Wilo HC 20.1 E3 Series User manual

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Wilo Motor HC 20.1 + EMU FA, Rexa SUPRA, Rexa
SOLID
6073324 • Ed.02/2019-01
en Installation and operating instructions

en
Installation and operating instructions Wilo Motor HC 20.1 + EMU FA, Rexa SUPRA, Rexa SOLID 3
Table of contents
1 General information ................................................................................................................................................................. 5
1.1 About these instructions ..................................................................................................................................................................................5
1.2 Copyright ............................................................................................................................................................................................................5
1.3 Subject to change..............................................................................................................................................................................................5
1.4 Warranty..............................................................................................................................................................................................................5
2 Safety......................................................................................................................................................................................... 5
2.1 Identification of safety instructions................................................................................................................................................................5
2.2 Personnel qualifications....................................................................................................................................................................................7
2.3 Electrical work ....................................................................................................................................................................................................7
2.4 Monitoring devices ............................................................................................................................................................................................7
2.5 Use in fluids hazardous to health ....................................................................................................................................................................8
2.6 Transport.............................................................................................................................................................................................................8
2.7 Installing/dismantling........................................................................................................................................................................................8
2.8 During operation ................................................................................................................................................................................................8
2.9 Maintenance tasks.............................................................................................................................................................................................9
2.10 Operating fluid ...................................................................................................................................................................................................9
2.11 Operator responsibilities...................................................................................................................................................................................9
3 Application/use....................................................................................................................................................................... 10
3.1 Intended use.................................................................................................................................................................................................... 10
3.2 Improper use.................................................................................................................................................................................................... 10
4 Product description................................................................................................................................................................ 10
4.1 Design............................................................................................................................................................................................................... 10
4.2 Monitoring devices ......................................................................................................................................................................................... 12
4.3 Operating modes............................................................................................................................................................................................. 12
4.4 Operation with frequency converter............................................................................................................................................................ 13
4.5 Operation in an explosive atmosphere ........................................................................................................................................................ 13
4.6 Rating plate...................................................................................................................................................................................................... 13
4.7 Type key........................................................................................................................................................................................................... 14
4.8 Scope of delivery............................................................................................................................................................................................. 15
4.9 Accessories ...................................................................................................................................................................................................... 15
5 Transportation and storage................................................................................................................................................... 15
5.1 Delivery............................................................................................................................................................................................................. 15
5.2 Transport.......................................................................................................................................................................................................... 15
5.3 Storage ............................................................................................................................................................................................................. 16
6 Installation and electrical connection .................................................................................................................................. 17
6.1 Personnel qualifications................................................................................................................................................................................. 17
6.2 Installation types............................................................................................................................................................................................. 17
6.3 Operator responsibilities................................................................................................................................................................................ 17
6.4 Installation ....................................................................................................................................................................................................... 17
6.5 Electrical connection...................................................................................................................................................................................... 23
7 Commissioning........................................................................................................................................................................ 27
7.1 Personnel qualifications................................................................................................................................................................................. 27
7.2 Operator responsibilities................................................................................................................................................................................ 27
7.3 Direction of rotation check (for three-phase current motors only)........................................................................................................ 27
7.4 Operation in an explosive atmosphere ........................................................................................................................................................ 28
7.5 Before switching on........................................................................................................................................................................................ 28
7.6 Switching on and off ...................................................................................................................................................................................... 29
7.7 During operation ............................................................................................................................................................................................. 29
8 Shut-down/dismantling......................................................................................................................................................... 30
8.1 Personnel qualifications................................................................................................................................................................................. 30
8.2 Operator responsibilities................................................................................................................................................................................ 30
8.3 Shut-down....................................................................................................................................................................................................... 30
8.4 Removal............................................................................................................................................................................................................ 31

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4 WILO SE 2019-01
9 Maintenance and repair.......................................................................................................................................................... 32
9.1 Personnel qualifications................................................................................................................................................................................. 33
9.2 Operator responsibilities................................................................................................................................................................................ 33
9.3 Operating fluid ................................................................................................................................................................................................ 33
9.4 Maintenance intervals.................................................................................................................................................................................... 34
9.5 Maintenance measures .................................................................................................................................................................................. 35
9.6 Repairs .............................................................................................................................................................................................................. 39
10 Faults, causes and remedies .................................................................................................................................................. 41
11 Spare parts............................................................................................................................................................................... 44
12 Disposal.................................................................................................................................................................................... 44
12.1 Oils and lubricants........................................................................................................................................................................................... 44
12.2 Water-glycol mixture..................................................................................................................................................................................... 44
12.3 Protective clothing .........................................................................................................................................................................................44
12.4 Information on the collection of used electrical and electronic products.............................................................................................. 44
13 Appendix.................................................................................................................................................................................. 44
13.1 Tightening torques ......................................................................................................................................................................................... 45
13.2 Operation with frequency converter............................................................................................................................................................ 45
13.3 Ex rating ........................................................................................................................................................................................................... 46

