly unscrew screw plug (D/D+).Attention: The operating fluid may be pres-surised!

3. Theoperatingfluidmustreachuptothebottomedge of the hole.

4. If there is not enough oil in the sealing cham-ber, top it up. To do so, follow the instructions under ‘Oil change’ in the ‘Maintenance and repair’ chapter.

5. Clean the screw plug (D/D+), replace the seal ring, if necessary, and screw the plug back in.

6. Pushontheplasticcover(iffitted)andcoatwithan acid-resistant sealant.

5.3.4. Stationary wet well installationA suspension unit must be installed for wet well installation. This must be ordered separately. The pipe system on the pressure side is connected to this.The connected pipe system must be self-supporting, i.e. it may not be supported by the suspension unit.

The operating space must be laid out so that the suspension unit can be installed and operated withoutdifficulty.If the motor should be operated non-immersed, thefollowingspecificationsmustbestrictlyobserved:

• Maximum ambient temperature• Maximumfluidtemperature• Details for ‘Non-immersed operating mode’

The ambient temperature is equivalent to the fluid temperature. For the maximum fluid temperature, refer to the rating plate or the separate data sheet.

56 WILO SE 07-2015 V05 DIN A4


Fig. 4: Stationary wet well installation

1 Suspension unit 6 Lifting gear

2 Non-return valve 7a Min. water level for im-mersed operation

3 Gate valve 7bMin. water level for non-immersed opera-tion

4 Pipe elbow 8 Impact protection plate

5Guide pipe (to be provided by the customer)

9 Inlet

A Minimum distances in parallel operation

W Minimum distances in alternating operation

* The operating mode for non-immersed opera-tion depends on the motor. See the rating plate and the enclosed data sheet.

Work steps1. Installationofthesuspensionunit:about1-2 h

(please see the operating manual for the suspen-sion unit).

2. Preparing the pump for operation on a suspension unit:about<1 h(pleaseseetheinstallationandoperating instructions for the suspension unit).

3. Installingthepump:about1-2 h• Checkthatthesuspensionunitisfirmlyfixed

and functions properly.• Secure the lifting equipment to the pump with

the shackle, lift the pump and then lower slowly on to the guide pipes in the operating space.

• Hold the power supply cables slightly taut when lowering.

• When the pump is connected to the suspension unit, make sure that the power supply cables are secured adequately against falling off and damage.

• Have the electrical connections made by a qualifiedelectrician.

• The pressure connection is sealed by its own weight.

4. Installing optional accessories, such as dry-run-ning protection or level controls.

5. Startingupthepump:about1 h• As described in the ‘Commissioning’ section• Fornewinstallation:Floodtheoperatingspace• Vent the pressure pipe.

5.3.5. Portable wet well installationIn this installation type, the pump has to be equipped with a pump support foot (available as an option). This is attached to the suction port and ensures the minimum ground clearance and a secure footing if placed on a solid bearing sur-face. In this version, the pump can be positioned anywhere in the operating space. If used in an op-erating space with a soft bearing surface, a hard base must be used to prevent sinking. A pressure hose is connected on the pressure side.If operated for longer periods of time in this in-stallation type, the pump must be fastened to the

floor.Thispreventsvibrationandensuresquietand low-wearing running.If the motor should be operated non-immersed, thefollowingspecificationsmustbestrictlyobserved:

• Maximum ambient temperature• Maximumfluidtemperature• Details for ‘Non-immersed operating mode’

The ambient temperature is equivalent to the fluid temperature. For the maximum fluid temperature, refer to the rating plate or the separate data sheet.

BEWARE of burns! The housing parts can heat up to well above 40°C. There is a risk of burns! After switch-ing it off, let the pump cool down to ambient temperature.

Fig. 5: Portable wet well installation

1 Lifting gear 5 Storz hose coupling

2 Pump support foot 6 Pressure hose

3Pipe elbow for hose connection or Storz pipe coupling

7a Min. water level for im-mersed operation

4 Storz pipe coupling 7b Min. water level for non-immersed operation

* The operating mode for non-immersed opera-tion depends on the motor. See the rating plate and the enclosed data sheet.

Work steps1. Preparingpumps:about1 h

• Install the pump support foot on the suction connection.

• Install the pipe elbow on the pressure connec-tion.

• Fasten the pressure hose to the pipe elbow with a hose clip. Alternatively, a Storz pipe coupling can be installed on the pipe elbow and a Storz hose coupling can be installed on the pressure hose.

2. Installingthepump:about1-2 h• Position pump in installation location. If neces-

sary, secure lifting equipment to the pump with a shackle, lift the pump and then lower to the intended location (pump chamber, pit).

• Check that the pump is vertical and on a solid bearing surface. Avoid sinking.

• Route the power supply cable so it cannot be damaged.


• Route the pressure hose so that it is not damaged and fasten it at certain points (e.g. outflow).



RISK of pressure hose becoming separated! Uncontrolled separation or movement of the pressure hose can result in injuries. Secure the pressure hose appropriately. Prevent buckling of the pressure hose.

3. Startingupthepump:about1 h• As described in the ‘Commissioning’ section

5.3.6. Stationary dry well installationIn this installation type, the operating space is di-vided:collectortankandmachineroom.Thefluidis collected in the collector tank and the pump is installed in the machine room. The operating space must be blocked out as per the manufac-turer'sconfigurationorconsultingguide.Thepump is connected to the suction- and pressure-sidepipesystematthespecifiedpointinthemachine room. The pump itself is not immersed inthefluid.The suction- and pressure-side pipe system must be self-supporting, i.e. it may not be supported by the pump. In addition, the pump connection to the pipe system must be free of stress and vibrations. We therefore recommend using elastic connection pieces (compensators).The following values must be strictly observed for drywellinstallation:

• Max.fluidtemperature:see rating plate or data sheet.

• Max.ambienttemperature:40 °C.• Details for ‘Non-immersed operating mode’

The pump is not self-priming so that hydrau-lics housing must be completely filled with the fluid. The minimum level in the collector tank must be at the same height as the upper edge of the hydraulics housing.

BEWARE of burns! The housing parts can heat up to well above 40°C. There is a risk of burns! After switch-ing it off, let the pump cool down to ambient temperature.

Fig. 6: Stationary dry well installation

1 Collector tank 5 Compensator

2 Machine room 6 Pump

3 Gate valve 7 Min. water level

4 Non-return valve 8 Dry-running protection

Work steps1. Installingthepump:about1-2 h

• Checkthatthepipesystemissecuredfirmly.• Secure lifting equipment to the pump with a

shackle, lift the pump and then lower slowly on to the pipe system.

• When lowering the pump, take care of the power supply cables.

• When the pump is resting on the piping, fasten the pump to the pipe system on the suction and pressure sides.

• Route the power supply cables in accordance with local requirements.


2. Installing optional accessories, such as dry-run-ning protection or level controls.

3. Startingupthepump:about1 h• As described in the ‘Commissioning’ section• Open slide valves on suction and pressure sides.• Vent the pressure pipe.

5.3.7. Level control

DANGER due to explosive atmosphere! If the level control is located within a poten-tially explosive area, the signal transmitter must be connected via an Ex cut-off relay or a Zener barrier! These are available as acces-sories.

Fill levels can be determined using the level control system, meaning the pump is switched onandoffautomatically.Thefilllevelcanberecordedusingfloatswitches,pressureandultra-sound measurements or level sensors.Notethefollowinginformation:

• Whenusingfloatswitches,ensurethattheycanmove freely in the operating area!

• The water level must not fall below the minimum!• The maximum switching frequency may not be

exceeded!• Ifthefilllevelsfluctuatestrongly,thenalevel

control should be made on two test points as standard. This means larger differential gaps are reached.

InstallationFor correct installation, please see the installation and operation instructions for the level control device.Observe the information on the maximum switching frequency and the minimum water level!

5.4. Dry-running protectionMake sure that no air enters the hydraulics housing. The pump must therefore always be immersedinthefluiduptothetopedgeofthehydraulic housing. For optimum operational reli-ability, we recommend installing a dry-running protection system.Correctrunningisensuredbyfloatswitchesorlevelsensors.Thefloatswitchorsensorisfixedin the pump chamber and switches off the pump when the water level falls below the minimum water submersion. If dry-running protection is putintoeffectwithonlyonefloaterwhenfilllevelsfluctuatesignificantly,thenthepumpmayturn on and off constantly! This can result in the maximum number of motor activations (switching cycles) being exceeded.

