15.Cat c2 0809 Int Screen

Submersible Pumps andAccessories for Building Engineering / Building Services,for Municipal and Industrial Applications

Catalogue Drainage and Sewage

Sewage PumpsDN 32 to DN 800

Catalogue C2 - 50 Hz - 2009 C2

Wilo-DrainLift L

C3

2

Wilo-Comfort-VarioCOR-3/MHIE VR

B4

3

Wilo-Economy CO-1 MVI/ER

B4

4

Wilo-Stratos-D

A1

5

Wilo-CronoLine-IL-E

A2

6

Wilo-CronoLine-IL-E

A2

6

Wilo-CronoBloc-BL

A3

7

Wilo-Stratos

A1

8

Wilo-CronoLine-IL

A2

9

Wilo-Drain TP 80

C2

10

Wilo-VeroNorm-NP

A3

11

Wilo-Comfort-VarioCOR-4/MVIE VR

B4

12

Wilo-Economy MHI

B3

13

Wilo-Comfort-VarioCOR-1 MVIE/GE

B4

14

2

7

7

8

10

11

14

1312

6

6

543

9

9

1 Series Catalogue

Wilo-Sub TWU 8

B2

1

7

1

2 3

5

4

6

89

10

12 11

Wilo-EMU KM

B2

1

Wilo-ASP

A3

2

Wilo-VeroNorm-NPG

A3

3

Wilo-ComfortCOR-6 MVI/CC

B4

Wilo-EMUPORT

on request

5

Wilo-DrainLift WS

C3

6

Wilo-VeroNorm-NPG

A3

3

Wilo-EMUFA 08.52

C2

7

Wilo-EMUMegaprop TR 325

C4

8

Wilo-EMU RZP

C4

9

Wilo-EMU FA

C2

10

Wilo-EMU KPR

C2

11

Wilo-CC-System

A1-A3, B4

12

Series Catalogue

4

Programme overview and fields of applications

Sewage pumps

Pump type Version Main field of application

Free

ball

pass

age

[mm

]

Mac

erat

or

Dry

wel

lins

talla

tion

Page

Submersible pumps with macerator - standard range

/ Wilo-Drain MTC 32, 40 S/M/C S/M/C 50/ Wilo-Drain MTS 40 S/M/C S/M/C 66

Submersible pumps without macerator - standard range

Wilo-Drain TC 40 35 S/M/C S/M/C S/M/C2) 84

/ Wilo-Drain STS 40 40 S/M/C S/M/C S/M/C1) C 91Wilo-Drain STS 65 65 M/C M/C M/C1) C 98Wilo-Drain TP 50 44 S/M/C S/M/C S/M/C1) 118

Wilo-Drain TP 65 44 M/C M/C S/M/C1) 118

/ Wilo-EMU FA 35 100 M/C M/C M/C C 144

Submersible pumps without macerator- configured range

/ Wilo-EMU FA 05 to FA 15 35 130 S/M/C S/M/C S/M/C C 308Wilo-EMU FA 20 to FA 25 80 200 M/C M/C M/C C 428Wilo-EMU FA 30 to FA 60 80 170 C C C C 468

Pumps for special applications

/ Wilo-Drain TP 80 80 M/C M/C M/C C M/C 512/ Wilo-Drain TP 100 80 95 M/C M/C M/C C M/C 512

Wilo-EMU FAWR 23 58 C C C 540

Wilo-EMU FARF 35 45 C C C C 572

Wilo-EMU KPR 85 130 C C C 584

Key:

/ New in the programme or series extensionor modification

1) Not within the scope of DIN EN 12050-12) Not within the scope of EN 12050-1 Can be used / applicable- Cannot be used / not applicableS Single- and two-family housesM Multi-family houseC Commercial

Wastewater/drainage Production sewage

Wastewater/coarse contaminantsCondensateCalorific value/air-cond. devices

Sewage/faeces

Drainage of buildings.Unique macerator.

Breaks up solid matter.Reliable, clean and energy-saving.

Wilo-Drain MTS 40.

The Wilo-Drain MTS 40 submersible pump is equipped with a modern, patented stainlesssteel macerator. This breaks up solid constituents to a size small enough to pass even smallest pipe cross-sections: this is perfect for pressurised drainage - especially over long distances. The stainless steel motor housing, the longitudinal watertight cable feed and the sturdy motor cable guarantee a long service life: even under extreme conditions. Powerful? We call it Pumpen Intelligenz.

www.wilo.com

3Contents

Wilo Catalogue C2 - 50 Hz - Sewage pumps DN 32 to DN 800

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General notes and abbreviations 6

Planning guide 8

Sewage pumps - standard range 48

Submersible pumps with maceratorSubmersible pumps without macerator

Sewage pumps - configured range 306

Submersible pumps from DN 50 to DN 150Submersible pumps from DN 200 to DN 250Submersible pumps from DN 300 to DN 600

Sewage pumps for special applications 508

Submersible pumps for industrial sewageSubmersible pumps with mechanical stirring apparatusSubmersible pumps made of cast stainless steelPropeller pumps for use in pipe sumps

Accessories 606

Electrical accessories

4 Subject to change 09/2008 WILO SE

Sewage pumps DN 32 to DN 800Contents

Sewage pumps - standard range

Submersible pumps with macerator Series overview 48

Wilo-Drain MTC 40, MTC 32 50

Wilo-Drain MTS 40 66

Submersible pumps without macerator Series overview 80

Wilo-Drain TC 40 84

Wilo-Drain STS 40 91

Wilo-Drain STS 65 98

Wilo-Drain TP 50 / TP 65 118

Wilo-EMU FA 05... - FA 15... 144

Sewage pumps - configured range

Submersible pumps without macerator Series overview 306

Wilo-EMU FA 05 - 15 308

Wilo-EMU FA 20 - 25 428

Wilo-EMU FA 30 - 60 468

Special pumps

Submersible pump for specialapplications

Series overview 508

Wilo-Drain TP 80... / TP 100... 512

Wilo-EMU FAWR 540

Wilo-EMU FARF 572

Wilo-EMU KPR 584

Electrical accessories

Recommended accessories 600

Series descriptions 606

Switchgear Wilo-EC-Drain 1x4,0 606

Switchgear Wilo-EC-Drain 2x4,0 606

Switchgear Wilo-DrainControl PL 1 607

Switchgear Wilo-DrainControl PL 1 WS 607

Switchgear Wilo-DrainControl PL 2 608

Switchgear Wilo-DrainControl PL 2 WS 608

Switchgear Wilo-DrainControl 1/2 609

Small alarm switchgear Wilo KAS 609

Wilo-DrainAlarm switchgear 609

Wilo-AlarmControl switchgear 610

Motor switchgear 610

Motor protection plug 610

Level sensor 611

5Sewage pumps DN 32 to DN 800Contents


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Electrical accessories (continued)

Float switch MS 611

Float switch WA 611

Ex-rated cut-off relay 611

Zener barrier 612

Switch cabinet for Wilo-DrainControl for outdoor installation 612

Flash light 612

Signal horn 612

Dynamic pressure system 613

Bubbling-through system 613

Tripping unit Wilo-SK 545 613


General notes and abbreviations

Abbreviations and what they mean Material designations and their meaning

Abbreviation Meaning

1~ 1-phase alternating current

1/min Revolutions per minute

3~ 3-phase alternating current

-A Float switch attached

D Direct activation

DI Leakage detection

DM Three-phase motor with direct activation

DN Nominal diameter of the flange connection

EBM Individual run signal

EM Single-phase motor with starting capacitor

ESM Individual fault signal

GRD/GLRD Mechanical seal

H Delivery head

IA Starting current

IN Rated current; current at P2

Inst. Installation: H = horizontal, V = vertical

LB Readiness for delivery (L = stock article, C = available in 2 weeks, K = available in 4 weeks, A = available on request)

P1 Power consumption (power supplied from the mains system)

PN = P2 Rated motor power

PN Pressure class in bar (e.g. PN10 = suitable up to 10 bar)

PTC Positive temperature coefficient (PTC thermistor sensor)

PT 100 Platinum temperature sensor with a resistance value of 100 at 0C

Q (=) Volume flow

-S Float switch attached

SBM Run signal or collective run signal

SSM Fault signal or collective fault signal

WSK Thermal winding contacts (in motor for monitoring the winding temperature, full motor protection by additional tripping unit)

Y/ Star/delta activation

Operating mode of double pumps:Individual operation of the respective duty pump

Operating mode of double pumps:Parallel operation of both pumps

Number of poles of electric motors:2-pole motor = approx. 2900 1/min at 50 Hz



Material Meaning

1.4021 Chrome steel X20Cr13

1.4057 Chrome steel X17CrNi16-2

1.4112 Chrome steel X 90 Cr Mo V 18

1.4122 Chrome steel X39CrMo17-1

1.4301 Chrome-nickel steel X5CrNi18-10

1.4305 Chrome-nickel steel X8CrNiS18-9

1.4306 Chrome-nickel steel X2CrNi19-11

1.4308 Chrome-nickel steel GX5CrNi19-10

1.4401 Chrome-nickel-molybdenum steel X5CrNiMo17-12-2

1.4408 Chrome-nickel-molybdenum steel GX5CrNiMo19-11-2

1.4462 Chrome-nickel-molybdenum steel X2CrNiMoN22-5-3

1.4470 Chrome-nickel-molybdenum steel GX2CrNiMoN22-5-3

1.4517 Chrome-nickel-molybdenum steel with copper addition GX2CrNiMoCuN25-6-3-3

1.4541 Chrome-nickel steel with titanium addition X6CrNiTi18-10

1.4542 Chrome-nickel steel with copper and niobium addi-tions X5CrNiCuNb16-4

1.4571 Chrome-nickel-molybdenum steel with titanium addition X6CrNiMoTi17-12-2

1.4581 Chrome-nickel-molybdenum steel with niobium addition GX5CrNiMoNb19-11-2

Abrasite Chilled cast iron for use in highly abrasive fluids

Al Light metal material (aluminium)