General information en
Installation and operating instructions Wilo Motor HC 20.1 + EMU FA, Rexa SUPRA, Rexa SOLID 5
1 General information
1.1 About these instructions These installation and operating instructions are an integral part of the product. Read
these instructions before commencing work and keep them in an accessible place at all
times. Strict adherence to these instructions is a precondition for the intended use and
correct operation of the product. All information and markings on the product must be
observed.
The language of the original operating instructions is German. All other languages of
these instructions are translations of the original operating instructions.
1.2 Copyright These installation and operating instructions have been copyrighted by the manufac-
turer. Contents of any kind may not be reproduced or distributed, or used for purposes
of competition and shared with others.
1.3 Subject to change The manufacturer reserves the right to make technical modifications to the device or
individual components. The illustrations used may differ from the original and are in-
tended as an example representation of the device.
1.4 Warranty The specifications in the current “General Terms and Conditions” apply to the warranty
and the warranty period. These can be found at www.wilo.com/legal
Any deviations must be contractually agreed and shall then be given priority.
Claim to warranty
If the following points are complied with, the manufacturer is obligated to rectify every
qualitative or constructive flaw:
ƒThe defects are reported in writing to the manufacturer within the warranty period.
ƒApplication according to intended use.
ƒAll monitoring devices are connected and tested before commissioning.
Exclusion from liability
Exclusion from liability excludes all liability for personal injury, material damage or fi-
nancial losses. This exclusion ensues as soon as one of the following applies:
ƒInadequate configuration due to inadequate or incorrect instructions by the operator
or the client
ƒNon-compliance with installation and operating instructions
ƒImproper use
ƒIncorrect storage or transport
ƒIncorrect installation or dismantling
ƒInsufficient maintenance
ƒUnauthorised repairs
ƒInadequate construction site
ƒChemical, electrical or electro-chemical influences
ƒWear
2 Safety This chapter contains basic information for the individual phases of the life cycle. Fail-
ure to observe this information carries the following risks:
ƒInjury to persons from electrical, mechanical and bacteriological factors as well as
electromagnetic fields
ƒEnvironmental damage from discharge of hazardous substances
ƒProperty damage
ƒFailure of important functions of the product
Failure to observe the information contained herein will result in the loss of claims for
damages.
The instructions and safety instructions in the other chapters must also be ob-
served!
2.1 Identification of safety instruc-
tions These installation and operating instructions set out safety instructions for preventing
personal injury and damage to property. These safety instructions are shown differ-
ently:
ƒSafety instructions relating to personal injury start with a signal word, are preceded
by a corresponding symbol and are shaded in grey.

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6 WILO SE 2019-01
DANGER
Type and source of the danger!
Consequences of the danger and instructions for avoidance.
ƒSafety instructions relating to property damage start with a signal word and are dis-
played without a symbol.
CAUTION
Type and source of the danger!
Consequences or information.
Signal words
ƒDANGER!
Failure to observe the safety instructions will result in serious injuries or death!
ƒWARNING!
Failure to follow the instructions can lead to (serious) injuries!
ƒCAUTION!
Failure to follow the instructions can lead to property damage and a possible total
loss.
ƒNOTICE!
Useful information on handling the product
Markups
‡Prerequisite
1. Work step/list
⇒ Notice/instructions
▶ Result
Symbols
These instructions use the following symbols:
Danger of electric voltage
Danger of bacterial infection
Danger of explosion
Danger – explosive atmosphere
General warning symbols
Warning of cutting injuries
Warning of hot surfaces
Warning of high pressure
Warning of suspended loads

Safety en
Installation and operating instructions Wilo Motor HC 20.1 + EMU FA, Rexa SUPRA, Rexa SOLID 7
Personal protective equipment: Wear a safety helmet
Personal protective equipment: Wear foot protection
Personal protective equipment: Wear hand protection
Personal protective equipment: Wear mouth protection
Personal protective equipment: Wear safety goggles
Autonomous work prohibited! A second person must be present.
Useful information
2.2 Personnel qualifications Personnel must:
ƒBe instructed about locally applicable regulations governing accident prevention.
ƒHave read and understood the installation and operating instructions.
Personnel must have the following qualifications.
ƒElectrical work: A qualified electrician must carry out the electrical work.
ƒInstallation/dismantling: The technician must be trained in the use of the necessary
tools and fixation materials for the relevant construction site.
ƒMaintenance tasks: The technician must be familiar with the use of operating fluids
and their disposal. In addition, the technician must have basic knowledge of mech-
anical engineering.
Definition of “qualified electrician”
A qualified electrician is a person with appropriate technical education, knowledge and
experience who can identify and prevent electrical hazards.
2.3 Electrical work ƒElectrical work must be carried out by a qualified electrician.
ƒBefore commencing work, disconnect the product from the mains and safeguard it
from being switched on again.
ƒObserve applicable local regulations when connecting to the mains power supply.
ƒAdhere to the requirements of the local energy supply company.
ƒTrain personnel in connecting electrics.
ƒInstruct personnel in options for switching off the device.
ƒComply with the technical specifications contained in these installation and operat-
ing instructions and on the rating plate.
ƒEarth the device.
ƒObserve regulations for connection to the electrical switching system.
ƒComply with the specifications on electro-magnetic compatibility when using elec-
tronic start-up controllers (e.g. soft starter or frequency converter). If required, take
into account special measures (e.g. shielded cables, filters etc.).
ƒReplace defective connection cables. Contact customer service.
2.4 Monitoring devices The following monitoring devices must be provided on-site:
Circuit breaker
The size and switching characteristics of the circuit breakers must conform to the rated
current of the connected product. Observe local regulations.

