Wilo FKT 20.2 User manual

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Wilo Motor FKT 20.2, 27.1, 27.2:
EMU FA, Rexa SUPRA, Rexa SOLID
6086014 • Ed.01/2019-10
en Installation and operating instructions

en
Installation and operating instructions Wilo Motor FKT 20.2, 27.1, 27.2:#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 Exclusion from warranty and liability..............................................................................................................................................................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 Permanent magnet motor ................................................................................................................................................................................8
2.7 Transport.............................................................................................................................................................................................................8
2.8 Installing/dismantling........................................................................................................................................................................................8
2.9 During operation ................................................................................................................................................................................................9
2.10 Maintenance tasks.............................................................................................................................................................................................9
2.11 Operating fluid ...................................................................................................................................................................................................9
2.12 Operator responsibilities................................................................................................................................................................................ 10
3 Application/use....................................................................................................................................................................... 10
3.1 Intended use.................................................................................................................................................................................................... 10
3.2 Improper use.................................................................................................................................................................................................... 10
4 Product description................................................................................................................................................................ 10
4.1 Design............................................................................................................................................................................................................... 10
4.2 Digital Data Interface ..................................................................................................................................................................................... 12
4.3 Monitoring devices ......................................................................................................................................................................................... 13
4.4 Operating modes............................................................................................................................................................................................. 14
4.5 Operation with frequency converter............................................................................................................................................................ 14
4.6 Operation in an explosive atmosphere ........................................................................................................................................................ 14
4.7 Rating plate...................................................................................................................................................................................................... 15
4.8 Type key........................................................................................................................................................................................................... 16
4.9 Scope of delivery............................................................................................................................................................................................. 17
4.10 Accessories ...................................................................................................................................................................................................... 17
5 Transportation and storage................................................................................................................................................... 17
5.1 Delivery............................................................................................................................................................................................................. 17
5.2 Transport.......................................................................................................................................................................................................... 17
5.3 Storage ............................................................................................................................................................................................................. 18
6 Installation and electrical connection .................................................................................................................................. 19
6.1 Personnel qualifications................................................................................................................................................................................. 19
6.2 Installation types............................................................................................................................................................................................. 19
6.3 Operator responsibilities................................................................................................................................................................................ 19
6.4 Installation ....................................................................................................................................................................................................... 19
6.5 Electrical connection...................................................................................................................................................................................... 26
7 Commissioning........................................................................................................................................................................ 32
7.1 Personnel qualifications................................................................................................................................................................................. 32
7.2 Operator responsibilities................................................................................................................................................................................ 32
7.3 Direction of rotation check (for three-phase current motors only)........................................................................................................ 33
7.4 Operation in an explosive atmosphere ........................................................................................................................................................ 33
7.5 Before switching on........................................................................................................................................................................................ 33
7.6 Switch on and off............................................................................................................................................................................................ 34
7.7 During operation ............................................................................................................................................................................................. 34
8 Shut-down/dismantling......................................................................................................................................................... 35
8.1 Personnel qualifications................................................................................................................................................................................. 35
8.2 Operator responsibilities................................................................................................................................................................................ 35

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4 WILO SE 2019-10
8.3 Shut-down....................................................................................................................................................................................................... 35
8.4 Removal............................................................................................................................................................................................................ 36
9 Maintenance and repair.......................................................................................................................................................... 38
9.1 Personnel qualifications................................................................................................................................................................................. 38
9.2 Operator responsibilities................................................................................................................................................................................ 38
9.3 Operating fluid ................................................................................................................................................................................................ 39
9.4 Maintenance intervals.................................................................................................................................................................................... 40
9.5 Maintenance measures .................................................................................................................................................................................. 41
9.6 Repairs .............................................................................................................................................................................................................. 45
10 Faults, causes and remedies .................................................................................................................................................. 47
11 Spare parts............................................................................................................................................................................... 50
12 Disposal.................................................................................................................................................................................... 50
12.1 Oils and lubricants........................................................................................................................................................................................... 51
12.2 Water-glycol mixture..................................................................................................................................................................................... 51
12.3 Protective clothing .........................................................................................................................................................................................51
12.4 Information on the collection of used electrical and electronic products.............................................................................................. 51
13 Ex rating................................................................................................................................................................................... 51
13.1 Identification of Ex-rated pumps................................................................................................................................................................. 51
13.2 Protection class...............................................................................................................................................................................................51
13.3 Intended use.................................................................................................................................................................................................... 51
13.4 Electrical connection...................................................................................................................................................................................... 52
13.5 Commissioning................................................................................................................................................................................................ 54
13.6 Maintenance and repair.................................................................................................................................................................................. 54
14 Appendix.................................................................................................................................................................................. 55
14.1 Tightening torques ......................................................................................................................................................................................... 55
14.2 Frequency converter operation .................................................................................................................................................................... 55

General information en
Installation and operating instructions Wilo Motor FKT 20.2, 27.1, 27.2:, EMU FA, Rexa SUPRA, Rexa SOLID 5
1 General information
1.1 About these instructions These instructions form part of the product. Adherence to these instructions is a re-
quirement for the intended use and correct operation of the product:
ƒCarefully read the instructions prior to any activities on and with the product.
ƒKeep the instructions in an accessible place at all times.
ƒObserve all product specifications and labels on the device.
The language of the original operating instructions is German. Versions of these in-
structions in any other language are translations of the original operating instructions.
1.2 Copyright Copyright remains with Wilo. Do not:
ƒReproduce any content.
ƒDistribute any content.
ƒUse any content for competition purposes without authorisation.
Wilo shall reserve the right to change the listed data without notice and shall not be li-
able for technical inaccuracies and/or omissions.
1.3 Subject to change Wilo shall reserve the rights to make technical changes to the product and individual
components. The illustrations used may differ from the original and are intended as a
sample representation of the device.
1.4 Exclusion from warranty and liab-
ility Wilo shall specifically not assume any warranty or liability in the following cases:
ƒInadequate configuration due to inadequate or incorrect instructions by the operator
or the client
ƒNon-compliance with these instructions
ƒImproper use
ƒIncorrect storage or transport
ƒIncorrect installation or dismantling
ƒInsufficient maintenance
ƒUnauthorised repairs
ƒInadequate construction site
ƒChemical, electrical or electrochemical 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.
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.