Al-oxide Aluminium oxide

C Carbon

Ceram Ceramic coating; coating with very high adhesive strength, protection against corrosion and abrasion

Composite High-strength plastic material

Cr Chromium

EN-GJL Cast iron (cast iron with lamellar graphite)

EN-GJS Cast iron (cast iron with spheroidal graphite, also referred to as spheroidal cast iron)

G-AlSi12 Die-cast aluminium

GFK Fibreglass plastic

GG See EN-GJL

GGG See EN-GJS

Inox Stainless steel

PA 30GF See Composite

7General notes and abbreviations


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Wear and tearPumps or parts of pumps are subject to wear in accordance with the latest technology (DIN 31051/DIN-EN 13306). This wear may vary depending on operating parameters (temperature, pressure, speed, water conditions) and the installation/usage situation and may result in the malfunction or failure at different times of the aforementioned products/components, including their electrical/electronic circuitry.Wearing parts are all components subject to rotary or dynamic stress, including electronic components under tension, in particular:

- Seals (incl. mechanical seals), seal rings- Stuffing boxes - Bearings and shafts- Impellers and pump components-Wear rings and counter rings- Stationary wear rings/wear plates-Macerators - Capacitors- Relays/contactors/switches- Electronic circuits, semiconductor components, etc.

With pumps and fluid flow machines (such as submersible mixers and recirculation pumps) and their components that have a coating (cataphoretic coating, 2K or ceram coating), this coating is subject to constant wear from the abrasive constituents of the fluid. For this reason, the coating is also among the wearing parts of these units.

We do not accept liability for faults or defects arising from natural wear and tear.

Wilo General Terms of Delivery and ServiceThe latest version of our General Terms of Delivery and Service can be found on the Internet at www.wilo.com

Material Meaning

PE-HD High-density polyethylene

PP-GF30 Polypropylene, reinforced with 30% fibreglass

PUR Polyurethane

SiC Silicon carbide

St Steel

St.vz. Galvanized steel

V2A (A2) Material group, e.g. 1.4301, 1.4306

V4A (A4) Material group, e.g. 1.4404, 1.4571


Planning guideSewage pumps

Basic hydraulic principles

Planning guide Sewage pumps Basic hydraulic principles Subject to change 09/2008 WILO SE Wilo Catalogue C2 - 50 Hz - Sewage pumps from DN 32 to DN 800Flow rateSolid matter and settling sediments in the sewage may be deposited in pipes, resulting in the clogging of the drainage system. To prevent pipe clogging, it is advisable to maintain the following minimum flow rates:

Depending on the composition of the fluid (e.g. high sand content, pumping sludge), the above-mentioned values may be higher. How-ever, the corresponding regional and national standards and guide-lines need to be observed. The flow rate is determined by the full vol-ume flow (m/s)per area (m)and should generally lie between 0.7 m/s and 2.5 m/s.

The following should be taken into account for the selection of the pipe diameter:The greater the flow velocity, the fewer deposits and the lower the risk of clogging. But then the resistances in the pipe increase with increasing flow velocity, which leads to system inefficiency and can lead to premature component damage due to abrasive constitu-ents.

Building services Both the sewage generated in a building or on a piece of land and the rainwater which accumulates on courtyard and roof surfaces should be pumped to the sewer system with the aid of pumping stations and lifting units, insofar as they do not flow naturally downhill into the lo-cal sewage network. There are different ways of disposing of this sewage, depending on the respective fluids to be pumped. Wilo sub-mersible pumps and sewage lifting units are designed especially to meet these different requirements and comply with currently valid EN standards. Planning must be carried out in accordance with DIN EN 12050/12056 Drainage systems for buildings and sites. A distinction is made here between sewage emerging from discharge points above the local backflow level, which must be guided to the public sewer system by taking advantage of natural slopes, and sew-age from discharge points whose water levels in the anti-siphon trap lie below the local backflow level. The backflow level is defined in by-laws. The upper street edge is usually taken as a rough guide value. Drainage and sewage (rainwater and wastewater), which accumulates below the backflow level, must be conveyed to the public sewer sys-tem via automatically operating lifting units Wilo sewage lifting units or Wilo submersible pumps.

The following details are to be observed for system planning and de-sign in accordance with DIN 1986-100, EN 12050 and EN 12056:

Lifting units are to be designed in terms of performance in such a way that a minimum flow velocity of 0.7 m/s is guaranteed for the pre-scribed nominal widths of the pressure pipe.Required minimum nominal widths:sewage lifting unit for sewage containing faeces without comminu-tion unit: DN 80 Sewage lifting unit for sewage containing faeces with comminution unit: DN 32 Sewage lifting unit for sewage free of faeces: DN 32 Sewage lifting unit for limited use for sewage containing faeces without comminution unit: DN 25 Sewage lifting unit for limited use for sewage containing faeces with comminution unit: DN 20

The pressure pipe of a lifting unit must be equipped with a non-re-turn valve and installed with its bottom above the backflow level (backflow loop). The pressure pipe may not be connected to waste-water downpipes.

Wastewater gate valves (supply and pressure sides) are to be installed in accordance with DIN 1986-100, EN 12050/EN 12056.

Ventilation pipes for lifting units are to be guided to heights above the roof level; the minimum nominal pipe width is DN 70 for sewage lifting units.

Feed lines are to be installed with sufficient slope (a minimum of 1:50).

It is practical to install pipes flexibly through masonry. An automatic standby pump is to be provided if the sewage drain pipe does not allow for interruptions.

Switchboxes and signalling systems are to be installed at a dry, easily accessible position. The signalling system is to be mounted at a posi-tion that can be observed.

Lifting units must be serviced regularly. At least:1x per year in single-family homesEvery six months in multi-family homesEvery 3 months for systems in commercial operations.

The installation room is to be provided with sufficient ventilation and lighting. Above and next to all operating elements and parts to be maintained there should be a working space of at least 600 mm.The lifting unit must be fastened so that it is anti-buoyant.

Sewage containing mineral oils or explosive admixtures must be guided through oil precipitators and/or petrol precipitators; those containing fatty substances must go through grease traps and those with sand through sand catchers. Acidic sewage must be neutralised.

Determining the required pump and/or system powerVolume flow Qp [l/s]:Equivalent to the sum of the incoming wastewater QS and the in-coming rainwater Qr, which must be determined in accordance with EN 12050/EN 12056: QS = Rate of wastewater flow [l/s] from the sum of all sewage sourc-es, taking the simultaneity into account, Qr = rainwater flow rate [l/s] as a product of rainfall, discharge coefficient and precipitation area.

Delivery head HGes [m]:Equivalent to the total height difference between the lowest collec-tion tank level and the bottom of the backflow loop + the total fric-tion losses Hf [m] in the pressure pipe.Attention: When selecting the lifting unit, it is necessary to take into account that the pressure difference between the delivery head in the duty point at the nominal flow rate (observe minimum volume flow) and the delivery head at zero volume flow must still amount to approximately 2-3 m in order to open the non-return valve.

Vibrations and resonanceWhen sewage pumps are installed and connected, various aspects must be observed to guarantee smooth operation. Fundamentally, every moving machine part causes vibrations.

Recommendations for flow velocities

Pipe/standard Value according to standard Recommendation

Free drainage via gravity

Horizontal pipe - Vmin = 0.7... 1.0 m/s

Vertical pipe - Vmin = 1.0 ... 1.5 m/s

Sewer pipes - Vmin = 2.0 ... 3.0 m/s

Pressure drainage

Pipe flushed with com-pressed air, EN 1671 0.6 Vmin * 0.9 0.7 Vmin

Non-flushed lines, ATV-DVWK A 134 0.5 < Vmin < 0.9 0.7 Vmin 2.5

9Planning guideSewage pumps

Basic hydraulic principles

Wilo Catalogue C2 - 50 Hz - Sewage pumps from DN 32 to DN 800

In the case of submersible motor pumps and monobloc pumps, dur-ing rotation, free centrifugal forces are generated at the circulation frequency. Also, the hydraulic forces acting on the pump impeller considerably contribute to the machine vibrations.

In order to avoid malfunctions and damage, the strength of the vibra-tions in the operating state may not exceed a certain threshold. This is achieved by statically and dynamically balancing the corresponding parts.

If the pumps are subject to additional external vibrations due to un-favourable installation and connections, these vibrations are super-imposed. These vibrations can put high levels of stress on individual components.

In order for the pumps to work without disturbances and to have long service lives, they must be installed according to the generally valid rules of technology.