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8 WILO SE 2019-01
Motor protection switch
Make provision for an on-site motor protection switch for devices without a plug! The
minimum requirement is a thermal relay/motor protection switch with temperature
compensation, differential triggering and anti-reactivation device in accordance with
the local regulations. In case of sensitive mains, make provision for the installation on-
site of other protective equipment (e.g. overvoltage, undervoltage or phase failure re-
lay, etc.).
Residual-current device (RCD)
Comply with the regulations of the local energy supply company! The use of a residual-
current device is recommended.
If persons come into contact with the device and conductive fluids, secure the connec-
tion with a residual-current device (RCD).
2.5 Use in fluids hazardous to health There is a danger of bacterial infection when using the device in fluids hazardous to
health! Thoroughly clean and disinfect the device after dismantling and prior to further
use. The operator must ensure the following:
ƒThe following protective equipment is provided and worn when cleaning the device:
–Closed safety goggles
–Breathing mask
–Protective gloves
ƒAll persons are informed about the fluid, the associated danger and its correct hand-
ling!
2.6 Transport ƒThe following protective equipment must be worn:
–Safety shoes
–Safety helmet (when using lifting equipment)
ƒAlways hold the handle to transport the device. Never pull the power supply cable!
ƒOnly use legally specified and approved lifting gear.
ƒSelect the lifting gear based on the existing conditions (weather, attachment point,
load, etc.).
ƒAlways attach the lifting gear to the attachment points (handle or lifting eyelet).
ƒThe stability of the lifting equipment must be ensured during operation.
ƒWhen using lifting equipment, a second person must be present to coordinate the
procedure if required (e.g. if the operator’s field of vision is blocked).
ƒPersons are not permitted to stand beneath suspended loads. Do not carry suspen-
ded loads over workplaces where people are present.
2.7 Installing/dismantling ƒWear the following protective equipment:
–Safety shoes
–Safety gloves for protection against cuts
–Safety helmet (when using lifting equipment)
ƒLocally applicable laws and regulations for work safety and accident prevention must
be complied with.
ƒDisconnect the device from the mains and secure it against being switched on again
without authorisation.
ƒAll rotating parts must be at a standstill.
ƒProvide adequate aeration in closed rooms.
ƒWhen working in chambers and closed spaces, a second person must be present for
safety reasons.
ƒTake immediate countermeasures if there is a build-up of toxic or suffocating gases!
ƒClean the device thoroughly. Disinfect devices that are used in fluids hazardous to
health!
ƒMake sure that there is no risk of explosion when carrying out any type of welding
work or work with electrical devices.
2.8 During operation ƒWear the following protective equipment:
–Safety shoes
–Ear protection (in accordance with the notice of the work regulations)
ƒWork area of the device is not a recreational area. No persons are allowed in the work
area during operation.
ƒThe operator must immediately report any faults or irregularities to their line man-
ager.
ƒIf safety-endangering defects occur, the operator must immediately deactivate the
device:

Safety en
Installation and operating instructions Wilo Motor HC 20.1 + EMU FA, Rexa SUPRA, Rexa SOLID 9
–Malfunction of the safety and monitoring device
–Damage to the housing parts
–Damage to the electrical equipment
ƒNever reach into the suction port. The rotating parts can crush and sever limbs.
ƒIf the motor emerges during operation, as well as in dry well installation, the motor
housing can heat up to above 40°C (104°F).
ƒOpen all gate valves in the piping on the suction and pressure side.
ƒEnsure minimum water submersion through dry-running protection.
ƒUnder normal operating conditions, the sound pressure level of the device is below
85dB(A). However, the actual sound-pressure level depends on several factors:
–Installation depth
–Installation
–Fixation of accessories and pipe
–Duty point
–Immersion depth
ƒIf the device is operated under normal operating conditions, the operator must
measure the sound pressure. Ear protection must be worn for sound pressure levels
of 85dB(A) and above and this must be noted in the work regulations!
2.9 Maintenance tasks ƒWear the following protective equipment:
–Closed safety goggles
–Safety shoes
–Safety gloves for protection against cuts
ƒAlways carry out maintenance tasks outside the operating space/installation site.
ƒOnly carry out maintenance tasks mentioned in these installation and operating in-
structions.
ƒOnly original parts from the manufacturer may be used for maintenance and repairs.
Use of parts other than the original parts releases the manufacturer from any liabil-
ity.
ƒCollect any leakage of fluid and operating fluid immediately and dispose of it ac-
cording to the locally applicable guidelines.
ƒStore tools at the designated locations.
ƒAfter completing work, reattach all safety and monitoring devices and check that
they function properly.
Changing operating fluid
In case of a defect, a pressure of several bar can build up in the motor! This pressure
escapes when the screw plugs are opened. If screw plugs are opened without due cau-
tion, they can be ejected at high speed! To avoid injuries, observe the following instruc-
tions:
ƒAdhere to the prescribed sequence of work steps.
ƒUnscrew the screw plugs slowly, but never unscrew them completely. As soon as the
pressure escapes (audible whistling or hissing of air), stop turning the screw plug any
further.
WARNING!Hot operating fluids can also spray out when the pressure is escaping.
This can result in scalding! To avoid injuries, allow the motor to cool down to the
ambient temperature before carrying out any work!
ƒWhen the pressure has completely dissipated, fully unscrew the screw plug.
2.10 Operating fluid The sealing chamber and the cooling system of the motor is filled with white oil or a
water-glycol mixture. Operating fluids must be replaced during regular maintenance
work and disposed of according to the local guidelines.
2.11 Operator responsibilities ƒInstallation and operating instructions must be in a language which the personnel
can understand.
ƒMake sure that the personnel is relevantly trained for the specified work.
ƒProvide the necessary protective equipment and make sure that the personnel wears
it.
ƒSafety and information signs mounted on the device must be always legible.
ƒTrain the personnel pertaining to the functioning of the system.
ƒEliminate risk from electrical current.
ƒEquip hazardous components inside the system with an on-site guard.
ƒIdentify and cordon off the work area.
ƒTo ensure safe working practice, define the responsibilities of the employees.