58 WILO SE 07-2015 V05 DIN A4


5.4.1. Remedies for avoiding excessive switching cycles

• Manual reset The motor is switched off when the water level falls below the minimum coverage level and switchedbackonwhenasufficientwaterlevelisreached.

• Separate reactivation point Asecondswitchingpoint(additionalfloaterorelectrode)isusedtoobtainasufficientdifferencebetween the activation and deactivation points. This prevents constant switching. This function can be put into effect with a level control relay.

5.5. Electrical connection

ELECTROCUTION hazard! Incorrect electrical connections can cause fa-tal electric shocks. Electrical connections may only be carried out by a qualified electrician approved by the local energy supply company, in accordance with locally applicable regula-tions.

DANGER due to explosive atmosphere! With Ex-rated pumps, the power supply cable must be connected outside the potentially explosive area, or inside a housing with igni-tion protection conforming to DIN EN 60079-0! Non-observance may lead to fatal injury due to explosion!

• Always have the connection carried out by a qualified electrician.

• Note the additional information about this in the appendix.

• The mains connection current and voltage must be as stated on the rating plate.

• Connect the power supply cable in accordance with the applicable standards and regulations and according to the conductor assignment.

• Any available monitoring equipment, e.g. for thermal motor monitoring, must be connected and tested to ensure that it is working properly.

• For three-phase AC motors, a clockwise rotating fieldmustbeavailable.

• Earth the pump properly. Pumps that are permanently installed must be grounded in compliance with nationally applicable standards. If a separate earth conductor is avail-able, it must be connected to the marked hole or earth terminal (;) using a suitable screw, nut, toothedwasherandflatwasher.Thecrosssectionof the cable for the earth conductor connection must comply with local regulations.

• A motor protection switch must be used for motors with a free cable end. We recommend using a residual-current device (RCD).

• Switchgear must be purchased as accessories.

5.5.1. Mains fusesThe back-up fuse must be rated according to the startingcurrent.Youwillfindthestartingcurrenton the rating plate.

Only slow-blow fuses or K characteristic auto-matic cut-outs may be used as a back-up fuse.

5.5.2. Check the motor winding and the monitoring devices before initial commissioning or after lengthy storageIfthevaluesmeasureddeviatefromthespecifi-cations, moisture may have penetrated into the motor or the power supply cable or the monitor-ing unit may be defective. Do not connect the pump and consult Wilo customer service.

Insulation resistance of the motor windingBefore connecting the power supply cable, the insulation resistance must be tested. This can be measured with an insulation tester (measuring voltage=1000 V):• Oninitialcommissioning:insulationresistancemaynotbelessthan20 MΩ.

• Forfurthermeasurements:valuemustbelargerthan2 MΩ.

Temperature sensor and pencil electrode (avail-able as an option) for sealing chamber controlBefore connecting the monitoring devices, these must be checked with an ohmmeter. The follow-ingvaluesmustbecompliedwith:• Bimetallicstrip:Value=‘0’passage• PTCthermistorsensor:APTCthermistorsensorhasacoldresistanceofbetween20and100 Ω. If there are 3 sensors in series, this results in a valueof60to300 Ω. If there are 4 sensors in series, this results in a valueof80to400 Ω.

• Pt100sensor:Pt100sensorshaveavalueof100 Ωat0 °C.Between0 °Cand100 °C,thisvalueincreasesby0.385 Ωevery1 °C.Atanambienttemperatureof20 °C,theyreachavalueof107.7 Ω.

• Pencilelectrode:Thisvaluemustapproachinfinity.Ifthevalueislow,thereiswaterinthe oil. Also observe the instructions of the optional evaluation relay.

5.5.3. Three-phase AC motorThe three-phase current version is supplied with bare cable ends. The connection to the mains is made at the switchgear.The following list of various connection diagrams only covers the cable assignments available as standard.Fororder-specificversions,aseparateconnection diagram is provided for each order.Please note that the individual wires are desig-nated according to the connection. Do not cut them off! Otherwise, it will no longer be pos-sible to allocate the wires to the connections!

Electrical connections may only be made by a qualified electrician!



Fig. 7: Motor connection diagram in direct starting

U

Mains connectionDK Leakage detection for

motor compartmentV

W PE Earth

Fig. 8: Motor connection diagram in star-delta starting

U1Mains connection; start of winding

U2Mains connection, end of windingV1 V2

W1 W2

PE Earth DK Leakage detection for motor compartment

5.5.4. Connecting the monitoring devicesThe following list of various connection diagrams only covers the cable assignments available as standard.Fororder-specificversions,aseparateconnection diagram is provided for each order.Each monitoring device must always be con-nected!

RISK of fatal injury due to explosive atmos-phere! If the monitors are not connected correctly, there is a risk of fatal injury due to explo-sion if used in potentially explosive areas! Always have the connection carried out by an electrician. If the pump is used in potentially explosive areas:

• the temperature monitor must be connected via an evaluation relay. We recommend the ‘CM-MSS’ relay for this. The threshold is already pre-set.

• Deactivation by the temperature limiter must be conducted with an anti-reactivation device! Reactivation should only be possi-ble if the ‘release button’ has been manually activated!

• The electrode for sealing chamber control must be connected via an intrinsically safe circuit with an evaluation relay! We recom-mend the ‘XR-41x’ relay for this. The thresh-old is 30 kΩ.

• Also note the additional information in the appendix!

Motor/terminal compartment monitoring• The motor/terminal compartment monitor-

ing (moisture sensor) must be connected via an evaluationrelay.Werecommendthe‘NIV 101/A’relayforthis.Thethresholdis30 kΩ. When the threshold is reached, the unit must deactivate.

Motor temperature monitoring• Bimetallic strips must be connected in the

switchgear itself or via an evaluation relay. Connectionvalues:max.250 V(AC),2.5 A,cosφ= 1

• PTC sensors (in accordance with DIN 44082) must be connected via an evaluation relay. We recom-

mend the ‘CM-MSS’ relay for this. The threshold is already pre-set.

• Depending on whether there are one or two tem-perature circuits present, the following triggering status must occur when the threshold value is reached:• Temperaturelimiting(onetemperaturecircuit):

When the threshold is reached, the unit must deactivate.

• Temperature control and limiting (two tem-peraturecircuits):Whenthethresholdforthelow temperature (control) is reached, an ‘early warning’ may be triggered, and when the threshold for the high temperature (limiting) is reached, a ‘deactivation’ must be triggered.

Comply with the information in the appendix regarding use in potentially explosive atmos-pheres!

For this reason, no warranty claims can be ac-cepted for any damage to the winding resulting from unsuitable motor monitoring.

Fig. 9: Bimetallic strip connection diagram

Temperature limiting(one temperature circuit)

Temperature control and limiting(two temperature circuits)

20 Temperature sensor connection

21 High temperature con-nection

21 20 Middle connection

22 Low temperature con-nection

Fig. 10: PTC sensor connection diagram

Temperature limiting(one temperature circuit)

Temperature control and limiting(two temperature circuits)

10 PTC connection (in accordance with DIN 44082)

11 High temperature con-nection

11 10 Middle connection

12 Low temperature con-nection

Sealing chamber monitoring• The sealing chamber is monitored by a pen-

cil electrode. This must be connected via an evaluationrelay.Werecommendthe‘NIV 101/A’relayforthis.Thethresholdis30 kΩ.Whenthethreshold is reached, a warning must be given or the unit switched off.Comply with the information in the appendix regarding use in potentially explosive atmos-pheres!

CAUTION! If there is only a warning, the pump could be irreparably damaged by water ingress. We always recommend switching the pump off!

60 WILO SE 07-2015 V05 DIN A4

English COMMISSIONING

Fig. 11: Connection diagram of electrode for sealing chamber control

DK Electrode

Leakage chamber monitoring• Theleakagechamberismonitoredbyafloat

switch. This is equipped with a potential-free normally closed contact. The switching capac-ity can be found in the particular connection diagram. Whenthefloatswitchistriggered,awarningmust be given or the unit switched off.

Fig. 12: Leakage floater connection diagram

K20Leakagechamberfloatswitch

K21

Temperature monitor for motor bearings• Thermal monitoring of the motor bearings is

performed by Pt100 sensors. These must be con-nected via an evaluation relay. We recommend the ‘DGW 2.01G’relayforthis. Thethresholdis100 °C.Whenthethresholdisreached, the unit must switch off.