Q/H diagramTo be able to get the required information out of the Q/H diagram, the following is to be observed:

In the standard program, each pump curve corresponds to one unit. Every pump curve is labelled with the respective type of unit.

In the configured program, every pump curve (1) corresponds to an impeller diameter for the respective hydraulics. Every pump curve is labelled with the impeller diameter.

The impeller shape is shown in every diagram (2). Below the impeller figure, the free ball passage is indicated (3). The duty points for the maximum efficiency are marked in bold face on the pump curve (4).

The dotted part of the pump curve (5) indicates the range in which the pump may not be operated.

In the configured program, the nominal power for each available mo-tor is shown as a dotted power curve (6) in the diagram.Based on this curve, you can see which hydraulics can be combined with which mo-tor and with how much power reserve the motor can be operated. In general, the intersection point of the hydraulics curve with the power curve must always be to the right of the selected duty point. The more distance between the selected duty point and the intersection point of the curves, the more reserve the motor has.

Figure: Q/H diagram from the configured range

3,75 kW 5,0 kW

1,6 kW

2,4 kW

2,2 kW

0

0

0

0

2 4 6 8 10 12 14 16 18 20 22 24

10 20 30 40 50 60 70 80

[l/s]

Q [m/h]

50

50 [IMPgpm]

[USgpm]100 150 200 250 300 350

100 150 200 250 300

[ft]

20

40

60

80

0,4

0,8

1,2

1,6

2,0

2,4

00

[bar]

H

80

90

100

110

120

130

140

150

= 45 mm1

2

4

36

5



Pressure losses

Planning guide Sewage pumps Pressure losses Subject to change 09/2008 WILO SE Wilo Catalogue C2 - 50 Hz - Sewage pumps from DN 32 to DN 800

Pressure loss in fixed pipes

Q = volume flow; Dv = pressure loss per 100 m hose (kb = 0.1)

30,0

[m] [m]

20,0

10,0

8,0

6,0

4,0

2,0

1,0

0,8

0,6

0,4

0,2

0,1

30,0

20,0

10,0

8,0

6,0

4,0

2,0

1,0

0,8

0,6

0,4

0,2

0,1

0,1 10 20 400,2 1,0 2,0 4,0 100 200 400 [l/s] 1000 2000

0,4 1,0 2,0 4,0 10 20 40 100 200 400 1000 [m/h] 6000

DN

40

DN50

DN65

DN20

DN25

DN32

DN80

DN

100

DN

125

DN

150

DN200

DN250

DN300

DN350

DN

400

DN500

DN600

DN

700

DN800

DN900

DN

1000

0,4 m/s

0,6 m/s

0,8 m/s

1,5 m/s

1,0 m/s

2,0 m/s

3,0 m/s

4,0 m/s

0,4

11


Pressure losses


Pressure loss in hoses

Q = volume flow; Dv = pressure loss per 100 m hose (kb = 0.25)

25m

m /

1

32m

m /

1

38m

m /

1

63m

m / 2

50m

m / 2

127mm

/ 5

152mm

/ 6

52m

m / C-Sc

hlauch

75m

m / B-Sc

hlauch

102mm

/ 4

/ A-Sc

hlauch

1

10

100

0,1

0,1

10 100 2001 Q [m/h]

Q [m/h]0,1 10 1001 200

Dv[m]

Dv[m]

1

10

100

0,1



Installation types

Planning guide Sewage pumps Installation types Subject to change 09/2008 WILO SE Wilo Catalogue C2 - 50 Hz - Sewage pumps from DN 32 to DN 800Very different types of installations are used in submersible systems in municipal applications. The type of installation depends mainly on the application purpose and the investment volume.

Basically, three main installation types are distinguished: Wet well installation, stationary Wet well installation, portable Dry well installation, stationary

The pipe sump installations are also required. The type of installation depends mainly on the requirements of the planning engineer and the operator. Different viewpoints arise, which each are justified in terms of the individual field of application.

Wet well installation or stationary tank installation

With wet well installation, the pump is installed in the fluid to be pumped. The motor is cooled by the circulating sewage. The advan-tage of this type of installation is low investment costs compared to the more sophisticated pumping station designs for dry-installed sewage pumps. In such a case, a construction above ground or an in-termediate base in the sump for the pumps is not required. In greater depths, an intermediate ceiling is necessary.

The pump is fastened by means of a suspension unit with lowering mechanism. That allows the pump to be "pulled" at all times, e.g. for maintenance work.

The coupling base and the elbow are usually cast in one piece. The guide consists of two pipes, thus preventing any twisting. The Wilo coupling connection is made in such a way that a lip prevents the seal ring from falling out.

The pressure pipe made of a galvanized steel pipe, or ideally of a stainless steel pipe, is fitted directly on the suspension unit via flang-es and leads out of the pump sump. The sump can be made at low costs from ready-made concrete sumps equipped with elastomer seals in accordance with EN 1917 (national addition: DIN 4034 T1). However, one-piece PEHD sumps without joints are a better solution, since these prevent any infiltration of external water.

As shown on the diagram alongside, this installation type gives the operator the option of special pump sump geometries adjusted to in-dividual requirements, the use of additional flushing valves or the in-stallation of vortex impellers with special mixer head technology.

The disadvantage of a wet well installation is the lack of ease of maintenance. In addition, with a wet-installed submersible sewage pump, the water level can only be lowered to a certain level, since op-timum cooling of the motor is only possible in submerged condition.

Stationary dry well installationThe dry well installation variant, in particular the dry-installed sub-mersible pump, provides a number of advantages compared to dry-installed pumps, and also compared to wet-installed submersible pumps.

Installation principle of a dry-installed submersible pumpThe main difference from a wet-installed submersible pump is the design of the motor. It is a fully encapsulated motor with internal closed-circuit cooling. A distinction is made between an open cooling system and a closed cooling system. With an open cooling system, the fluid to be pumped is used as the coolant. With a closed system (single-chamber or two-chamber system), cooling is performed by an external fluid, such as e.g. water-glycol or medical white oil, in a closed circuit.

Another main difference from the wet-installed submersible pump is that the dry-installed submersible pump is not installed in the fluid to be pumped. In terms of the technical construction, an intermediate base is required directly in the pumping station. The major advantag-es are the combination. On the one hand, this submersible pump of-fers all benefits of a dry-installed pump and, on the other hand, all benefits of a submersible pump, such as being overflow-proof.

As already mentioned, the pump is installed in a separate pump room. The pump is fastened to the inflow pipe unspectacularly via a pipe el-bow.

13


Installation types


Stationary dry well installation

Advantages compared to dry-installed pumps (not submersible pumps)

Overflow-proof and thus more operational reliability Low-maintenance carbide mechanical seals or seal cartridges No couplings or V-belts, thus fewer wearing parts and less mainte-nance required

Ex protection possible at all times Clean and hygienic working conditions Easy to maintain

Portable installation

With this type of installation, the motor is cooled in the same way as for stationary wet well installation, However, the pump is not fas-tened firmly in the pump by means of a suspension unit. The pump can thus be installed in any sump via a base component on the pump housing. With the right couplings, hoses of appropriate length can be installed on the pressure port. When selecting the pump, hydraulic conditions, such as volume flow and delivery head as well as the pump's NPSH, must also be taken into account.

Portable pumps are frequently used for municipal applications as emergency drainage or residual drainage pumps.



Pumped fluids and impeller shapes

Planning guide Sewage pumps Pumped fluids and impeller shapes Subject to change 09/2008 WILO SE Wilo Catalogue C2 - 50 Hz - Sewage pumps from DN 32 to DN 800Pumped fluid (untreated sewage, sludge)Solids concentrationNon-clog impellers and vortex impellers are suitable for fluids with a DM content (dry matter) of max. 8% (rough guideline).

The prerequisite for perfect pumping in all cases is that the pump's fluid still flows on its own.

ViscosityThe pump curve and the given motor power values in the type sheets apply to the pumping of water = 1.0 x 10-6 m2/sec. The diagram for friction losses also applies to water only. If the viscosity of the fluid is greater than v = 1.5 x 10-6 m2/sec., the following aspects need to be observed in particular:

Increased friction losses in the pipe (when determining the delivery head)

Increased power requirement of the pump (when determining the drive power)

Specific weightThe motor power values given in the type sheets apply to water as the fluid (= 1 kg/dm3). With a higher specific weight of the fluid than that of water, an increased power requirement of the pump needs to be taken into account.

Impeller shapes Closed single-blade impeller (single-channel impeller)

Properties: For the most part, insensitive to clogging Wide ball passage Low wear susceptibility Gentle pumping Power correction possible by trimming the impeller High degree of efficiency For solid matter concentrations up to 8% dry matter, depending on the type of sludge

In the event of wear, only the stationary wear ring and the counter ring need to be replaced

Hydraulic compensation of the axial thrust due to back vanes, thus reduced load on the bearings

Fields of application Untreated sewage Circulation and heating sludge Mixed water Raw and digested sludge Activated sludge

Closed multi-blade impeller (multi-channel impeller)

Properties: Smooth running Largely insensitive to clogging Larger ball passage Low wear susceptibility Gentle pumping Power correction possible by trimming the impeller High degree of efficiency For solid matter concentrations up to 5% dry matter, depending on the type of sludge

In the event of wear, only the stationary wear ring and the counter ring need to be replaced

Hydraulic compensation of the axial thrust due to back vanes, thus reduced load on the bearings

Fields of application: Rake-cleaned sewage Mechanically treated sewage Industrial waste water Landfill water Activated sludge Industrial sewage

Open multi-blade impeller with macerator

The upstream macerator system cuts up the admixtures in the sew-age to the required size. The macerator system consists of an Abra-site macerator unit and a cutting plate made of the material 1.4034. The macerator system has easy-to-use adjustment options for vari-ous gap clearances.