en Application/use
10 WILO SE 2019-01
Children and persons younger than 16years or with reduced physical, sensory or mental
capacities or limited experience are prohibited from handling the product! A technician
must supervise persons younger than 18years!
3 Application/use
3.1 Intended use Submersible pumps are suitable for pumping:
ƒSewage containing faeces
ƒWastewater (with small amounts of sand and gravel)
ƒProcess sewage
ƒFluids with dry matter up to max. 8%
3.2 Improper use
DANGER
Explosion due to pumping of explosive fluids!
Pumping of highly flammable and explosive fluids (gasoline, kerosene, etc.) in pure
form is strictly prohibited. There is a risk of fatal injury due to explosion! The pumps
are not designed for these fluids.
DANGER
Danger due to fluids hazardous to health!
If the pump is used in fluids hazardous to health, decontaminate the pump after dis-
mantling and before carrying out any other work! There is a risk of fatal injury! Ob-
serve the specifications in the work regulations! The operator must make sure that
the personnel have received and read the work regulations!
The submersible pumps must not be used for pumping:
ƒDrinking water
ƒFluids containing hard components (such as stones, wood, metal, etc.)
ƒFluids containing large quantities of abrasive contents (e.g. sand, gavel)
Intended use also includes compliance with this manual. Any other use is regarded as
non-compliant with the intended use.
4 Product description
4.1 Design Submersible sewage pump as submersible monobloc unit for continuous duty in wet
well and dry well installation.
1
2
3
4
5
6
Fig.1: Overview
1 Handle
2 Motor
3 Connection cable
4 Pressure port
5 Hydraulics housing
6 Bearing housing
4.1.1 Hydraulics Centrifugal hydraulics with different impeller shapes, horizontal flange connection on
the pressure side, inspection cover as well as casing and impeller wear rings.

Product description en
Installation and operating instructions Wilo Motor HC 20.1 + EMU FA, Rexa SUPRA, Rexa SOLID 11
The hydraulics are not self-priming, in other words, the fluid must flow in either auto-
matically or with supply pressure.
Impeller shapes
The individual impeller shapes depend on the size of the hydraulics and not every im-
peller shape is available for every hydraulic system. The following is an overview of the
different impeller shapes:
ƒVortex impeller
ƒSingle-channel impeller
ƒTwo-channel impeller
ƒThree-channel impeller
ƒFour-channel impeller
ƒSOLID impeller, closed or half open
Inspection cover (depending on the hydraulics)
Additional opening on the hydraulics housing. This opening is used to remove clogging
in the hydraulics.
Casing and impeller wear rings (depending on the hydraulics)
The suction port and impeller are subjected to the most stress when pumping. In the
case of channel impellers, the gap between the impeller and the suction port is an im-
portant factor for a constant efficiency. The larger the gap between the impeller and
the suction port, the higher the losses in the delivery rate. The efficiency decreases and
the danger of clogging increases. In order to ensure long and efficient operation of the
hydraulics, an impeller wear ring and/or casing wear ring is installed depending on the
impeller and the hydraulics.
ƒImpeller wear ring
The impeller wear ring is attached to the channel impellers and protects the incom-
ing flow edge of the impeller.
ƒCasing wear ring
The casing wear ring is installed in the suction port of the hydraulics and protects
the incoming flow edge in the centrifugal chamber.
The two components can be replaced easily when worn.
4.1.2 Motor In the three-phase current version, self-cooling submersible motors are used as the
drive. The motor can be used in continuous duty both immersed and non-immersed.
Continuous duty is also possible in dry well installation. The roller bearings are perman-
ently lubricated, which means they are maintenance-free. The connection cable is lon-
gitudinally watertight and has bare cable ends.
4.1.3 Cooling system The motor has an active cooling system with separate cooling circuit. The water-glycol
mixture P35 is used as coolant. Coolant circulation is performed by an impeller. The im-
peller is driven with a magnetic coupling by the motor shaft. The waste heat is trans-
ferred directly to the fluid via the cooling flange. The cooling system is not pressurised
when in cold state. A built-in overpressure valve limits the max. pressure to 3bar in the
event of a fault.
CAUTION!The overpressure valve is only fitted as standard from year of manufac-
ture 2015 onwards. In the case of motors without an overpressure valve, extremely
high pressure can occur in the cooling system if there is a fault. It is imperative that
a conversion is made! Please contact customer service for the conversion!
4.1.4 Seal Different methods are used for the seal to the fluid and the motor compartment:
ƒVersion “G”: two separate mechanical seals
ƒVersion “K”: two mechanical seals in a block seal cartridge made of stainless steel
Leakage from the seal is caught in the sealing chamber or leakage chamber:
ƒThe sealing chamber accommodates any possible leakage of the seal on the fluid
side.
ƒThe leakage chamber accommodates any possible leakage of the seal on the motor
side.
The sealing chamber between the mechanical seals is filled with medical white oil. The
leakage chamber is empty.
4.1.5 Material The following materials are used in the standard version:

en Product description
12 WILO SE 2019-01
ƒPump housing: EN-GJL-250 (ASTMA48 Class35/40B)
ƒImpeller: EN-GJL-250 (ASTMA48 Class35/40B)
ƒMotor housing: EN-GJL-250 (ASTMA48 Class35/40B)
ƒSeal:
–Motor side:
• Version “G”: Carbon/Ceramic
• Version “K”: SiC/SiC
–Fluid side: SiC/SiC
–Static: NBR (nitrile)
The precise details of the materials are shown in the respective configuration.
4.2 Monitoring devices Overview of possible monitoring devices:
HC 20.1 HC 20.1 ...-E3
Internal monitoring devices
Terminal room/motor compartment • •
Motor winding • •
Motor bearings o o
Sealing chamber − −
Leakage chamber • •
Vibration sensor − −
External monitoring devices
Sealing chamber o o
Key: − = not available/possible, o = optional, • = as standard
All the monitoring devices fitted must always be connected!
Monitoring the terminal room and motor compartment
The terminal room and motor compartment monitoring protects the motor terminals
and winding from short-circuits. An electrode in both the terminal room and the motor
compartment measures the moisture content.
Monitoring of motor winding
The thermal motor monitoring protects the motor winding from overheating. Temper-
ature limiting with PTC sensor is fitted.
External monitoring of the sealing chamber
The sealing chamber can be equipped with an external pencil electrode. The electrode
registers fluid ingress through the mechanical seal on the fluid side. An alarm or deac-
tivation of the pump can therefore take place by pump control.
Leakage chamber monitoring
The leakage chamber is equipped with a float switch. The float switch registers fluid in-
gress through the mechanical seal on the motor side. An alarm or deactivation of the
pump can therefore take place by pump control.
Monitoring of motor bearing
The thermal monitoring of the motor bearing protects the roller bearings against over-
heating. Pt100 sensors are used for temperature measurement.
4.3 Operating modes
Operating mode S1: Continuous duty
The pump can operate continuously at the rated load without exceeding the permiss-
ible temperature.
Operating mode: Non-immersed operation
The “non-immersed operation” operating mode describes the possibility of the motor
emerging during the drainage pumping sequence. This allows a further lowering of the
water level as far as the upper edge of the hydraulics. Observe the following points dur-
ing non-immersed operation:

Product description en
Installation and operating instructions Wilo Motor HC 20.1 + EMU FA, Rexa SUPRA, Rexa SOLID 13
ƒOperating mode: Continuous duty (S1).
ƒMax. fluid and ambient temperature: The max. ambient temperature corresponds to
the max. fluid temperature shown on the rating plate.
4.4 Operation with frequency con-
verter Operation on the frequency converter is permitted. Refer to the appendix for the relev-
ant requirements!
4.5 Operation in an explosive atmo-
sphere HC 20.1 HC 20.1 ...-E3
ATEX approval o o
FM approval o −
CSA-Ex approval − −
Key: − = not available/possible, o = optional, • = as standard
For use in explosive atmospheres, the pump must be marked as follows on the rating
plate:
ƒ“Ex” symbol of the corresponding approval
ƒEx classification
For the relevant requirements, refer to the explosion protection chapter in the ap-
pendix of these installation and operating instructions!
ATEX approval
The pumps are suitable for operation in potentially explosive atmospheres:
ƒDevice group: II
ƒCategory: 2, zone 1 and zone 2
These pumps must not be used in zone 0!
FM approval
The pumps are suitable for operation in potentially explosive atmospheres:
ƒProtection class: Explosionproof
ƒCategory: Class I, Division 1
Notice: If the cabling is carried out according to Division 1, installation in Class I, Di-
vision 2 is also permitted.
4.6 Rating plate The following is an overview of the abbreviations and associated data on the rating
plate:
Rating plate
designation
Value
P-Typ Pump type
M-Typ Motor type
S/N Serial number
Art.-No. Article number
MFY Date of manufacture*
QNVolume flow duty point
Qmax Max. volume flow
HNDelivery head duty point
Hmax Max. delivery head
Hmin Min. delivery head
nSpeed
TMax. fluid temperature
IP Protection class
IRated current
IST Starting current
ISF Rated current at service factor
P1Power consumption
P2Rated power