5.6. Motor protection and activation types

5.6.1. Motor protectionThe minimum requirement for motors with a free cable end is a thermal relay/motor protection switch with temperature compensation, differ-ential triggering and an anti-reactivation device inaccordancewithVDE 0660ortheappropriatenational regulations.If the pump is connected to electrical systems in which faults frequently occur, we recommend installing additional protective devices provided by the customer (overvoltage, undervoltage or phase failure relays, lightning protection etc.). We also recommend installing a residual-current device (RCD).Local and national regulations must be observed when connecting the pump.

5.6.2. Activation types

Direct activationAt full load, the motor protection should be set to the rated current shown on the rating plate.At partial load, we recommend that the motor protectionbeset5%abovethecurrentmeasuredat the duty point.The rated current must not be exceeded!

Star-delta activationThe motor protection setting depends on the installation:• Motorprotectioninstalledinthemotorline:Setthemotorprotectionto0.58 x theratedcurrent.

• Motor protection installed in the mains supply cable:Setthemotorprotectiontotheratedcurrent.

The maximum start-up time in star connection is 3 seconds.

Soft start activation• At full load, the motor protection should be set to

the rated current at the duty point. At partial load, we recommend that the motor protection be set 5%abovethecurrentmeasuredatthedutypoint.

• The current consumption must be below the rated current throughout the entire operation.

• Due to the upstream motor protection, starting or stopping should be completed within 30 seconds.

• To avoid power dissipation during operation, bypass the electronic starter (soft start) once normal operation is reached.

Pumps with a plugAt full load, the motor protection should be set to the rated current shown on the rating plate. At partial load, we recommend that the motor protectionbeset5%abovethecurrentmeasuredat the duty point.Plugs are not overflow-proof. Observe the information on the protection class (IP). The socket be installed so it is overflow-proof.

5.6.3. Operation with frequency convertersOperation on a frequency converter is possible. Note the information about this in the appendix.

6. CommissioningThe ‘Commissioning’ section contains all the im-portant instructions for the operating personnel for starting up and operating the pump.The following conditions must be adhered to and monitored:

• Type of installation• Operating mode• Minimum water submersion/max. immersion

depthThese general conditions must also be checked after a lengthy period without operation, and any defects detected must be repaired!

Always keep this manual either by the pump or in a place specially reserved for it, where it is ac-cessible for the entire operating personnel at all times.In order to prevent damage or serious injury when commissioning the pump, the following points mustbeobserved:

• Commissioning of the pump may only be carried outbyqualifiedandtrainedpersonnelinaccord-ance with the safety instructions.

• All persons working on or with the pump must have received, read and understood this operating and maintenance manual.

• All safety devices and emergency cut-outs must be connected and checked to ensure that they work properly.


COMMISSIONING English

• Electrical engineering and mechanical adjust-mentsmustbemadebyqualifiedpersonnel.

• Thepumpissuitableforuseunderthespecifiedoperating conditions.

• The work area of the pump is not a recreational area and is to be kept free of people! No persons are allowed in the work area during start-up or operation.

• When working in pump chambers, a second per-son must be present for safety reasons. Adequate ventilation must be ensured if there is danger of poisonous gases forming.

6.1. Electrical systemConnect the pump and install the power supply cables as described in the ‘Installation’ section and in accordance with the VDE guidelines and applicable national regulations.The pump must be properly protected and earthed.Observe the direction of rotation. If the direction of rotation is incorrect, the pump will not perform asspecifiedandmaybedamaged.Make sure all monitoring devices are connected and have been tested.

ELECTRICAL hazard! Electrical current can cause fatal injuries if not handled correctly! All pumps with free cable ends (i.e. without plugs) must be connected by a qualified electrician.

6.2. Rotation controlThe pump is checked and adjusted in the factory to ensure that the direction of rotation is correct. The connection must be made according to the wiring labels.A test run must be performed under general op-erating conditions!

6.2.1. Checking the direction of rotationThe direction of rotation must be checked with a rotatingfieldtesterbyalocalelectrician.Forthecorrect direction of rotation, a clockwise rotating fieldmustbeavailable.The pump is not approved for operation with a counter-clockwise rotating field!

6.2.2. If the direction of rotation is incorrectIf the direction of rotation is incorrect for direct start motors, 2 phases must be swapped. In the case of star-delta motors, the connections of two windings must be swapped, e.g. U1 with V1 and U2 with V2.

6.3. Level controlThe level control device is to be checked to en-sure it is installed properly and the settings of the switching points are to be inspected. For the re-quired information please refer to the installation and operating instructions for the level control device, as well as the consulting documentation.

6.4. Operation in potentially explosive areasIf the pump is labelled accordingly, it can be used inside potentially explosive areas.

RISK of fatal injury due to explosive atmos-phere! Pumps without Ex labelling may not be used in potentially explosive areas! There is a risk of fatal injury due to explosion! Check your pump before use to verify that it has corre-sponding approval:

• Ex symbol• Ex classification, e.g. II 2G EEx d IIB T4• Also note the additional information in the

appendix!

6.5. CommissioningMinor oil leakage in the mechanical shaft seal on delivery is no cause for concern. However, it must beremovedpriortosubmersioninthefluid.Keep out of the pump's work area. No persons are allowed in the work area during start-up or operation.

WARNING: Danger of crushing! In portable installations, the pump can fall over when it is switched on or during opera-tion. Make sure that the pump is positioned on a firm bearing surface and that the pump support foot is mounted correctly.

If the pump falls over, it must be switched off before setting it up again.In the version with a plug, note the plug's IP pro-tection class.

6.5.1. Before switching on

DANGER of fatal injuries from explosions If the slide valves on the suction and pres-sure sides are closed during operation, the fluid in the hydraulics housing is heated up by the pumping movement. This heating creates strong pressure in the hydraulics housing. The pressure can result in the pump exploding. Before switching on the unit, ensure that all the slide valves are open and open any closed slide valves.

Checkthefollowing:• Cable guidance – no loops, slightly taut• Checkthetemperatureofthefluidandtheim-

mersion depth – see technical data• The pump sump is to be cleaned of any coarse

contaminants, especially of solids such as sand/grit, metal and stone

• Clean the pipe system on the pressure side• Open all slide valves on the pressure side• Thefluidmustbepresentatleastuptothesuc-

tion opening of the hydraulics housing.• The pipe system must be vented by suitable

venting devices in the system.• Checktoensureallaccessoriesareproperlyfitted

62 WILO SE 07-2015 V05 DIN A4

English DECOMMISSIONING/DISPOSAL

• Check switching level of level control and dry-running protection systems

6.5.2. Switching on/offThe pump is switched on and off using a sepa-rate operating point (on/off switch, switchgear) provided by the customer.During the start-up procedure, the rated current is temporarily exceeded. After the start-up pro-cedureisfinished,thecurrentmustnotexceedthe rated current again.If the motor does not start up, it must be switched off without delay. Before switching it on again,waitforthespecifiedstartpauseandmakesure to rectify the fault.

6.6. Conduct during operation

DANGER of fatal injuries from explosions If the slide valves on the suction and pres-sure sides are closed during operation, the fluid in the hydraulics housing is heated up by the pumping movement. This heating creates strong pressure in the hydraulics housing. The pressure can result in the pump exploding. Before switching on the unit, ensure that all the slide valves are open and open any closed slide valves.

WARNING: rotating parts! The rotating parts can crush and sever limbs. Never reach into the hydraulics or touch the rotating parts when the machine is in opera-tion.

• Before performing maintenance or repairs, switch off the pump, disconnect it from the mains and secure it against being switched on again without authorization.

• Allow the rotating parts to come to a stand-still!

When operating the pump, always follow the locally applicable laws and regulations for work safety, accident prevention and handling elec-trical machinery. To help ensure safe working practice, the responsibilities of employees should beclearlyspecifiedbytheoperator.Allpersonnelare responsible for ensuring that regulations are observed.The pump is equipped with moving parts. During operation, these parts rotate in order to pump the fluid.Certainsubstancesinthefluidcanresultinvery sharp edges forming on the moving parts.The following must be checked at regular inter-vals:• Operating voltage (permissible deviation +/-5%oftheratedvoltage)

• Frequency(permissibledeviation+/-2%oftherated frequency)

• Current consumption (permissible deviation betweenphasesisamaximumof5%)

• Voltage difference between the individual phases(max.1%)

• Switching frequency (see technical data)

• Airentryintheintake,adeflectorplateshouldbefittedifnecessary

• Minimum water submersion, level control de-vice, dry-running protection

• Smooth running• Gate valves in the inlet and pressure pipes must

be open.