Properties: Largely insensitive to clogging Small ball passage Sensitive to wearing fluids, e.g. containing sand

Fields of application: Domestic sewage

15




Wastewater Faeces Suitable for low-pressure drainage

Vortex impeller

Properties: Hardly any clogging No gap sealing Optimum ball passage Suitable for some bubble-forming fluids Power correction possible by trimming the impeller Lower degree of efficiency compared to the non-clog impeller For solid matter concentrations up to 8% dry matter, depending on the type of sludge

Insensitive to fibrous sewage and sewage containing textiles Hydraulic compensation of the axial thrust due to back vanes, thus reduced load on the bearings

Low-wearing Also suitable for bubble-forming fluids

Fields of application: Untreated sewage Activated sludge Raw and digested sludge Mixed water Fluids with problematic constituents Fluids with wearing constituents

Vortex impeller with mixer head

The mixer head is a mechanical stirring apparatus, which forms a unit with the vortex impeller. The sand is thus only stirred up in the area of the pump inlet. Solid deposits are loosened up and pumped. Due to the narrowly limited flow zone, the depositing of sand is not dis-

turbed. The mixer head is made of the highly wear-resistant special material, Abrasite.

Properties: See vortex impeller Loosening up of solidified sand deposits High wear-resistance Self-cleaning mixer head

Fields of application: In the grit chamber Sand and gravel systems Sludge settling ponds Sedimentation tanks Wherever deposits are possible

Propeller impeller (axial impeller)

Properties: For very high volume flow and very low delivery head High degree of efficiency Power consumption falls with increasing volume flow May not be operated against closed slide valve

Fields of application: Fluids with small amounts of dirt Rainwater Return activated sludge Circulation of activated sludge Water drawing units, etc.

Impeller selectionThe precise selection of the right impeller depends on the following:

The application conditions The system conditions The duty point of the pump And several other factors

These factors need to be checked carefully from case to case.




Free (ball) passageSewage pumps and their hydraulic components are adapted to the different conditions and the corresponding constituents of the pumped fluids. However, one needs to take into account which de-sign shape of the impeller is best suited for the corresponding fluid and its composition.

An increase of the free ball passage means a reduction of the hydrau-lic efficiency. That results in a higher motor power with the same hy-draulic result, which in turn has an effect on the operating and acqui-sition costs.

Dimensioning is important: Economic aspects Trouble-free operation of the sewage pumps Operational reliability

Impeller properties

Impeller shape No cloggingPumping of bub-

ble-containing fluids

Sludge pumping Efficiency Smooth operation

Wearresistance

Vortex impeller +++ + + o +++ +++Closed single-blade impeller ++ - + ++ + ++*

Closed multi-blade impeller + o + ++ ++ ++*

Axial impeller + o o +++ ++ ++*+++ = ideal; ++ = very good; + = good; 0 = limited; - = unfavourable; * = with counter and stationary wear ring

17


General calculation instructions


Planning guide Sewage pumps General calculation instructions Subject to change 09/2008 WILO SE Wilo Catalogue C2 - 50 Hz - Sewage pumps from DN 32 to DN 800General notes The volume flow to be handled by the pump must exceed the volume flow of approaching sewage. Make sure that the pumps run as close to the optimum duty point as possible to ensure durability and opti-mum performance.

Consider a loss in performance with increasing pump age. The volume flow and pressures can be negatively influenced by abrasion and cor-rosion.

Design the pump so that it operates as efficiently as possible. Steep pump curves prevent clogging in the pressure pipe, since when there's increased backpressure, the pump also increases pressure along its pump curve and rinses away the deposits.

When selecting accessories, take the material properties into consid-eration with regard to the corrosion- and abrasion-resistance.

Compensate for peak inflows for economical and safety reasons by using double-pump systems (pump splitting, standby pump is always to be considered separately).

If the transfer point (drainage pipe) lies underneath the sump level, ventilation should be provided, since otherwise the created suction could empty the complete sump, incl. the pump. This would result in ventilation difficulties and should therefore be checked in advance.

Observe the various operating conditions for pipes which are not per-manently installed in one place. The partial and full-filling situations should be observed.

Pipe and pump material When designing, observe that the following influences could mean additional requirements for your system:

Flow velocity of the fluid > Noises, wear pH value of the fluid > Material damage, corrosion Chemical constituents of the fluid > Corrosion Atmospheric conditions, such as humidity, salt content in the air, etc.

> Corrosion Outside and fluid temperature > Fluid aggressiveness, corrosion Dwell time of the fluid in the pipe > Odour development Leakage currents due to using materials having different electron negativity

Due to the material changes and the resulting pressure level change, pipes for underground use should be designed as PN 10 pipes.



Basic electric principles

Planning guide Sewage pumps Basic electric principles Subject to change 09/2008 WILO SE Wilo Catalogue C2 - 50 Hz - Sewage pumps from DN 32 to DN 800Starting currentThis is the current which is required during the start-up operation of a machine to overcome friction losses and starting torques. The starting current can be up to seven times that of the nominal current, depending on the type of start-up. When there is instability in the electric mains or for larger motors, corresponding devices must be provided to reduce the starting current. These could be soft starters, frequency converters, etc. Designing the motor as a star-delta motor can already reduce the starting current.

ATEXSee "Explosion protection" chapter

Operating modes (in acc. with DIN EN 60034-1)See "Operating modes" chapter

Individual run signalIndicates the fault of the individual pump and demonstrates an exact evaluation method for building control systems.

Explosion protectionExplosion protection has been modified in the EU. Since July 1, 2003, the European directive 94/9/EC has applied for explosion protection. The modifications generally have to do with the fact that the entire unit (not only the electrical part) has to be tested and certified taking explosion-protection aspects into account. A definition concerning the zones in which explosion protection is to be provided is the re-sponsibility of the operator. The units identified by Wilo as explo-sion-protected are designed for Zone 1, Group II, Category 2, i.e. for a high degree of safety and for the cast that potentially explosive at-mospheres can be expected.

Furthermore, a few series are also approved according to the Ameri-can FM directive.

For further information, see the "Ex protection" chapter.

Ex-rated cut-off relayUsing ex-rated cut-off relays, float switches can also be used in po-tentially explosive environments (Zone 1 for fluids containing fae-ces). These relays reduce the flowing current to a magnitude which doesn't cause sparks, even in the event of an error, which would cause the fluid or its surroundings to ignite.

FMSee "Ex protection" chapter

Motor protectionFor a safe operation of a motor, this must be protected against unac-ceptable high warming. Such an unacceptable warming can result from faults which increase the motor current and strongly heat up the motor:

Overload Phase failure Undervoltage Blocking

These faults can be recognised by an overload relay or a motor pro-tection switch which then switch off the motor. Overload relays and motor protection switches may only be set to the maximum nominal current of the motor.

Overload relayPrinciple of operation:The thermal protection is ensured by bimetals which heat up as the motor current flows via heating windings. For every conductive line to the motor, a separate bimetal with corresponding heating winding is provided. If the power consumption of just one motor winding ex-ceeds the predefined value over several seconds, the generated heat will deform the bimetal which then triggers the latch and switches off the motor contactor. Also, if a phase fails (irregular heating of the bi-metal strips), the motor is switched off after a short period of time. After a thermal triggering has taken place, the switch can only be switched on again after the bimetals have cooled down sufficiently. Overload relays don't switch off the motor directly, they have a con-tact for relatively low switching frequencies. This contact activates a contactor which then switches the motor off in the event of a fault. In contrast to the motor protection switch, an overload relay does not have a short-circuit trip. This is why safety fuses should be installed in the supply line for one or several motors which are protected by overload relays. Moreover, the reactivation of overload relays can be done manually or automatically. The reactivation should be done manually in order to avoid a permanent switching on and off when there is a fault.

Motor protection switchWith motor protection switches, motors can be switched on and off under normal operating conditions. The thermal triggering is based on the principle of the overload relay. However, the operator is in a position to switch off the motor during operation or in the event of fault. Moreover, most motor protection switches have an additional magnetic quick triggering which protects the downstream line and the motor against short circuits. With lower currents, these switches are short-circuit proof, i.e. a back-up fuse may not be required.

Other faults which lead up to an increased heating-up: Dry-running of motors that may only operate in a submerged state Unacceptable high fluid temperatures / ambient temperature Unacceptable running times in short-term operation

These faults do not influence the current consumption of the motor and can therefore not be recognised by the upstream overload pro-tection! For such faults, temperature sensors are used which are di-rectly imbedded in the component to be protected (motor winding).

19


Basic electric principles


Protection measures (DIN VDE 0100-410)Protection classes: (DIN EN 50529 / VDE 0470 Part 1)The type of protection which a housing offers to e.g. protect against direct contact, is defined by the IP (International Protection) codes. This is made up of the IP and two digits (e.g. IP 54).