en Product description
14 WILO SE 2019-01
Rating plate
designation
Value
URated voltage
fFrequency
Cos φ Motor efficiency
SF Service factor
OTSOperating mode: immersed
OTEOperating mode: non-immersed
AT Starting mode
IMorg Impeller diameter: original
IMkorr Impeller diameter: corrected
*The date of manufacture is stated in accordance with ISO8601: JJJJWww
ƒJJJJ = year
ƒW = abbreviation for week
ƒww = calendar week
4.7 Type key Example: Wilo-EMU FA 10.82E + HC 20.1-4/22KEx-E3
Wilo-Rexa SUPRA-V10-736A + HC 20.1-4/22KEx-E3
Wilo-Rexa SOLID-Q10-345A + HC 20.1-4/22KEx-E3
Hydraulics type key “EMU FA”
FA Sewage pump
10 x10 = nominal diameter of pressure connection
82 Internal performance coefficient
E
Impeller shape:
W = vortex impeller
E = single-channel impeller
Z = two-channel impeller
D = three-channel impeller
V = four-channel impeller
T = closed two-channel impeller
G = half-open single-channel impeller
Hydraulics type key “Rexa SUPRA”
SUPRA Sewage pump
V
Impeller shape:
V = vortex impeller
C = single-channel impeller
M = multi-channel impeller
10 x10 = nominal diameter of pressure connection
73 Internal performance coefficient
6Characteristic curve number
A
Material version:
A = standard version
B = corrosion protection 1
D = abrasion protection 1
X = special configuration
Hydraulics type key “Rexa SOLID”
SOLID Sewage pump with SOLID impeller
Q
Impeller shape:
T = closed two-channel impeller
G = semi-open single-channel impeller
Q = half-open two-channel impeller
10 x10 = nominal diameter of pressure connection
34 Internal performance coefficient
5Characteristic curve number

Transportation and storage en
Installation and operating instructions Wilo Motor HC 20.1 + EMU FA, Rexa SUPRA, Rexa SOLID 15
Example: Wilo-EMU FA 10.82E + HC 20.1-4/22KEx-E3
Wilo-Rexa SUPRA-V10-736A + HC 20.1-4/22KEx-E3
Wilo-Rexa SOLID-Q10-345A + HC 20.1-4/22KEx-E3
A
Material version:
A = standard version
B = corrosion protection 1
D = abrasion protection 1
X = special configuration
Motor type key
HC Self-cooling motor with separate cooling circuit
20 Size
1Internal code figure
4Number of poles
22 Package length in cm
KSeal version
Ex Ex-rated
E3 IE-efficiency class (derived from IEC60034-30)
4.8 Scope of delivery ƒPump with free cable end
ƒCable length per customer request
ƒMounted accessories, e.g. external pencil electrode, pump support foot, etc.
ƒInstallation and operating instructions
4.9 Accessories ƒSuspension unit
ƒPump support foot
ƒSpecial versions with Ceram coatings or special materials
ƒExternal pencil electrode for sealing chamber control
ƒLevel control devices
ƒFixation accessories and chains
ƒSwitchgear, relays and plugs
5 Transportation and storage
5.1 Delivery After receiving the shipment, this must be checked immediately for defects (damage,
completeness). Defects must be noted on the freight documentation! Furthermore, de-
fects must be notified to the transport company or the manufacturer immediately on
the day of receipt of shipment. Subsequently notified defects can no longer be asser-
ted.
5.2 Transport
WARNING
Standing under suspended loads!
Never allow anyone to stand under suspended loads! Danger of (serious) injuries
caused by falling parts. Loads may not be carried over work places where people are
present!
WARNING
Head and foot injuries due to a lack of protective equipment!
Danger of (serious) injuries during work. Wear the following protective equipment:
• Safety shoes
• Safety helmet must be worn if lifting equipment are used!
NOTICE
Use only properly functioning lifting equipment!
Use only properly functioning lifting equipment to lift and lower the pump. Ensure
that the pump does not become jammed during lifting and lowering. Do not exceed

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16 WILO SE 2019-01
the maximum bearing capacity of the lifting equipment! Check that lifting equip-
ment is functioning properly before use!
Only remove the outer packaging at the place of utilisation to ensure that the pump is
not damaged during transport. Use tear-proof plastic sacks of sufficient size to pack-
age used pumps for transport in a leak-proof manner.
The following points must also be observed:
Fig.2: Attachment point
ƒAdhere to the applicable national safety regulations.
ƒUse legally specified and approved lifting gear.
ƒSelect the lifting gear based on the existing conditions (weather, attachment point,
load, etc.).
ƒOnly attach the lifting gear to the attachment point. Fix with a shackle.
ƒUse lifting equipment with sufficient bearing capacity.
ƒThe stability of the lifting equipment must be ensured during operation.
ƒWhen using lifting equipment, a second person must be present to coordinate the
procedure if required (e.g. if the operator’s field of vision is blocked).
5.3 Storage
DANGER
Danger due to fluids hazardous to health!
If the pump is used in fluids hazardous to health, decontaminate the pump after dis-
mantling and before carrying out any other work! There is a risk of fatal injury! Ob-
serve the specifications in the work regulations! The operator must make sure that
the personnel have received and read the work regulations!
WARNING
Sharp edges on the impeller and suction port!
Sharp edges can form on the impeller and suction port. There is danger of limbs be-
ing severed! Protective gloves must be worn to protect from cuts.
CAUTION
Total damage due to moisture ingress
Moisture ingress in the power supply cable damages the power supply cable and the
pump! Never immerse the end of the power supply cable in a fluid and firmly seal it
during storage.
Newly supplied pumps can be stored for one year. Contact customer service to store
the pump for more than one year.
The following must be observed for storage:
ƒPlace the pump upright (vertical) on a firm bearing surface and secure it against
slipping and falling over!
ƒThe max. storage temperature is -15°C to +60°C (5°F to 140°F) at a max. relative
humidity of 90%, non-condensing. Frost-proof storage at a temperature of 5°C to
25°C (41°F to 77°F) with relative humidity of 40% to 50% is recommended.
ƒDo not store the pump in rooms in which welding work is carried out. The resulting
gases or radiation can corrode the elastomer parts and coatings.
ƒSeal the suction and pressure connection tightly.
ƒProtect power supply cables against kinking and damage.
ƒProtect the pump from direct sunlight and heat. Extreme heat can cause damage to
the impellers and the coating!