6.6.1. Operation in the limit rangeIfcircumstancesrequireit,thepumpcanbrieflybe operated in the limit range. The following pa-rametersmustbestrictlyobservedinthiscase:• Operating voltage (permissible deviation +/-10%oftheratedvoltage)

• Frequency(permissibledeviation+3%to-5%of the rated frequency)

• Voltage difference between the individual phases(max.1%)

Expect relatively large deviations from the oper-atingdata(seealsoDIN VDE 0530,part1).Continuous duty in the limit range is not recom-mended because the pump is exposed to high wear and thus there is a greater risk of failure!

7. Decommissioning/disposal• All work must be carried out with the greatest

care.• Proper protective clothing is to be worn.• When carrying out work in basins and/or tanks,

the respective local protection measures must be observed in all cases. A second person must be present for safety reasons.

• Only lifting equipment that is in a technically perfect condition and lifting gear that has been officiallyapprovedmaybeusedforloweringandraising the pump.

RISK of fatal injury due to malfunctions! Lifting gear and equipment must be in a perfect technical condition. Work may only commence if the lifting equipment has been checked and found to be in perfect working order. If it is not inspected, fatal injuries may result.

7.1. Temporary decommissioningFor this type of shutdown, the pump remains in-stalled and is not cut off from the electricity sup-ply. In the event of temporary decommissioning the pump must remain completely immersed so that it is protected from frost and ice. Ensure that thetemperatureofthefluidandintheoperatingspacedoesnotfallbelow+3 °C.This ensures that the pump is always ready for operation. For extended downtime, a regular (monthly to quarterly) 5 minute function test should be carried out.

CAUTION! Only perform function runs under the proper operating and usage conditions. Never run the machine dry! This can result in irreparable damage!


MAINTENANCE AND REPAIR English

7.2. Decommissioning for maintenance work or storageThe system must be switched off and the pump must be disconnected from the mains by an electrician and secured against being switched on again without permission. Pumps with plugs must be unplugged (do not pull the cable!). Work on removal, maintenance and storage can then commence.

BEWARE of poisonous substances! Pumps that pump liquids hazardous to health must always be decontaminated before un-dertaking any other work! Otherwise, there is a risk of fatal injury! Wear the necessary physical protection equipment!

BEWARE of burns! The housing parts can heat up to well above 40 °C. There is a risk of burns! After switch-ing it off, let the pump cool down to ambient temperature.

7.2.1. Removal

Portable wet well installationPumps in portable wet well installation can be lifted out of the pit once they have been discon-nected from the mains and the pressure pipe has been drained. It may be necessary to dismantle thehosefirst.Itmaybenecessarytouseasuit-able lifting device.

Stationary wet well installationPumps in stationary wet well installations with a suspension unit are raised out of the pump chamber using the appropriate lifting equipment. During lifting, always hold the power supply cable slightly taut to prevent it being damaged.The operating space does not have to be emptied especially for this purpose. The gate valves in the inlet and in the pressure pipeline must be closed topreventtheoperatingspaceoverflowingorthepressure pipeline being emptied, respectively.

Stationary dry well installationFor pumps in stationary dry well installation, the suction and pressure-side gate valves have to be closedbeforeremoval.Notethatthefluidinthehydraulics housing will escape during removal. Suitable collector tanks should be positioned to collectalloftheescapingfluid.After undoing the screwed connections on the suction and pressure connections, the pump can be removed using suitable lifting equipment. The operating space must be cleaned thoroughly after the pump is removed and any drips must be wiped up.

7.3. Return delivery/storageFor shipping, the parts must be packed in tear-proofplasticbagsofsufficientsizeinsuchamanner that they are tightly sealed and leak-proof.

For return delivery and storage please also refer to the ‘Transport and storage’ section!

7.4. Disposal

7.4.1. Operating fluidOils and lubricants must be collected in appropri-ate containers and properly disposed of in terms of EC Directive 75/439/EEC as well as in compli-ance with the provisions of sections 5a and 5b of the German Waste Act or the applicable local laws.

7.4.2. Protective clothingProtective clothing worn for cleaning and main-tenance work is to be disposed of in accordance with the German Waste Code TA 524 02 and EC Directive 91/689/EEC.

7.4.3. ProductProper disposal of this product avoids damage to the environment and risks to personal health.

• Use the services of public or private waste dis-posal companies, or consult them for the disposal of the product or parts thereof.

• For more information on proper disposal, please contactyourlocalcouncilorwastedisposalofficeor the supplier from whom you purchased the product.

8. Maintenance and repairELECTROCUTION hazard! There is a risk of fatal electric shocks when performing work on electrical devices. With all maintenance or repair work, the pump must be disconnected from the mains and secured against being switched on again without permission. Damage to the power supply cable may only be rectified by a quali-fied electrician.

UNAUTHORISED work could result in fatal injuries! Maintenance and repair work that impairs the safety of Ex protection must only be carried out by the manufacturer or authorised service workshops! Also note the additional information in the appendix!

• Switch off and remove the pump as described in the ‘Decommissioning/disposal’ chapter.

• After maintenance or repair work, the pump must be installed and connected as described in the ‘Installation’ chapter.

• The pump must be switched on as described in the ‘Commissioning’ chapter.Notethefollowing:

• All maintenance and repair work must be carried out by Wilo customer service, authorised service workshops or trained specialists with the greatest

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English MAINTENANCE AND REPAIR

of care and in a safe workplace. Proper protective clothing is to be worn.

• This manual must be available to and observed by the maintenance staff. Only maintenance and repair work described in this manual may be car-ried out.Any other work and/or alterations to the construction must only be carried out by Wilo customer service.

• When carrying out work in basins and/or tanks, the respective local protection measures must be observed in all cases. A second person must be present for safety reasons.

• Only lifting equipment that is in a technically perfect condition and lifting gear that has been officiallyapprovedmaybeusedforloweringandraising the pump. Make sure that the pump does not jam during lifting and lowering. If the pump does jam, no lifting forces greater than 1.2 times the pump weight must be applied. The maxi-mum permissible bearing capacity must never be exceeded!Make sure the lifting gear, wire rope and safety devices of the lifting equipment are in perfect working order. Work may only commence if the lifting equipment has been checked and found to be in perfect working order. If it is not inspected, fatal injuries may result.

• Electrical work on the pump and the system must becarriedoutbyaqualifiedelectrician.Defectivefuses must be replaced immediately. They must neverberepaired.Onlyfusesforthespecifiedelectriccurrentandofthespecifiedtypemaybeused.

• Ifflammablesolventsandcleaningagentsareused,nakedflamesandsmokingareprohibited.

• Pumpsthatcirculatefluidsthatarehazardoustohealthorcomeintocontactwithsuchfluidsmustbe decontaminated. In addition, make sure that no gases that are hazardous to health form or are present.

• Ifinjuriesarecausedbyfluidsorgasesthatarehazardoustohealth,applythefirst-aidmeasuresspecifiedonthenoticeattheworkingpremisesand notify a doctor immediately!

• Operatingfluids(e.g.oils,lubricants,etc.)shouldbe collected in suitable containers and disposed of properly. Also comply with the information in section 7.4 ‘Disposal’!

• Only use genuine parts from the manufacturer.

8.1. Operating fluid

8.1.1. Overview of white oilThesealingchamberisfilledwithwhiteoilthatispotentially biodegradable.When changing the oil, we recommend the fol-lowingoiltypes:

• Aral Autin PL*• Shell ONDINA 919• Esso MARCOL 52* or 82*• BP WHITEMORE WOM 14*

• Texaco Pharmaceutical 30* or 40*All oil types marked with ‘*’ are approved for use with foods in accordance with ‘USDA-H1’.

Filling quantitiesThesealingchamberisalwaysfilleduptothefilleropeningwithwhiteoil.Fortheexactfillingquan-tity,refertotheorder-specifictechnicaldata.

8.1.2. Overview of greaseThe following lubricating grease can be used in accordancewithDIN 51818/NLGlClass3:

• Esso Unirex N3

8.2. Maintenance intervalsTo ensure reliable operation, various maintenance tasks must be carried out regularly.Themaintenanceintervalsmustbespecifiedaccording to the load on the pump. Regardless of thespecifiedmaintenanceintervals,thepumporinstallation must be checked if strong vibrations occur during operation.When used in sewage lifting units inside build-ings or on areas of land, the maintenance inter-vals and work shown in DIN EN 12056‐4 must be adhered to.