First digit: Protection of people against contact with dangerous parts Protection of the equipment against ingress of solid foreign matter

Second digit: Protection of the equipment against the ingress of water

First digit Second digit

Index Protection against contact Protection against foreign matter Protecton against water0 No protection No protection No protection

1 Protection against contact with the back of the handProtection against solid foreign matter 50mm diameter Protection against vertically dripping water

2 Protection against touching with fingers Protection against solid foreign matter 12.5mm diameterProtection against dripping water falling at a tilted angle (15)

3 Protection against touching with tools Protection against solid foreign matter 2.5mm diameterProtection against spraying water falling at a tilted angle of up to 60

4 Protection against touching with a wire Protection against solid foreign matter 1.0mm diameterProtection against splashing water from all directions

5 Protection against touching with a wire Dustprotected Protection against water jets6 Protection against touching with a wire Dustproof Protection against strong water jets

7 - - Protection against temporary submersion in the water

8 - - Protection against permanent submersion in the water



Operating modes

Planning guide Sewage pumps Operating modes Subject to change 09/2008 WILO SE Wilo Catalogue C2 - 50 Hz - Sewage pumps from DN 32 to DN 800The operating mode determines the permissible duty cycle of motors. One should always make sure that the built-in temperature control of the motors is connected correctly. It ensures that the temperature classes of the windings are adhered to in the event of the operating time being exceeded or the wrong operating mode.

S1 Permanent operationDefinition:Operation at a constant load until the machine can reach the thermal state of inertia.

The machine is designed in such a way that cooling is sufficient at the specified conditions. The operating mode does not give any informa-tion as to whether the machine is to be operated dry or wet. If no op-erating mode is stated on the name plate of a machine, S1 permanent operation applies.

P = loadPV = electrical losses = temperature max = maximum temperature t = timeTC = cycle duration tp = operating time with constant loadtR = downtime with dead windings, relative duty cycle = tP/TC

S2 Short-term operationDefinition:Operation at constant load and with a duration that is not sufficient to reach the thermal state of inertia, and a following standstill time, during which the fallen machine temperatures only deviate from the temperature of the coolant by less than 2 K.

The power dissipation of the machine is higher than can be dissipated via the coolant. In S2, the permissible operating time is always also specified (e.g. S2 15min). After this operating time, the machine must cool down again to the ambient temperature. This operating mode is mainly used for dry-installed machines.

P

t

t

t

PV

max

P

t

t

t

PV

tP

max

21


Operating modes


S3 Intermittent operation without affecting the starting currentDefinition:Operation that consists of a sequence of identical cycles, each one consisting of an operating time with constant load and a downtime, and the starting current does not have a significant effect on the ex-cess temperature.

The power dissipation of the machine is higher than can be dissipated via the coolant. In S3 operating mode, the cycle duration is specified in percent and the cycle time is also specified.

Example for S3 25 % 10min: The duty cycle is 2.5min and the pause is 7.5min. If no cycle duration is specified, the cycle duration of 10 min applies.

P = loadPV = electrical losses = temperature max = maximum temperature t = timeTC = cycle duration tp = operating time with constant loadtR = downtime with dead windings, relative duty cycle = tP/TC

P

t

t

t

PV

tP tR

TC

max



Level measuring systems

Planning guide Sewage pumps Level measuring systems Subject to change 09/2008 WILO SE Wilo Catalogue C2 - 50 Hz - Sewage pumps from DN 32 to DN 800Level measuring systems are for measuring the water level in tanks. Depending on the application conditions, various systems are availa-ble.

Float switchWith this method, switching contacts are closed or opened in a float-ing body according to the inclination angle. With float switches, one should always make sure that they can move freely in the sump. They can also be used in potentially explosive areas if they are operated via an ex-rated cut-off relay (Ex-i).

A basic distinction must be between two different designs:

Single-point float switch:These floaters have a short connection to the cable with a slight dif-ference between the activation point and deactivation point. Some of these floaters are also available as heavy versions that tilt around their centre of gravity. To avoid the constant switching of the pump, at least two of these floaters must be used for level control. Due to their good floating properties, however, they are better suited for sewage applications.

Two-point float switch:These float switches have a larger angle between activation point and deactivation point. They are fastened to their pipe. That makes it possible to switch smaller differences with only one float switch ac-cording to the drawn-out pipe length.

1

0

23




Dynamic pressure system (measurement of the hydrostatic pressure)With this method, a measuring bell / velocity head bell is used to measure the pressure at the point of installation. The filling height of the fluid generates a pressure that is forwarded to the evaluation unit via a hose. In the evaluation unit, the pressure is converted into an electrical signal. That enables the continuous measurement of the filling level, and the switching points can be freely defined.

A distinction is made between open systems and closed systems. The selection depends on the field of application and the type of fluid. The application in potentially explosive areas is possible.

Open system:With this version, the bell is open in the direction of the fluid. Every time the fluid is pumped out, the bell must surface to vent the sys-tem. It is switched "Off" after a certain time. Another way to vent the system is by connecting to a small compressor (bubbling-through system), that vents the system constantly or periodically. Its "Off" state depends on the water level.

Closed system:With this version, the air cushion in the bell is separated from the fluid by a diaphragm. The system is therefore suitable for heavily contami-nated fluids. Leakages / air loss in the system result in measuring er-rors or a system malfunction.

Pressure probe (electronic pressure transducer)Like the velocity head probes, the hydrostatic pressure is measured at the installation point here, too. However, a diaphragm is used here to convert the pressure in the pressure transducer directly into an elec-trical signal.

Conductivity (conductive measurement method)In this case, submersible electrodes are connected to an evaluation relay. The relay detects whether fluid is present or not based on the resistance. The trigger resistance can be set on most relays. In this way, simple level controls for filling or draining can be implemented. The application as a dry-running protection system is also very fre-quent. Not suitable for sewage pumping stations.Ultrasound




Measurement with ultrasound is based on the measurement of the running time. The ultrasonic pulses emitted by a sensor are reflected by the surface of the fluid and detected by the sensor. The required running time is a measure for the distance covered in the empty tank. This value is deducted from the overall tank height, which results in the filling level.

The advantage of this method is that measurement of the filling level in the tank is possible without contact, regardless of the fluid. During installation, one should ensure that the measuring cone emitted by the sensor is free of installations. A minimum clearance to the wall of the tank must also be kept.

25


Motors


Planning guide Sewage pumps Motors Subject to change 09/2008 WILO SE Wilo Catalogue C2 - 50 Hz - Sewage pumps from DN 32 to DN 800Motor coolingThe motor cooling was realised in different ways. Depending on the construction, either oil, water/glycol or air is used as a heat carrier in the self-cooling motors. The coolant is cooled off by a heat exchang-er, which conducts the heat given off to the fluid. Air-filled dry mo-tors give off heat directly to the fluids flowing around it via the hous-ing.

The self-cooling motors can be operated both submerged and dry in permanent operation. Dry motors can be immersed in permanent op-eration, but can only be operated dry for a short time.

Figure: Motor with active closed-circuit cooling and two-chamber system for wet and dry well installation

Figure: Dry motor with active closed-circuit cooling and two-cham-ber system for wet and dry well installation

Motor overview

Motor Coolant Cooling and sealing system

Ex

MTC... Air One-chamber system MTS... Air One-chamber system TC 40... Air One-chamber system

STS 40... Air One-chamber system

STS 65... Air One-chamber system

STS 65...CS AirOne-chamber system with sheath current cooling

TP 50... Air One-chamber system

TP 65... Air One-chamber system

TP 80... AirOne-chamber system with sheath current cooling

TP 100... AirOne-chamber system with sheath current cooling

F-motor Oil in the motorTwo-chamber system with passive closed-cir-cuit cooling

FK motor Oil in the motorTwo-chamber system with active closed-cir-cuit cooling

FK 17.1 motor Oil in the motorTwo-chamber system with active closed-cir-cuit cooling

FKT 27.1 mo-tor

Water/glycol mixture in the cooling circuit

Two-chamber system with active closed-cir-cuit cooling

FKT 49.../56... motor

Oil in the cooling cir-cuit

One-chamber system with active closed-cir-cuit cooling

FKT 72 motor Oil in the cooling cir-cuit


HC motorWater/glycol mixture in the hermetically sealed cooling circuit


T motor Air One-chamber system T 20.1 motor Air One-chamber system



Motors

Figure: Dry motor for wet well installation

Figure: Dry motor with sheath current cooling

Sealing variants Each motor is equipped with a sealing housing in which there is a separate sealing chamber. This is between the fluid and the motor space and is filled with white oil. This chamber accommodates the leakage of the sealing on the fluid side.

The sealing can be done in different ways and depends on the select-ed motor.

Figure: Basic sealing, mechanical seal on the fluid side, special radial shaft seal on motor side for normal applications

Figure: Two mechanical seals for high loads and difficult operating conditions

Figure: Block seal cartridge for high wear and corrosion resistance, as well as high operational reliability

Monitoring equipmentThe integrated monitoring units are for protecting the motor:

Excess temperature in winding/bearing/oil Over pressure in the motor Penetration of water in- sealing chamber- leakage chamber- motor compartment- clamping space

27


Motors


The possible sensor equipment depends on the different motor types. The individual sensors will be described below.