Installation and electrical connection en
Installation and operating instructions Wilo Motor HC 20.1 + EMU FA, Rexa SUPRA, Rexa SOLID 17
ƒImpellers must be turned by 180° at regular intervals (3–6months). This prevents
locking of the bearings and renews the lubrication film of the mechanical seal.
WARNING!There is a risk of injury due to sharp edges on the impeller and suction
port!
ƒElastomer parts and the coating are subject to natural brittleness. Contact customer
service if the pump must be stored for more than 6months.
After storage, remove any dust and oil from the pump and check the coating for dam-
age. Repair damaged coatings before further use.
6 Installation and electrical con-
nection
6.1 Personnel qualifications ƒElectrical work: A qualified electrician must carry out the electrical work.
ƒInstallation/dismantling: The technician must be trained in the use of the necessary
tools and fixation materials for the relevant construction site.
6.2 Installation types ƒVertical stationary wet well installation with suspension unit
ƒVertical portable wet well installation with pump support foot
ƒVertical stationary dry well installation
The following installation types are not permitted:
ƒHorizontal installation
6.3 Operator responsibilities ƒObserve locally applicable accident prevention and safety regulations of trade asso-
ciations.
ƒObserve all regulations for working with heavy loads and under suspended loads.
ƒProvide protective equipment and ensure that the protective equipment is worn by
personnel.
ƒObserve local sewage technology regulations for the operation of sewage systems.
ƒAvoid pressure surges!
Pressure surges can occur in long pressure pipes with steep terrain. These pressure
surges can lead to the destruction of the pump!
ƒEnsure the cooling time of the motor depending on the operating conditions and the
size of the pump chamber.
ƒStructural components and foundations must be of sufficient stability in order to al-
low the device to be fixed securely and functionally. The operator is responsible for
the provision and suitability of the structural component/foundation!
ƒCheck that the available consulting documents (installation plans, design of the op-
erating space, inflow conditions) are complete and correct.
6.4 Installation
DANGER
Risk of fatal injury due to dangerous lone working practices!
Work in chambers and narrow rooms as well as work involving risk of falling are dan-
gerous work. Such work may not be carried out autonomously! A second person
must be present for safety reasons.
WARNING
Hand and foot injuries due to lack of protective equipment!
Danger of (serious) injuries during work. Wear the following protective equipment:
• Safety gloves for protection against cuts
• Safety shoes
• Safety helmet must be worn if lifting equipment are used!
NOTICE
Use only properly functioning lifting equipment!
Use only properly functioning lifting equipment to lift and lower the pump. Ensure
that the pump does not become jammed during lifting and lowering. Do not exceed

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18 WILO SE 2019-01
the maximum bearing capacity of the lifting equipment! Check that lifting equip-
ment is functioning properly before use!
ƒPrepare operating space/installation location as follows:
–Clean, free of coarse solids
–Dry well
–Frost-free
–Decontaminated
ƒTake immediate countermeasures if there is a build-up of toxic or suffocating gases!
ƒAttach the lifting gear to the attachment point using a shackle. Only use lifting gear
which has been technically approved.
ƒUse lifting gear for lifting, lowering and transporting the pump. Never pull the pump
by the power supply cable!
ƒIt must be possible to attach lifting equipment safely. The storage place and the op-
erating space/installation site must be accessible with the lifting equipment. The
set-down location must have a solid bearing surface.
ƒThe routed power supply cables must allow safe operation. Check whether the cable
cross-section and the cable length are sufficient for the selected installation type.
ƒThe corresponding IP class must be observed when using switchgear. Install the
switchgear overflow-proof and outside potentially explosive areas!
ƒAvoid air intake into the fluid, use baffles or deflector plates for the inlet. Air which
has entered the system can collect in the pipe system and lead to impermissible op-
erating conditions. Air pockets must be removed via ventilation systems!
ƒA dry run of the pump is prohibited! Avoid air pockets in the hydraulics housing or in
the pipe system. Ensure the water level never falls below the minimum. The installa-
tion of a dry-running protection is recommended!
6.4.1 Indications for double pump oper-
ation If several pumps are used in an operating space, minimum distances between the
pumps and the wall must be complied with. Here there is a difference in the distances
depending on the type of system: Alternating operation or parallel operation.
d
A2
A1
Fig.3: Minimum distances
d Diameter hydraulics housing
A1
Minimum distance from the wall:
- alternating operation: min. 0.3×d
- parallel operation: min. 1×d
A2
Distance to pressure pipes
- alternating operation: min. 1.5×d
- parallel operation: min. 2×d
6.4.2 Maintenance tasks After a storage period of more than 6months, carry out the following maintenance
tasks before installation:
ƒRotate the impeller.
ƒCheck the oil in the sealing chamber.
ƒCheck the coolant.
6.4.2.1 Rotate impeller
WARNING
Sharp edges on the impeller and suction port!
Sharp edges can form on the impeller and suction port. There is danger of limbs be-
ing severed! Protective gloves must be worn to protect from cuts.
‡Pump is not connected to the mains!
‡Protective equipment has been put on!