8.2.1. Intervals for normal operating conditions

8000 operating hours or after 2 years at the latest

• Visual inspection of the power supply cable• Visual inspection of accessories• Visual inspection of the housing for wear• Functional inspection of all safety and control

devices• Inspection of the switchgear/relays used• Oil change

If using a pencil electrode for sealing chamber control, change the oil according to the indica-tion.

• Empty the leakage chamber• Grease roller bearings• Drain condensation water

Also observe the table ‘Maintenance work depending on the motor used’ on the following page!

15000 operating hours or after 10 years at the latest

• General overhaul

8.2.2. Intervals for harsh operating conditionsUnderharshoperatingconditions,thespecifiedmaintenance intervals must be shortened accord-ingly. In this case, contact Wilo customer service. If using the pump under harsh conditions, we also recommend signing a maintenance contract.Harshoperatingconditionsinclude:

• Alargeproportionoffibrousmaterialorsandinthefluid

• Turbulent inlet (e.g. due to air entry, cavitation)• Stronglycorrosivefluids• Stronglygassingfluids



• Unfavourable duty points• Operation at risk from water hammers

8.2.3. Recommended maintenance measures to en-sure smooth operationWe recommend regular inspections of the current consumption and the operating voltage in all phases. In normal operation, these values remain constant.Slightfluctuationsdependonthechar-acteristicsofthefluid.Thecurrentconsumptioncan provide an early indication of damage and/or malfunctions in the impeller, bearings and/or motor,whichcanberectified.Largervoltagefluc-tuations strain the motor winding and can cause the pump to break down. Regular inspections can therefore largely prevent major secondary damage and reduce the risk of total breakdown. We recommend the use of remote monitoring for regular inspections. Please contact Wilo customer service.

8.3. Maintenance workBeforecarryingoutmaintenancework:

• Disconnect the pump from the power and secure it against being switched on inadvertently.

• Allow the pump to cool down and clean it thor-oughly.

• Immediately wipe up any drips!• Make sure that all the operationally-relevant

parts are in good condition.

8.3.1. Visual inspection of the power supply cableThe power supply cables must be checked for blisters, cracks, scratches, abrasion and/or crush-ing. If any damage is detected, the pump must be decommissioned immediately and the damaged power supply cable must be replaced.The cables may only be replaced by Wilo cus-tomer service or an authorised or certified ser-vice workshop. The pump may only be started

up again once the damage has been properly remedied.

8.3.2. Visual inspection of accessoriesAccessories must be checked to ensure they are properlyfittedandfunctioncorrectly.Looseand/or faulty accessories must be repaired or replaced immediately.

8.3.3. Visual inspection of the housing for wearThe housing parts are not allowed to have any apparent damage. If there is visible damage to housing parts, contact Wilo customer service.

8.3.4. Functional inspection of safety and monitoring devicesMonitoring devices include the temperature sen-sors in the motor, humidity electrodes, overload relay, overvoltage relay, etc.

• Motor protection relays and other triggers can generally be triggered manually for test purposes.

• To check the pencil electrode or the temperature sensor, the pump has to be cooled to the ambient temperature and the electrical connection for the monitoring equipment has to be disconnected in the switchgear. Use an insulation tester (measur-ingvoltage500 V)tochecktheresistanceofthemonitoring device. Thefollowingvaluesshouldbemeasured:• Bimetallicstrip:Value=‘0’passage• PTCthermistorsensor:APTCthermistorsensorhasacoldresistanceofbetween20and100 Ω. If there are 3 sensors in series, this results in a valueof60to300 Ω. If there are 4 sensors in series, this results in a valueof80to400 Ω.

• Pt100sensor:Pt100sensorshaveavalueof100 Ωat0 °C.Between0 °Cand100 °C,thisvalueincreasesby0.385 Ωevery1 °C.Atan

Overview of maintenance work depending on the motor used

Maintenance work

Motor type

T 12 T 13 T 17 T 20 T 20.1 T 24 T 30 T 34 T 42 T 49T 56

T 50T 50.1T 57T 63.1

T 63.2T 72

Visual inspection of the power supply cables ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠Visual inspection of accessories ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠Visual inspection of the housing for wear ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠Functional inspection of all safety and moni-toring devices ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠

Inspection of the switchgear and relays used ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠Oil change ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠ ٠Empty the leakage chamber – – – – ٠ – – – – – ٠ ٠Grease roller bearings – – – – – – – – – – ٠ ٠Drain condensation water – – – – – ٠ ٠ ٠ ٠ ٠ ٠ ٠

Legend- = Maintenance work must not be carried out• = Maintenance work must be carried out

66 WILO SE 07-2015 V05 DIN A4


ambienttemperatureof20 °C,theyreachavalueof107.7 Ω.

• Pencilelectrodeforsealingchambercontrol:Thisvaluemustapproachinfinity.Ifthevalueislowerthan30kΩ,thereiswaterintheoil.Alsoobserve the instructions of the optional evalu-ation relay.

If there are larger deviations, consult the manu-facturer.

8.3.5. Inspection of the switchgear/relays usedSee the relevant installation and operating in-structions for a description of the individual work steps for inspecting the switchgear/relay. Faulty devices must be replaced immediately as they provide no protection to the pump.

8.3.6. Oil change in sealing chamberThe sealing chamber has either one common hole fordrainingandfillingthechamberortwosepa-rate holes, depending on the motor.

RISK of injury from hot and/or pressurised operating fluid! After the pump is switched off, the oil is still hot and pressurised. This can cause the screw plug to be ejected and hot oil to escape. There is a risk of injury or burns! First let the oil cool down to ambient temperature, and always unscrew the screw plug(s) slowly.

Fig. 13: Sealing chamber screw plugs

D Filling and drain hole screw plug

D+ Filler hole screw plug

D- Drain hole screw plug


2. Removetheplasticcover(iffitted)andcarefullyand slowly unscrew screw plug (D or D+).

3. Draintheoperatingfluid,collectinasuitablecontainer and dispose of it in accordance with the requirements in the ‘Disposal’ chapter.

4. Inthecaseofmotorswithseparatefillinganddrainholes,cleanthescrewplug(D-),fititwithanew seal ring and screw it back in.

5. Pourthenewoperatingfluidinthroughtheholefor the screw plug (D or D+). The oil must reach up to the bottom edge of the hole. Note the recommendedoperatingfluids.

6. Clean the screw plug (D or D+), replace the seal ring and screw it back in.

7. Pushontheplasticcovers(iffitted)andcoatwithan acid-resistant sealant.

Note for pumps with shut-off ball cock on the drain hole

Fig. 14: Shut-off ball cock

D* Drain hole with shut-off ball cock

When shut-off ball cocks are used, the screw plug on the ball cock must be removed before operat-ing the lever. The oil is drained by moving the lever on the ball cock.

• Todraintheoperatingfluid,turnthelevertothedirectionofflow(paralleltotheballcock).

• To close the drain hole, turn the lever so it is again atrightanglestothedirectionofflow(totheshut-off ball cock).To ensure the ball cock is tight, the screw plug must be screwed in again!

8.3.7. Motors T 50, T 50.1, T 57, T 63.1, T 63.2, T 72: Emptying the leakage chamber

Fig. 15: Leakage chamber screw plugs

L Venting screw plug (onlyT 50,T 50.1,T 57,T 63.1)

L- Drain hole screw plug


2. Removetheplasticcover(iffitted)andcarefullyand slowly unscrew screw plug(s) (L and L-).

3. Drainthefluid,collectinasuitablecontaineranddispose of it in accordance with the requirements in the ‘Disposal’ chapter.

4. Clean the screw plug(s) (L and L-), replace the seal ring and screw back in.

5. Pushontheplasticcover(iffitted)andcoatwithan acid-resistant sealant.

8.3.8. Motors T 50, T 50.1, T 57, T 63.1, T 63.2, T 72: Greasing roller bearings

Fig. 16: Grease nipples

F Venting screw plug (onlyT 50,T 50.1,T 57,T 63.1)

F+ Grease nipple

L- Leakage chamber screw plug

1. Removethescrewplugs:• On motors T 50, T 50.1, T 57, T 63.1 the screw

plugs F and F+ must be removed.• On motors T 63.2 and T 72 the screw plugs F+

and L- must be removed.2. The relevantgreasenippleforlubricatingthe

bearings is located behind the screw plug F+.3. Use a grease gun to inject the new grease into

the grease nipples (F+). The following quantities shouldbeused:• MotorT 50,T 50.1,T 57,T 63.1,T 63.2: Lowerrollerbearings:200 g



• MotorT 72: Upperrollerbearings:20 g Lowerrollerbearings:160 g

4. Clean the grease nipples and screw the screw plug(s) (F and F+) back in.

8.3.9. T 24 … T 72: Draining condensation water

Fig. 17: Condensation water screw plug

S- Drainage screw for condensation water

1. Remove the screw plug (S-).2. The condensation water will drain out by gravity

and must be collected in a container.3. Clean the screw plug (S-), replace the seal ring

and screw it back in.