Bimetal temperature sensorBimetal temperature sensors are mechanical switches which trigger a switching operation as a result of heat. "Normally closed contacts" are used, i.e. when the tripping temperature is reached, the electrical circuit is interrupted. When the temperature drops accordingly (hys-teresis), the sensor closes automatically again. 2 or 3 temperature sensors are installed in series in the windings. Another application option is the monitoring of the oil temperature in oil motors. In Ex motors for submerged operation and in special versions, there are 2 temperature circuits with different tripping temperatures.

Application for the following: Slowly rising temperatures, e.g. obstruction of cooling by deposits Overload Surfacing of motors that may only operate in submerged state Unacceptably high ambient temperatures Operating time too long during S2 operation

Thermistor/PTCPTC thermistor sensors are temperature-sensitive resistors. These sensors do not have any mechanical components. When the nominal activation temperature (NAT) is reached, the electrical resistance of the sensors increases rapidly. This change is evaluated by an elec-tronic switchgear. 3 temperature sensors are installed in series in the windings. In large machines and special versions, there are 2 temper-ature circuits each with different tripping temperatures (e.g. 130/140 C). A switchgear is required for each temperature circuit (e.g. WILO CM-MSS).

Application for the following: All types of temperature protection Blocking of sewage motors Motors for speed control (specification for Ex motors on the convert-er)

PT 100 temperature sensor PT 100 sensors are temperature-dependent resistors with an almost linear pump curve. At 0 C, the resistance is 100 . The resistance dif-ference between 0 and 100 C is 0.385 /K. This change is evaluated by an electronic switchgear (e.g. WILO DGW 2.01 G). The switching temperature is determined by the setting on the switchgear, not by the sensor. In addition to the adjustment of the switching points, the temperature can also be measured.

Application for the following: Slowly rising temperature e.g. cooling obstructed by deposits Overload Surfacing of motors that may only operate in submerged state Unacceptable ambient temperature Long running time during S2 operation Blocking only to a limited extent

In order to be able to compensate the fault caused by the line resist-ance, the connection is usually established in the form of three-wire switching. Almost all PT 100 evaluation relays support this connec-tion.

Leakage floaterLeakage floaters are mechanical switches that trigger a switching op-eration in the event of fluid penetration. Therefore if fluid penetrates the leakage chamber via the second mechanical seal, the motor can be shut down or a warning emitted. "Normally closed contacts" are used, i.e. if fluid enters the leakage chamber, the electrical circuit is interrupted.

No special relay is required for the evaluation. The switching capacity of the floater contacts deviates with different motor types and must therefore be taken from the connection diagram for the respective motor.

Pressure switchPressure switches are mechanical switches that trigger a switching operation in the event of over pressure in the motor. They are used in motors that have an oil-filled motor compartment. "Normally closed contacts" are used, i.e. when an over pressure builds up in the motor, the electrical circuit is interrupted.

No special relay is required for the evaluation.

Thermal float switchThermal float switches are mechanical switches that trigger a switch-ing operation in the event of a low oil level or if the temperature in the motor is too high. They are used in motors that have an oil-filled motor compartment. "Normally closed contacts" are used, i.e. if there is a lack of oil or if the temperature of the oil is too high, the electrical circuit is interrupted.

No special relay is required for the evaluation.

Conductive electrodesConductive electrodes (based on the measurement of the resistance) are used to evaluate conductive fluids. The sensor consists mainly of a rust-proof electrode rod. It is used to measure the conductivity of the fluid in relation to a reference earth (motor housing). This change is evaluated by an electronic switchgear (e.g. Wilo NIV 101). The switching resistance is determined by the setting on the switchgear, not by the sensor.

A special electrode relay is always required, e.g. Wilo NIV 101/A, NIV 105/S or ER 143 (for potentially explosive areas). The sensitivity of the relay is to be set to > 20 k.



Explosion protection

Planning guide Sewage pumps Explosion protection Subject to change 09/2008 WILO SE Wilo Catalogue C2 - 50 Hz - Sewage pumps from DN 32 to DN 800Wilo units are approved for use in potentially explosive areas. For this, they are certified according to two different standards: The European ATEX standard as well as the American FM standard.

Atex standard The units are designed in accordance with "EU Directive 94/ 09/EC" (ATEX 95) and the European standards DIN EN 60079-0 and EN 60079-1. They may be operated in potentially explosive atmos-pheres which require electrical devices of device group II, category 2.

It is therefore possible to use them in zone 1 and zone 2. These units may not be used in zone 0.

The Wilo units are labelled as follows: II 2 G Ex d IIB T4

FM standardThe units are certified and approved by the recognised testing and approval authority "FM Approvals" in accordance with the standards FM 3600, 3615, 3615.80 and ANSI/UL-1004. They may be operated in potentially explosive areas which require electrical devices with the protection class "Explosion-proof, Class 1, Division 1". Operation in areas with the required protection class "Explosion-proof, Class 1, Division 2" in accordance with the FM standard is also possible.

The Wilo units are labelled as follows:

Temperature monitoringStandard explosion-certified motors are equipped with a tempera-ture monitor. This includes:

Motors of size T 12 and T 13winding: 140 C temperature limiter

Motors of size T 17 and largewinding: 130 C temperature controller, 140 C temperature limiter

Motors of size FK 17.1winding: 120 C temperature limiter, oil: 100 C temperature limiter

Motors of size T 20.1, HC 20.1 and FKT 27.1winding: 160 C temperature limiter, laminated core: 110 C temper-ature limiter

The temperature monitor is to be connected so that automatic reac-tivation is possible when the "temperature controller" is triggered. When the "temperature limiter" is triggered, reactivation should only be possible when the "release button" has been pressed by hand.

Frequency converter operationFor operation with a frequency converter, the motors must be equipped with a PTC thermistor temperature sensor. Specify the in-tended use when making your order so that we can equip the motors accordingly.

Sealing chamber control The units can be equipped with an external sealing chamber control. This can also be retrofitted. If the unit is equipped with an external sealing chamber control, this may only be connected to an intrinsi-cally safe electric circuit.

Definition of the Ex zonesThe Ex zones are defined in the respective standards. The operator must label the zones in the operating area of the units. When order-ing, please state which Ex standard you are using as the basis and in which zone you want to operate the unit.

II Device group IIDescription: For potentially explosive locations, with the exception of mines

2 CategoryG Substance group

Description: GasesEx Ex-protected device in accordance with European

standardd Ignition protection category for motor housing

Description: Pressure-proof enclosureIIB Explosion group

Description: For use in combination with gases of subdivision B, all gases with the exception of H2, C2H2, CS2

T4 Temperature classDescription: Max. surface temperature of the device is 135 C

Class 1 Division 1; Groups C, DDescription: Gases, vapours, mists; explosive at-mosphere present constantly or occasionally during normal conditions; Gas groups: Ethylene (C), propane (D)

Class 2 Division 1; Groups E, F, GDescription: Dusts; explosive atmosphere present constantly or occasionally during normal conditions; Dust groups: Metal (E), carbon (F), grain (G)

Class 3 Description: Fibres and lint

T3C Temperature classDescription: Max. surface temperature of the machine 160 C

FMAPPROVED

29


Explosion protection




Materials

Planning guide Sewage pumps Materials Subject to change 09/2008 WILO SE Wilo Catalogue C2 - 50 Hz - Sewage pumps from DN 32 to DN 800AbrasiteSpecial materials for pump housings and impellers. This is a high-al-loyed, extremely wear-resistant cast material. The material has a martensitic basic structure with a high chrome-alloy carbide content. Through this, there is especially high wear-resistance to sewage which has a high concentration of abrasive particles (like sewage having a high sand content). In laboratory tests, it could be deter-mined that a pump service life 7 times longer than that of normal cast materials is possible for pumping abrasive media when "Abrasite" is used.

Concrete Material for creating sumps in accordance with DIN 4034-1. The con-crete quality used by Wilo meets DIN EN 206 (formerly DIN 1045). The exact name is B45WU with a prescribed max. water penetration depth of 30 mm, according to the standard. From experience, the max. penetration depth of the Wilo-DrainLift WB is even just 20mm. The following have a corrosive effect on concrete: Fluids with pH val-ue < 6.5, sulphuric, hydrochloric, butyric and lactic acids, sulphates, salts, animal and vegetable fats and oils.

CeramSee chapter "Ceram coating".

Stainless steel 1.4301 - V2A (AISI 304 - X5CrNi18-10)V2A comes from the Thyssen Krupp definition (test series 2, type Austenite) for a chrome-nickel steel. This is the generally common stainless steel standard in the pump industry, which unifies the strength properties with good temperature resistance.In addition, the material is very resistant to organic solutions.

Stainless steel 1.4404 - V4A (AISI 316L - X2CrNiMo17-12-3)V4A comes from the Thyssen Krupp definition (test series 4, type Austenite) and refers to a high-alloyed non-rusting steel (as com-pared to 1.4301) with a molybdenum constituent, which can some-times also be used in seawater. High strength and high elasticity are characteristic features which make stainless steel superior to cast iron.

Cast ironCast iron is the standard material in pump construction. For years, most units have been made of cast iron. The advantages of cast iron are mainly their price and robustness.