Installation and electrical connection en
Installation and operating instructions Wilo Motor HC 20.1 + EMU FA, Rexa SUPRA, Rexa SOLID 19
1. Place the pump upright on a firm surface. WARNING!Risk of hands being crushed.
Ensure that the pump cannot fall over or slip away!
2. Carefully and slowly reach into the hydraulics housing through the pressure port
and rotate the impeller.
6.4.2.2 Check the coolant
- -
12
max
Fig.4: Check the coolant
1 Overpressure valve
2 Interior hexagonal head screw for motor cover fixation
- Drain the coolant
‡Pump is not installed.
‡Pump is not connected to the mains.
‡Protective equipment must be put on!
1. Place the pump on a firm surface in a vertical position. WARNING!Risk of hands
being crushed. Make sure that the pump can not fall over or slip!
2. Position a suitable tank to collect the operating fluid.
3. To vent possible overpressure, unscrew the overpressure valve by around 3 to 4
turns.
CAUTION!Do not unscrew the overpressure valve completely!
4. Once the overpressure has vented, screw the overpressure valve back in. Max.
tightening torque: 55Nm (40.5ft·lb)!
5. Unscrew the interior hexagonal head screws on the motor cover in a crosswise
manner.
6. Remove the motor cover.
7. Two marks are worked into the inside of the housing. The operating fluid must
reach the upper “max.” mark. If there is not enough operating fluid, fill the operat-
ing fluid up to the marking. Note information on operating fluid type, see chapter
“Maintenance and repair”.
8. Take a sample of operating fluid using a test pipette.
9. Check the operating fluid:
⇒ If the operating fluid is clear, continue to use the operating fluid.
⇒ If the operating fluid is contaminated (cloudy/dark), add new operating fluid,
see chapter “Maintenance and repair”. Dispose of operating fluid in accord-
ance with local regulations!
⇒ Notify customer service if the operating fluid contains metal swarf!
10.Clean the motor cover and renew the O-ring.
11.Place the motor cover on the motor housing and re-tighten the interior hexagonal
head screws. Max. tightening torque: see appendix!

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20 WILO SE 2019-01
6.4.2.3 Check oil in the sealing chamber
-
+
Fig.5: Sealing chamber: Check oil
+ Add the oil to the sealing chamber
- Drain the oil in the sealing chamber
‡Pump is not installed.
‡Pump is not connected to the mains.
‡Protective equipment has been put on!
1. Place the pump upright on a firm surface.WARNING!Risk of hands being crushed.
Ensure that the pump cannot fall over or slip away!
2. Place a suitable tank to collect the operating fluid.
3. Unscrew the screw plug (+).
4. Unscrew screw plug (-) and drain the operating fluid. If a shut-off ball cock is in-
stalled on the outlet opening, open the shut-off ball cock.
5. Check the operating fluid:
⇒ If the operating fluid is clear, reuse operating fluid.
⇒ If the operating fluid is contaminated (black), fill with new operating fluid. Dis-
pose of operating fluid in accordance with the local regulations!
⇒ Notify customer service if the operating fluid contains swarf!
6. If a shut-off ball cock is installed on the outlet opening, close the shut-off ball
cock.
7. Clean the screw plug (-), replace the seal ring and screw it back in. Max. tightening
torque: 8Nm (5.9ft·lb)!
8. Pour the new operating fluid in through the hole for the screw plug (+).
⇒ Comply with the specifications for operating fluid type and quantity! When re-
cycling the operating fluid, check the quantity and if required adjust it!
9. Clean the screw plug (+), replace the seal ring and screw it back in. Max. tightening
torque: 8Nm (5.9ft·lb)!
6.4.3 Stationary wet well installation
NOTICE
Pumping problems due to water level being too low
If the fluid is lowered too much, separation of the volume flow may occur. Further-
more, air cushions may form in the hydraulic system, resulting in undesirable beha-
viour during operation. The minimum permissible water level must reach the upper
edge of the hydraulics housing!
The pump is installed in the fluid for the wet well installation. For this, a suspension unit
must be installed in the chamber. On the pressure side, the on-site pipe system is con-
nected to the suspension unit and on the suction side to the pump. The connected pipe
system must be self-supporting. The suspension unit must not support the pipe sys-
tem!