8.3.10. General overhaulIn a general overhaul, the normal maintenance work is carried out and in addition the motor bearings, shaft seals, O-rings and power supply cables are checked and replaced, if necessary. This work may be performed only by the manu-facturer or an authorised service workshop.

8.4. Repairs

DANGER due to toxic substances! Pumps that pump liquids hazardous to health must always be decontaminated before un-dertaking any other work! Otherwise, there is a risk of fatal injury! Wear the necessary physical protection equipment!

BEWARE of sharp edges! Sharp edges can form on the impellers and hydraulic opening. There is a risk of injury! Wear the necessary protective clothing, such as protective gloves.

Beforecarryingoutrepairs:• Disconnect the pump from the power supply,

secure it against being switched on inadvertently and allow the pump to cool down.

• Dismantle the pump according to the chapter ‘Removal’ and clean it thoroughly, particularly the hydraulics. Immediately wipe up any drips!

• Make sure that all the operationally-relevant parts are in good condition.

• Always replace O-rings, seals and screw locking devices (spring lock washers, Nord-Lock wash-ers).

• Thespecifiedtighteningtorquesmustbecom-plied with.

• Never use force when carrying out this work!

8.4.1. Use of screw lockingScrew locking is used on all screws. This must always be renewed after disassembly.The screw locking can be applied in different ways:

• Liquid screw locking compound, e.g. Loctite 243• Mechanical screw locking with Nord-Lock washer

Liquid screw locking compoundLiquid screw locking compound can be unfas-tened by applying increased force. If this is not possible, the connection must be heated to about300 °Cinordertobereleased.Theaffectedcomponents must be thoroughly cleaned and, on assembly, once again have the screw locking compound applied to them.

Mechanical screw lockingThe Nord-Lock washer is only used on bolts with strength class 10.9 which have been coated with Geomet.The Nord-Lock washer must not be used for screw locking with stainless screws!

8.4.2. Which repair work is allowed to be performed?• Impeller change• Change of hydraulics• Readjust the suction port of half open SOLID

impellers (G-impeller)

8.4.3. Hydraulics and impeller changeThere are 2 different dismantling variants, de-pendingontheimpellergeometry:• In variant 1, the hydraulics must always be

removed in order to change the impeller.• In variant 2, the impeller can be dismantled

separately. The impeller must be dismantled in order for the hydraulics to be changed.

Variant 1: Hydraulics and impeller change

Fig. 18: Component overview

1 Hexagon nuts for hy-draulics attachment 3 Impeller

2 Hydraulics 4 Impeller fastening screw


2. Unscrew the hexagon nuts (1) for fastening the hydraulics on the sealing or bearing housing.

3. Secure the hydraulics (2) with suitable means and pull the motor with impeller up and off. If neces-sary, use suitable lifting equipment with adequate bearing capacity!

4. Placethemotorhorizontallyonafirmsurfaceandsecure it against slipping.

5. Secure the impeller (3) with suitable means, un-screw and remove the fastening screw (4).Observe the screw locking!

6. Pull the impeller (3) off the shaft with a suitable puller.

7. Clean the shaft.8. Push a new impeller onto the shaft.

Make sure that the sliding surfaces are not damaged!

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9. Apply new screw locking to a new fastening screw (4) and screw it back in. Secure the impeller and tighten the fastening screw tightly.

10. Lift the motor with impeller and swivel it over the hydraulics. If necessary, use suitable lifting equip-ment with adequate bearing capacity!

11. Slowly lower the motor onto the hydraulics and secure the hydraulics again with the hexagon nuts (1).

12. Test:Itmustbepossibletoturntheimpellerbyhand.

Variant 2: Impeller change1. Positionthepumphorizontallyonafirmsurface.

Make sure that the pump cannot fall over and/or slip!

2. Unscrew the fastening screws of the suction port on the hydraulics.

3. Remove the suction port and place it on secure surface.

4. Secure the impeller with suitable means, unscrew and remove the fastening screw.Observe the screw locking!

5. Pull the impeller off the shaft with a suitable puller.

6. Clean the shaft.7. Push a new impeller onto the shaft.

Make sure that the sliding surfaces are not damaged!

8. Apply new screw locking to a new fastening screw and screw it back in. Secure the impeller and tighten the fastening screw tightly.

9. Mount the suction port on the hydraulics and screw it on with the fastening screws.

Variant 2: Change of hydraulicsTheimpellermustfirstbedismantledinorderforthe hydraulics to be changed, and the suction port reinstalled!


2. Unscrew the hexagon nuts for fastening the hy-draulics on the sealing or bearing housing.

3. Secure the hydraulics with suitable means and pull the motor up and off. If necessary, use suit-able lifting equipment with adequate bearing capacity!

4. Swivel the motor over the new hydraulics. If necessary, use suitable lifting equipment with adequate bearing capacity!

5. Slowly lower the motor onto the hydraulics and secure the hydraulics again with the hexagon nuts (1).

6. Now reinstall the impeller.7. Test:Itmustbepossibletoturntheimpellerby

hand.

8.4.4. Readjusting the suction port of half open SOLID impellers

Fig. 19: Component overview

1 Hexagonnutsforfixationofthesuctionport

2 Threaded bolt

3 Fastening screws for the laminated cores

4 Laminated cores

5 Gap between suction port and hydraulics housing

Version for wet well installation1. Secure lifting equipment to the pump with ap-

proved lifting gear (sling).2. Lift the pump so that it is suspended freely above

the ground.Danger due to suspended load! The pump is only suspended via the lifting equipment during work. Before starting work, check to ensure the lifting equipment does not have any technical flaws and that it exhibits sufficient load-bearing capacity!

3. Loosen the hexagon nuts that are used to secure the suction port. Unscrew these until the hexagon nutsareflushwiththethreadedbolt.Warning: Danger of crushing! The suction port can stick due to encrustations on the hydraulics housing and slide down sud-denly. Loosen the nuts in a crosswise manner, grasp the nuts from the bottom only and wear protective gloves!

4. The suction port should slide down by loosening the nuts. If this is not the case, loosen it with a wedge.

5. Clean the sliding surface and the screwed-on laminated cores.Warning of toxic substances! The pump has been used in sewage. Collect the cleaning water in a suitable container and dis-pose of it in the sewer system! Wear protective goggles and protective gloves!

6. Loosen the screws from the laminated cores and remove the individual laminated cores.

7. Slowly re-tighten the three hexagon nuts cross-wise until the suction port is in contact with the impeller.Caution! Only tighten the hexagon nuts by hand! If these are excessively tightened, it can result in dam-age to the impeller and the motor bearings!

8. Measure the gap between the suction port and hydraulics housing.

9. Adjust the laminated cores according to the measured dimension and add another lamination.

10. Unscrew the three hexagon nuts again until they areflushwiththethreadedboltoncemore.


TROUBLESHOOTING AND POSSIBLE SOLUTIONS English

11. Insert the individual laminated cores again and re-tighten the fastening screws for the laminated cores.

12. Tighten the hexagon nuts crosswise until the suctionportisflushwiththelaminatedcores.

13. Firmly tighten the hexagon nuts crosswise. Observethetighteningtorquesspecifiedintheappendix here!

14. Reach into the suction port from below and rotate the impeller. If the gap has been set correctly, the impeller must be able to be rotated.Warning: Danger of amputation of limbs! Sharp edges may have formed on the suction port and impeller. Wear the appropriate protec-tive gloves!

15. Reinstall the pump according to the instructions in the ‘Installation’ chapter.

Version for dry well installationThe individual steps are the same as for wet well installation. However, the pump does not necessarily have to be dismantled here. If the gap develops with a built-in pump, the following must beobserved:

• The pressure connection must be completely released!

• When the hexagon nuts on the suction port have been released, the pump must be lifted slowly and carefully.Beware of material damage! If the pump is lifted too quickly, the suction port can be pulled off. The pump would then no longer be of use! If the pump is drained too quickly (without laminated cores), the impeller may be damaged! Exercise special care when performing any work with the lifting equipment!