PE-HD (polyethylene - high density)The most used material in pipe construction for sewage pipes with very good chemical resistance and extremely low surface roughness to prevent depositing and flow losses. High impact resistance and ul-timate strain with low influence of temperature are other advantag-es. The material PE100 is used more and more in practice and is re-placing PE80 and GGG. Advantages, such as laying pipes during renovations, offer a high cost-savings potential.

PP (polypropylene)Temperature resistance as well as chemical resistance characterize this material. DIN 8078 is extremely robust thanks to the high impact resistance of the material.

PUR (polyurethane)PUR is available in many variations. The outstanding advantages of Baydur GS, which is used by Wilo and has been proven in industrial applications, such as the high chemical resistance to diluted acids, al-kaline solutions, motor oils, greases, benzines, etc. as well as the cor-rosion- and micro-resistance, are predestined for use in aggressive fluids. In addition, it is characterized by its superior wear-resistance, rot resistance, weather resistance, dimensional stability under heat and impact resistance at a much lower weight as compared to metal-lic materials, such as cast iron. In a sand-slurry test conducted by Bayer, the wear resistance or PUR is about twice as high as that of cast iron under the same conditions.

PVC (polyvinyl-chloride)PE sumps are designed in accordance with DIN 19537-1 and offer great advantages compared to conventional concrete sumps, such as durability, flexibility, easy installation and reduced installation costs. It is a flame-resistant material, which equally combines mechanical strength and chemical resistance.

Material table for austenitic steels

DIN designation US designation Chemical symbol European standard American standard Material number AISI EN ASTM1.4301 304 X5CrNi18-10 10088-3 A 167 /2761.4401 316 X5CrNiMo17-12-2 10088-3 A 167 /2761.4404 316 L X2CrNiMo17-12-3 10088-3 A 167 /2761.4571 316 Ti X6CrNiMoTi17-12-2 10088-3 A 167 /276

31


Materials


Planning guide Sewage pumps Materials Subject to change 09/2008 WILO SE Wilo Catalogue C2 - 50 Hz - Sewage pumps from DN 32 to DN 800

Material table - Properties

Designation Service temperature Resistant Non-resistant Application areas[C]

Seal materials

EPDM

-30...+120

Water without chemical additives,caustic sodas,

hydrochloric acid,phosphoric acid,

salt water

Fuels,kerosene,

sulphuric acid,nitric acid

Housing seals,Mechanical seal bellows

FPM (= Viton)

-25...+120

Sewage pH 3 to pH 10,fuels,

mineral oils,phosphoric and sulphuric acids

Acetic acid,nitric acid,benzol


NBR

-30...+100

Sewage pH 6 to pH 10,water without chemical additives,

fuels,mineral oils,salt water

Nitric acid,sulphuric acid


Housing and peripheral materials

Abrasite-25...+200 Sewage withabrasive constituents Acids

Pump housings,impellers,mixer head

Stainless steel 1.4301

-20...+120Mineral oils,

water without chem. additives,alcohols

Seawater*,hydrochloric acid,

concentrated acids and alkaline solutions

Motor housings,hydraulics housings,

impellers

Stainless steel 1.4404

-20...+120Mineral oils,

water with chem. additives,alcohols

Seawater*,hydrochloric acid,

concentrated acids and alkaline solutions

Motor housings,hydraulics housings,

impellers

PE

0...+90Sewage pH 4 to pH 9,

water without chem. additives,inorganic dilute fluids

Concentrated acids and alkaline solutions

Pump housings,impellers,pipes,

pump sumps,fitting ducts

PP

0...+90Sewage pH 4 to pH 9,

water without chem. additives,inorganic dilute fluids,*salt water

Concentrated acids and alkaline solutions

Pump housings,impellers,

non-return valves,pump sumps

PUR

0...+80

Seawater*,acids,bases,

pH 3 to pH 13,fats,

machine oils,benzine

Highly aggressiveacids and bases

Pump housings,impellers,

connection elements, agitators

* Conditionally resistant depending on the fluid temperature and other organic and inorganic fluid constituents



Ceram coating

Planning guide Sewage pumps Ceram coating Subject to change 09/2008 WILO SE Wilo Catalogue C2 - 50 Hz - Sewage pumps from DN 32 to DN 800Modern corrosion and abrasion protectionUnits that come into contact with the fluid are subject both to highly corrosive as well as abrasive influences. For this, Wilo offers its Ceram coating. This provides reliable protection against this type of stress.

Normal heavy corrosion protection methods, such as zinc dust prim-ing with three coats of tar epoxy resin are called onion layer models. The advantage of zinc dust priming is that the zinc dust sacrifices and the zinc carbonate can seal microscopic cracks. This is referred to as the self-healing effect of the coating. The disadvantage is that the wet adhesion of this zinc dust priming isn't very high. Because of the onion layer model of conventional solvent-containing coatings, the adhesive force depends on the quality of the individual layers.

The Ceram coating, on the other hand, is based on the diamond mod-el. It unifies the positive properties of two materials by combining aluminium oxide particles in one polymer matrix. The aluminium ox-ide particles are enclosed in the matrix. Thus, there are no predeter-mined breaking points and the adhesion is very high, e.g. in the case of Ceram C0 15 N/mm2. Since Ceram is solvent-free, these coatings can be applied with one layer.

Ceram coatings are available in four different quality levels. These are distinguished in terms of their resistance to abrasive corrosion. While corrosion resistance is very good for all four quality levels, resistance to abrasion increases the higher the ordinal number (C0 = low pro-tection from abrasion; C3 = very good protection from abrasion) of the coating, since coarser aluminium particles are processed. The in-dividual layers get thicker and the mixture of large, medium-sized and small aluminium oxide particles is such that even in the case of abrasion with fine sand, the coatings are very stable.

Ceram C0: The coating is applied using the airless method in one lay-er of 0.4 mm.

Ceram C1: The coating is applied with a paintbrush and may consist of up to three layers. The layer thickness is 1.5 mm.

Ceram C2: The coating is applied with a spatula. The layer thickness is 1.5 mm and consists of one coat.

Ceram C3: The coating is applied with a spatula. The layer thickness is 3 mm and consists of one coat. For tight gaps/clearance, a mechani-cal process is necessary.

For use in special fluids, the individual Ceram qualities can be com-bined with one another, e.g. C2 + C1.

The Ceram coating is also very well suited for use in maritime envi-ronments. For its Ceram C0 coating, Wilo grants a guarantee of 5

years for use in seawater. The prerequisite is that the coating is intact

Structure of different coatings

1.) Basic material e.g. housing in cast iron2.) 1st coating: zinc dust priming (50 m), adhesiveness 2.5 N/mm2

3.) 2nd to 4thcoating: tar epoxy resin (110 m), adhesiveness 5 N/mm2

The illustration shows the structure of a tar expoxy resin coating with zinc dust priming. The coating consists of 4 individual layers with total layer thickness of 380 m. The three lines in dark grey represent the weak points of this coating, the black line shows the predetermined breaking point.

1.) Basic material e.g. housing in cast iron2.) 1st coating: Ceram C0 (400 m), adhesiveness 15 N/mm2

This illustration shows the structure of a Ceram C0 coating. The coating con-sists of a one individual layer with a total layer thickness of 400 m. The airless application method allows a very high surface quality.

1

2

3

3

3

1

2

33


Ceram coating


Increase efficiency, reduce costsSince water is being used more and more economically, the propor-tion of contaminants is increasing relative to the amount of water. This means that the concentration of corrosive and abrasive constit-uents is higher.

Sewage units are always exposed to this aggressive fluid. Corrosion and abrasion affect the surfaces and material structures of the units, sometimes with considerable impairments to the material, and thus also the performance.

This significantly reduces the hydraulic efficiency. This results in the units having an increased current consumption. On the other hand, the pumps no longer work at their optimum, the radial forces in-crease, there is more stress on the bearings and mechanical seals, and the service life of the machines is reduced.

When standard materials are used, such as grey cast iron, under high stress, it may be necessary to exchange the components already after 500 hours of operation. Ceram coatings allow the service life to be increased by a factor of 4, and this at the same high efficiency, which means minimum energy costs.

If one takes the overall costs over the entire service life of the pump into account, the investment costs for a unit coated with Ceram are less than 10%, and thus negligible. On the other hand, there is a high savings potential due to the fact that fewer repairs are required, re-sulting in a significant reduction of system downtimes. The amortisa-tion is then usually quickly reached due to the higher efficiency.

Use of the various Ceram qualities Ceram C0 is used for the complete outer and inner coating. It's ideally suited for corrosion protection.

Ceram C1 is used for the inner coating of pump components. The main field of application is the coating of the impeller and the suction port .

Ceram C2 and C3 are used for the inner coating of pump components. The main field of application is the coating of the pump housing.

In order to guarantee protection even in especially aggressive and corrosive fluids, the Ceram types are combined with each other, e.g. C2 + C1 or C3 + C1.



Ceram coating

Planning guide Sewage pumps Ceram coating Subject to change 09/2008 WILO SE Wilo Catalogue C2 - 50 Hz - Sewage pumps from DN 32 to DN 800Ceram C0 - Technical data DescriptionCeram C0 is a sprayable, solvent-free two-component polymer coat-ing substance with an aluminium oxide basis for protecting our prod-ucts against corrosion when there is additional strong mechanical stress.

CompositionSolvent-free epoxy polymer with solvent-free polyamine hardener and various extenders.