9. Troubleshooting and possible solutionsIn order to prevent damage or serious injury while rectifying pump faults, the following points must beobserved:

• Only attempt to rectify a fault if you have quali-fiedstaff.Thismeansthateachjobmustbecar-ried out by trained specialist staff. For example, electrical work must be performed by a trained electrician.

• Always secure the pump against an accidental restart by disconnecting it from the mains. Take appropriate safety precautions.

• Always have a second person on hand to ensure the pump is switched off in an emergency.

• Secure moving parts to prevent injury.• Unsanctioned changes to the pump are made at

the operator's own risk and release the manufac-turer from any warranty obligations.

Fault: The unit will not start1. Electricity supply interrupted, short-circuit or

earth fault in the cable and/or motor winding• Have the motor and wires checked by a special-

ist and replaced if necessary2. Fuses, the motor protection switch and/or moni-

toring devices are triggered• Have a specialist inspect the connections and

correct them as necessary.• Have the motor protection switches and fuses

installed or adjusted according to the technical specifications,andresetmonitoringequip-ment.

• Check that the impeller runs freely. If necessary clean it and ensure it runs freely again

3. The sealing chamber control (optional) has inter-rupted the electric circuit (operator-related)• Seefault:Mechanicalsealleaks,sealingcham-

ber control reports a fault or switches the pump off

Fault: The unit starts, but the motor protection switch triggers shortly after commissioning

1. The thermal trigger on the motor protection switch is incorrectly set• Have a specialist compare the setting of the triggerwiththetechnicalspecificationsandcorrect it as necessary

2. Increased power consumption due to major volt-age drop• Have an electrician check the voltage on each

phase and rewire if necessary3. Two-phase operation

• Have a specialist inspect the connection and correct it as necessary

4. Excessive voltage differences on the three phases• Have a specialist inspect the connection and

the switching system and correct as necessary5. Incorrect direction of rotation

• Swap the 2 phases of the mains supply6. Impeller slowed by accumulation, clogging and/or

solid matter, increased current consumption• Switch off the pump, secure it against being

switched back on again and free the impeller or clear the suction port

7. Thefluidistoodense• Contact the manufacturer

Fault: Unit is running but not pumping1. Nofluidavailable

• Open inlet for tank or slide valve2. Intake blocked

• Clean the supply line, slide valve, suction piece, suction port or suction strainer

3. Impeller blocked or slowed• Switch off the pump, secure it against being

switched back on again and free the impeller4. Faulty hose/piping

• Replace defective parts5. Intermittent operation

• Check switching system

70 WILO SE 07-2015 V05 DIN A4

English APPENDIX

Fault: The unit runs, but not within the specified operating parameters

1. Intake blocked• Clean the supply line, slide valve, suction piece,

suction port or suction strainer2. Slide valve in the pressure pipe shut

• Fully open the slide valve3. Impeller blocked or slowed

• Switch off the pump, secure it against being switched back on again and free the impeller

4. Incorrect direction of rotation• Replace two phases on the mains supply

5. Air in the system• Check the pipelines, pressure shroud and/or

hydraulics, and vent if necessary6. Pump pumping against excessive pressure

• Check the slide valve in the pressure pipe and open it completely if necessary, use a different impeller, consult the plant

7. Signs of wear• Replace worn parts

8. Faulty hose/piping• Replace defective parts

9. Inadmissiblelevelsofgasinthefluid• Contact the manufacturer

10. Two-phase operation• Have a specialist inspect the connection and

correct it as necessary11. Excessive decrease in the water table during

operation• Check the supply and capacity of the system,

and inspect the level control settings and functionality

Fault: The unit does not run smoothly and is noisy

1. Pump is operating in an inadmissible range• Check the operational data of the pump and

correct if necessary and/or adjust the operating conditions

2. Suction port, suction strainer and/or impeller clogged• Clean the suction port, suction strainer and/or

impeller3. Impeller stiff

• Switch off the pump, secure it against being switched back on again and free the impeller

4. Inadmissiblelevelsofgasinthefluid• Contact the manufacturer

5. Two-phase operation• Have a specialist inspect the connection and

correct it as necessary6. Incorrect direction of rotation

• Replace two phases on the mains supply7. Signs of wear

• Replace worn parts8. Defective motor bearing

• Contact the manufacturer9. Pump is installed under tension

• Check installation, use expansion joints if necessary

Fault: Mechanical shaft seal leak, sealing cham-ber control reports a fault or shuts down the unit

1. Condensation build-up due to extended storage and/ortemperaturefluctuations• Operatethepumpbriefly(max.5min.)without

pencil electrode2. Increased leakage when running in new mechani-

cal shaft seals• Change the oil

3. Defective pencil electrode cables• Replace pencil electrode

4. Mechanical shaft seal is defective• Replace the mechanical shaft seal and contact

the manufacturer!

Further steps for troubleshootingIf the points listed here do not rectify the fault, contact Wilo customer service. They can help you asfollows:

• Telephone and/or written support from Wilo customer service

• On-site support from Wilo customer service• Inspection or repair of the pump at the factory

Please note that you may be charged for some services provided by our customer service. For more details, please contact Wilo customer service.

10. Appendix

10.1. Tightening torques

Rust-free screws (A2/A4)

ThreadTightening torque

Nm kp m

M5 5.5 0.56

M6 7.5 0.76

M8 18.5 1.89

M10 37 3.77

M12 57 5.81

M16 135 13.76

M20 230 23.45

M24 285 29.05

M27 415 42.30

M30 565 57.59

Geomet-coated screws (strength 10.9) with Nord-Lock washer


Nm kp m

M5 9.2 0.94

M6 15 1.53

M8 36.8 3.75

M10 73.6 7.50


APPENDIX English

Geomet-coated screws (strength 10.9) with Nord-Lock washer


Nm kp m

M12 126.5 12.90

M16 155 15.84

M20 265 27.08

10.2. Operation with frequency convertersAnystandardmotorconformingtoIEC 60034-17can be used. If the rated voltage is above 415 V/50 Hzor480 V/60 Hz,youmustconsultthe manufacturer. Because of the additional heating caused by harmonics, the rated power of themotorshouldbearound10%morethanthepower requirement of the pump. For frequency converters with a low-harmonic output, it may be possibletoreducethe10%powerreserve.Thisisnormallydonebyusingoutputfilters.Further-more, the standard motors are not equipped with shielded cables. The frequency converter andfiltermustbesynchronizedwitheachother.Ask the manufacturer.

Theconfigurationofthefrequencyconverterde-pends on the rated motor current. Make sure that the pump operates without jerking or vibrating, especially in the lower speed range. Otherwise, the mechanical shaft seals could be damaged and startleaking.Youmustalsoconsidertheflowrateinthepipe.Theslowertheflowrate,thegreaterthe risk of solids depositing in the pump and pip-ing. We recommend complying with a minimum flowrateof0.7 m/satapumpingpressureof0.4 bar.

It is important that the pump operates across the entire control range without vibrations, resonance, oscillation or excessive noise (ask the manufacturer if necessary). Increased motor noise caused by the harmonics of the power supply is normal.Whenconfiguringthefrequencyconverter,always make sure the quadratic curve (U/F pump curve) for pumps and fans is correctly set! This ensures that the output voltage at frequencies lessthantheratedfrequency(50 Hzor60 Hz)isadjusted to the power requirement of the pump. Newer frequency converters feature an automatic power optimization function which achieves the same effect. For the frequency converter set-ting, please refer to its installation and operating instructions.

Faults with the motor monitor may occur on mo-tors fed by a frequency converter depending on the type used and installation conditions present. The following general measures could help to reduceoravoidfaults:

• Keeping within the thresholds stated in IEC 60034-17forthevoltagepeaksandrisespeed(outputfiltersmaybenecessary).

• Varying the pulse frequency of the frequency converter.

• Using our external double pencil electrode for faults with the sealing chamber monitor.The following construction measures could also helptoreduceorpreventfaults:

• Separate power supply cables for the main and control cable (depending on the motor size).

• Adequate clearance between the main and con-trol cable.

• Using shielded power cables.

Summary• Continuous operation up to rated frequency (50 Hzor60 Hz),observingthemin.flowrate

• Consider additional measures with regard to EMC (choiceoffrequencyconverter,usingfilters,etc.).

• Never exceed the rated current or rated speed of the motor.

• It must be possible to connect the motor’s own temperature monitor (bimetallic strip or PTC sen-sor).

10.3. Ex-approvalThis section contains special information for owners and operators of pumps which have been builtandcertifiedforuseinenvironmentswhereexplosions may occur.It expands on and therefore supplements the standard instructions for these pumps. It also expands on and supplements the ‘General safety information’ section and must be read and fully understood by all users and operators of the pump.This section applies only to Ex-rated pumps and contains additional instructions for these pumps!

10.3.1. Identification of Ex-rated pumpsPumps that have been approved for use in an explosive atmosphere are be marked as follows on theratingplate:

• ‘Ex’ symbol of the corresponding approval• InformationonExclassification• Certificationnumber

10.3.2. ATEX approvalThemotorsarecertifiedforuseinpotentiallyexplosive areas in accordance with EC direc-tive 94/09/EC,whichrequiresdevicegroupII,category 2.The motors can be used in both zone 1 and zone 2.These motors may not be used in zone 0!

Non-electrical devices (e.g. hydraulics) also com-ply with EC directive 94/09/EC.

ATEX classificationTheExclassification,forexample,II 2G Ex de IIB T4Gbontheratingplateindicatesthefollowing:

• II = device group• 2G = device category (2 = suitable for zone 1, G =

gas, vapour and mist)

72 WILO SE 07-2015 V05 DIN A4

English APPENDIX

• Ex = explosion-protected device complying to Euro norm

• d=ignitionprotectiontypeformotorcasing:Pressure-resistant encapsulation

• e=ignitionprotectionforterminals:Increasedsafety

• II = intended for places where explosions may oc-cur, with the exception of mines

• B = intended for use with gases in sub-group B (all gases excluding hydrogen, acetylene, carbon disulphide)

• T4 = Max. surface temperature of the device is 135 °C

• Gb = device protection level ‘b’

‘Pressure-resistant encapsulation’ protection classMotors in this protection type must be equipped with a temperature limit.

Certification numberThecertificationnumberoftheapprovalislo-catedontheratingplate,inyourorderconfirma-tion as well as on the technical data sheet.

10.3.3. Electrical connection

ELECTROCUTION hazard! Incorrect electrical connections can cause fa-tal electric shocks. Electrical connections may only be carried out by a qualified electrician approved by the local energy supply company, in accordance with locally applicable regula-tions.

In addition to the information in the ‘Electrical connection’ section, the following points must be observedforEx-ratedpumps:

• The power supply cable must be connected outside the potentially explosive area, or inside a housing with ignition protection conforming to DIN EN 60079-0!

• The following voltage tolerances must be com-pliedwith:• T 12…T 34:±10%• T 42…T 56:±5%

• All monitoring devices outside the ‘spark-proof areas’ must be connected via an ex-rated cut-off relay.

‘Motor/terminal compartment monitoring’ con-nectionThe connection is made as described in the ‘Elec-trical connection’ section.

‘Motor temperature monitoring’ connectionThemotormustbefittedwith1-circuittempera-ture monitoring (limit function only). Themotorcanoptionallybefittedwith2-circuittemperature monitoring (temperature control and limit function).

RISK of fatal injury due to incorrect connec-tion! Risk of explosion due to overheating of the motor! The temperature monitoring device must be connected in such a way that, when triggered, it can only be restarted after the ‘release button’ has been activated manually!

In 2-circuit temperature monitoring, automatic restarting can be implemented via the tempera-ture control. This requires compliance with the specificationsformax.switchingfrequencyandswitching break as stated in the technical data.

• Bimetallic strips must be connected via an evalu-ation relay. We recommend the ‘CM-MSS’ relay for this. The threshold is already pre-set. Connectionvalues:max.250 V(AC),2.5 A,cosφ= 1

• PTC sensors (in accordance with DIN 44082) must be connected via an evaluation relay. We recom-mend the ‘CM-MSS’ relay for this. The threshold is already pre-set.When the threshold for temperature control is reached, deactivation may be triggered, and when the threshold for the temperature limit is reached, deactivation must be triggered.

‘Sealing chamber control’ connection• The pencil electrode must be connected via an

Ex-rated evaluation relay! We recommend the ‘XR-41x’relayforthis.Thethresholdis30 kΩ.

• The connection must be made using an intrinsi-cally safe electric circuit!

‘Leakage chamber monitoring’ connectionTheleakagechamberismonitoredbyafloatswitch. This is equipped with a potential-free normally closed contact. The switching capac-ity can be found in the particular connection diagram. Thefloatswitchmustbeconnectedviaanevalu-ation relay! We recommend the ‘CM-MSS’ relay for this. The threshold is already pre-set. When thefloatswitchistriggered,awarningmustbegiven or the unit switched off.‘Motor bearing temperature monitoring’ con-nectionFor design reasons, monitoring of the motor bearing temperature is possible only on some motors. Please see the separate data sheet for the connection.

Frequency converter operation• Continuous operation up to rated frequency (50 Hzor60 Hz),observingthemin.flowrate

• Consider additional measures with regard to EMC (choice of frequency converter, using filters,etc.).

• Never exceed the rated current or rated speed of the motor.

• It must be possible to connect the motor’s own temperature monitor (bimetallic strip or PTC sensor).


APPENDIX English

10.3.4. Commissioning

RISK of fatal injury due to explosion! Pumps without Ex labelling may not be used in potentially explosive areas! There is a risk of fatal injury due to explosion! Observe the following when using the pump in explosion hazard areas:

• The pump must be approved for use in poten-tially explosive areas!

• The power supply cable must be connected outside the potentially explosive area, or inside a housing with ignition protection con-forming to DIN EN 60079-0!

• Switchgears must be installed outside the potentially explosive area, or inside a hous-ing with ignition protection conforming to DIN EN 60079-0! Furthermore, these must be configured for operation of pumps with explo-sion approval.

DANGER of explosion! The housing of the hydraulics must be fully flooded (completely filled with the fluid) dur-ing operation. If the housing is not immersed or there is air in the hydraulics, flying sparks may cause an explosion, for example due to static charge! Ensure that dry-running pro-tection is in place for switching off.

In addition to the information in the ‘Commis-sioning’ section, note the following points for Ex-ratedpumps:

• Theoperatorisresponsiblefordefiningthepo-tentially explosive area. Only pumps with Ex ap-proval may be used within a potentially explosive area.

• Ex-ratedpumpsmustbeidentifiedaccordingly.

10.3.5. Maintenance and repair

ELECTROCUTION hazard! There is a risk of fatal electric shocks when performing work on electrical devices. With all maintenance or repair work, the pump must be disconnected from the mains and secured against being switched on again without permission. Damage to the power supply cable may only be rectified by a quali-fied electrician.

In addition to the information in the ‘Maintenance and repair’ section, note the following points for Ex-ratedpumps:

• The maintenance and repair work described in this operating and maintenance manual must be carried out properly.

• Repairs and alterations to the construction which are not listed in this operating and maintenance handbook or which may impair explosion protec-tion may only be performed by the manufacturer orbyservicedealerscertifiedbythemanufac-turer.

• The spark-proof gaps may only be repaired according to the manufacturer’s design speci-fications.Itisnotpermittedtocarryoutrepairsaccording to the values in tables 1 and 2 of DIN EN 60079-1.

• Only the plugs stipulated by the manufacturer, fulfillingatleastastrengthcategoryof600 N/mm²,maybeused.

Change of the seal on the fluid sideThe following table lists the motors in which the sealonthefluidsidecanberenewedwithoutimpairing the explosion protection.

Overview for seal change

Motor type Mechanical seal Cartridge seal

T 12 • -

T 13 • -

T 17 • -

T 20 • •

T 20.1 • o

T 24 - •

T 30 - •

T 34 - •

T 42 • -

T 50, T 50.1 • -

T 56 • -

Legend- = Not applicable or change not possible without endangering explosion protection!• = Change possible without endangering explo-sion protection.o = Change of cartridge possible, rotary shaft seal cannot be removed!

Cable changesCable changes are strictly prohibited and may only be carried out by the manufacturer or by servicecentrescertifiedbythemanufacturer.

10.4. Spare partsSpare parts can be ordered from Wilo customer service. To avoid return queries and incorrect or-ders, the serial and/or article number must always be supplied.

Subject to change without prior notice!

Pioneering for You

WILO SENortkirchenstraße 10044263 DortmundGermanyT +49 (0)231 4102-0F +49 (0)231 [email protected]

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