Properties Tough and durable coating with high mechanical and chemical resist-ance and very good abrasion resistance.

Excellent wet adhesion and compatibility with cathodic corrosion protection as single-layer coating on steel surfaces.

Very good adhesion to steel surfaces. Replaces bituminous coatings. Saves costs due to the long service life, low maintenance and easy reparability.

Tested by the "Bundesanstalt fr Wasserbau" (German Federal Insti-tute for Hydraulic Engineering) (BAW).

Solvent-free. Hardened coating has a high-gloss finish.

Key: 1 = stable; 2 = stable, short-term; 3 = overflow-stable, immedi-ate cleaning; 4 = not recommended for direct contact

Technical data

Density (mixture) adhesive strength/steel

ASTM D 792 ISO 4624

1.4 g/cm3

15 N/mm2

Impact resistance / strength DIN EN ISO 6272 9 J

Temperature resistance: dry, long-term

60 C

Temperature resistance: dry, short-term

120 C

Temperature resistance: wet/ liquid Depending on the fluid; On request

Solid content (mixture) Volumeweight

97 %98 %

Resistance table

Fluid Temperature FactorSewage, alkaline (pH 11) +20 C 1

Sewage, alkaline (pH 11) +40 C 1

Sewage, slightly acidic (pH 6) +20 C 1

Sewage, slightly acidic (pH 6) +40 C 1

Sewage, highly acidic (pH 1) +20 C 2

Sewage, highly acidic (pH 1) +40 C 3

Ammonium hydroxide (5%) +40 C 3

Decanol (fatty alcohol) +20 C 1

Decanol (fatty alcohol) +50 C 1

Ethanol (40%) +20 C 1

Ethanol (96%) +20 C 3

Ethylene glycol +20 C 1

Heating oil/diesel +20 C 1

Compressor oil +20 C 1

Methyl ethyl ketone (MEK) +20 C 3

Caustic soda (5%) +20 C 1

Caustic soda (5%) +50 C 2

Sodium chloride solution (10%) +20 C 1

Hydrochloric acid (5%) +20 C 2



Sulphuric acid (10%) +20 C 2

Sulphuric acid (20%) +20 C 3

Nitric acid (5%) +20 C 3

Toluene +20 C 2

Water (cooling/industrial water) +50 C 1

Xylene +20 C 1

Resistance table

Fluid Temperature Factor

35


Ceram coating


Planning guide Sewage pumps Ceram coating Subject to change 09/2008 WILO SE Wilo Catalogue C2 - 50 Hz - Sewage pumps from DN 32 to DN 800Ceram C1 - Technical dataDescriptionCeram C1 is a cold-hardening, solvent-free composite material based on two components with selected reinforcement fillers and extend-ers.

CompositionPolymer/aluminium oxide composite material made of a base com-pound and reinforcement.Base compound: A modified polymer made up of two parts with an aliphatic hardening agent.Reinforcement: A mixture (protected by proprietary rights) made up of aluminium oxide and extenders.This mixture has excellent abrasion resistance and can be applied very easily.

Properties The completely hardened Ceram C1 coating has a glossy finish, no pores and is easy to clean, mechanically very resistant, abrasion-proof and has excellent adhesive properties.

Ceram C1 hardens without shrinking and is resistant to a large number of chemicals, oils, greases, solvents, diluted organic and inor-ganic acids and bases and saline solutions.

Ceram C1 reduces friction and improves flow and efficiency. Excellent corrosion protection.

Tested at 20 C. Sample hardened for 12 days at 20 C. Longer hard-ening improves the chemical resistance.Key: 1 = stable; 2 = stable, short-term; 3 = overflow-stable, immedi-ate cleaning; 4 = not recommended for direct contact

Technical data

Hardness Buchholz 115

Density / mixture ASTM D 792 1.4 g/cm3

Shrinkage during hardening ASTM D 2566 0.002mm/cm

Tensile shear resistance ASTM D 1002 13.8 N/mm2

Tensile strength / ultimate strain

ASTM D 638 26.2 N/mm2

Compressive strength ASTM D 695 60 N/mm2

Bending strength ASTM D 790 55.2 N/mm2

Adhesive strength / steel ISO 4624 13.8 N/mm2

Impact resistance / strength ASTM D 256 11 J/m

Coefficient of linear expan-sion

ASTM D 696 34.5 x 10-61 1/K

Electrical resistance ASTM D 257 8 Ohm cm

Thermal conductivity ASTM C 177 0.7 W/m x K

Porosity test Test voltage 5 V/m layer thickness

Temperature resistance, dry ASTM D 648 140 C

Temperature resistance, wet ASTM D 648 60 C

Resistance table

Fluid FactorAcidsSulphuric acid (10%) 2

Sulphuric acid (20%) 3

Hydrochloric acid (5%) 1



Nitric acid (5%) 1

Nitric acid (10%) 3

Phosphoric acid (5%) 1

Phosphoric acid (20%) 3

Bases and bleaches

Sodium hydroxide (10%) 1

Sodium hydroxide (50%) 1

Ammonia (5%) 2

Ammonium hydroxide (28%) 1

Potassium hydroxide (10%) 1


Fixing salt (6%) 1

Soap solution (5%) 1

Cement mortar / concrete 1

Other compounds

Isopropanol 1

Kerosene 1

Naphtha 1

Salt water 1

Sewage 1

Toluene 1

Xylene 1

Bunker C 1

Diesel oil 1

Resistance table

Fluid Factor



Ceram coating

Planning guide Sewage pumps Ceram coating Subject to change 09/2008 WILO SE Wilo Catalogue C2 - 50 Hz - Sewage pumps from DN 32 to DN 800Ceram C2 - Technical dataDescriptionCeram C2 is a high-performance composite material for repairing and protecting all metal surfaces which are subject to abrasion, corrosion, cavitation and chemical exposure. Ceram C2 is applied with a coating thickness of 1.5 mm. It does not shrink and consists almost entirely of solids. Ceram C2 contains a high percentage of carbides for use under extremely abrasive operating conditions which involve complex and expensive repair measures. The material can either be used for re-storing abraded metal surfaces or as a preventive coating which is su-perior to the original metal in terms of its abrasive strength. Ceram C2 can be used instead of metal applications, tiles, rubber fillers, etc. Its thermal stability is outstanding.

CompositionPolymer/aluminium oxide composite material made of a base com-pound and reinforcement.Base compound: A modified polymer made up of two parts with an aliphatic hardening agent.Reinforcement: A mixture (protected by proprietary rights) made up of aluminium oxide and silicon carbide particles.This mixture has excellent abrasion resistance and can be applied very easily.

Properties Excellent abrasion resistance ensures long operation and usually lasts longer than a welded-on metal coating.

Can be easily moulded to any metal surface. Its tough synthetic resin structure is resistant to temperature shocks and impact.

Excellent adhesion ensures reliability and prevents stripping. Simple application reduces work expenses and downtimes. Withstands varying chemical operating conditions when metals fail. Practical 4:1 weight and volume mixture ratio.

Tested at 20 C. Sample hardened for 7 days at 20 C. Longer hard-ening improves the chemical resistance.Key: 1 = stable; 2 = stable, short-term; 3 = overflow-stable, immedi-ate cleaning; 4 = not recommended for direct contact

Technical data

Hardness Shore D 90

Density ASTM D 792 1.85 g/cm2

Shrinkage during hardening ASTM D 2566 0mm/cm

Tensile shear resistance ASTM D 1002 13.24 N/mm2

Tensile strength / ultimate strain

ASTM D 638 27 N/mm2

Compressive strength ASTM D 695 103.4 N/mm2

Bending strength ASTM D 790 69.0 N/mm2

Adhesive strength / steel ASTM C 633 ---

Impact resistance / strength ASTM D 256 3.3 J/m

Linear expansion coefficient ASTM D 696 ---

Electrical resistance ASTM D 257 ---

Thermal conductivity ASTM C 177 ---

Dielectric strength ASTM D 149 4 kV/mm

Temperature resistance, dry ASTM D 648 250 C

Temperature resistance, wet ASTM D 648 80 C

Resistance table

Fluid Factor

Acids






Acetic acid (5%) 2

Acetic acid (10%) 4

Bases and bleachesCaustic soda (10%) 1

Caustic soda (30%) 1

Ammonium hydroxide (28%) 1



Other compounds

Isopropyl alcohol 1

Kerosene 1

Naphtha 1

Salt water 1

Sewage 1

Toluene 1

Xylene 1

Bunker C 1

Diesel 1

Resistance table

Fluid Factor

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Ceram coating


Planning guide Sewage pumps Ceram coating Subject to change 09/2008 WILO SE Wilo Catalogue C2 - 50 Hz - Sewage pumps from DN 32 to DN 800Ceram C3 - Technical dataDescriptionCeram C3 is a high-performance composite material for repairing and protecting all metal surfaces which are subject to abrasion, corrosion, cavitation and chemical exposure. Ceram C3 is applied with a coating thickness of 3 mm. It does not shrink and consists almost entirely of solids. Ceram C3 contains a high percentage of carbides for use under extremely abrasive operating conditions which involve complex and expensive repair measures. The material can either be used for re-storing abraded metal surfaces or as a preventive coating which is su-perior to the original metal with regard to abrasive strength. Cera

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