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6 WILO SE 2019-10
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 caused by electric voltage
Danger of bacterial infection
Danger caused by strong magnetic field
Danger of explosion
Danger caused by explosive atmosphere
General warning symbol
Warning – risk of cutting injuries
Warning – hot surfaces
Warning – high pressure
Warning – suspended loads
Personal protective equipment: wear a safety helmet

Safety en
Installation and operating instructions Wilo Motor FKT 20.2, 27.1, 27.2:, EMU FA, Rexa SUPRA, Rexa SOLID 7
Personal protective equipment: wear safety footwear
Personal protective equipment: wear protective gloves
Personal protective equipment: wear face mask
Personal protective equipment: wear safety goggles
Working alone is 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.
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-

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8 WILO SE 2019-10
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 Permanent magnet motor Permanent magnet motors are driven by a permanently magnetised rotor. Please note
the following when using permanent magnet motors:
ƒMagnet and magnetic field
There is no risk from magnets and the magnetic field as long as the motor housing is
closed. Persons with a pacemaker are also not at any particular risk. Screw plugs can
be undone for maintenance purposes without hesitation. Do not open the motor
housing! Only customer service staff are permitted to work on an open motor!
ƒGenerator operation
The motor generates an inductive voltage if the rotor is driven without electrical en-
ergy (e.g. when the fluid returns). In this case, the connection cable is live. Once the
pump has been connected, energy is fed back into the connected frequency con-
verter. Implement the following options to prevent destruction of the frequency
converter and motor as a result of overvoltage:
–Feed back input energy into the supply network.
–Dissipate input energy using a brake resistor.
2.7 Transport ƒWear the following protective equipment:
–Safety shoes
–Safety helmet (when using lifting equipment)
ƒAlways hold the handle to transport the device. Never pull the device by the connec-
tion cable!
ƒOnly use legally specified and approved lifting gear.
ƒSelect the lifting gear based on the prevailing conditions (weather, attachment
point, load, etc.).
ƒAlways attach the lifting gear to the attachment points (handle or lifting eye).
ƒThe stability of the lifting equipment must be ensured during operation.
ƒWhen using lifting equipment, ensure a second person is present to coordinate the
procedure if required (e.g. if the operator’s field of vision is blocked).
ƒPersons must not stand underneath suspended loads. Do not move suspended loads
over workplaces where people are present.
2.8 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!

Safety en
Installation and operating instructions Wilo Motor FKT 20.2, 27.1, 27.2:, EMU FA, Rexa SUPRA, Rexa SOLID 9
ƒMake sure that there is no risk of explosion when carrying out any type of welding
work or work with electrical devices.
2.9 During operation ƒWear the following protective equipment:
–Safety footwear
–Hearing protection (in accordance with work regulations notice)
ƒThe work area in which the device is used is not a recreational area. No persons are
allowed in the work area during operation.
ƒDepending on the process, the product is switched on and off using separate con-
trols. The product may automatically switch on following power cuts.
ƒUsers must immediately notify the person in charge of every fault or irregularity.
ƒIf hazardous defects occur, the operator must immediately deactivate the device.
Hazardous defects include:
–Malfunction of safety and monitoring devices
–Damage to housing parts
–Damage to electrical equipment
ƒDo not 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 both the suction and pressure sides.
ƒEnsure minimum water submersion by using dry-running protection.
ƒUnder normal operating conditions, the sound-pressure level of the product is below
85dB(A). However, the actual sound-pressure level depends on several factors:
–Installation depth
–Installation
–Fixation of accessories and piping
–Duty point
–Immersion depth
ƒIf the device is operated under normal operating conditions, the operator must
measure the sound pressure. From a sound-pressure level of 85dB(A), wear hearing
protection and mark out the working area!
2.10 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.
2.11 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.

en Application/use
10 WILO SE 2019-10
2.12 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.
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 wet well and dry well in-
stallation.

Product description en
Installation and operating instructions Wilo Motor FKT 20.2, 27.1, 27.2:, EMU FA, Rexa SUPRA, Rexa SOLID 11
Y
X
Z
1
2
3
4
5
6
7
8
Fig.1: Sample illustration
1 Connection cable inlet
2 Motor with cooling shroud
3 Sealing/bearing housing
4 Pressure port
5 Suction port
6 Hydraulics housing
7 Attachment point/handle
8 Coordinate system: Vibration sensor in Digital Data Interface
4.1.1 Hydraulics Centrifugal hydraulics with different impeller shapes, horizontal flange connection on
the pressure side, casing and impeller wear rings.
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 impellers, closed or half open
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 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 hy-
draulics, an impeller wear ring and/or neck 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.
ƒNeck ring
The neck ring is installed in the suction port of the hydraulics and protects the in-
coming flow edge in the centrifugal chamber.
If worn, customer service can simply replace both components.
4.1.2 Motor Self-cooling asynchronous or permanent magnet motor as three-phase current version.
An active cooling system takes care of cooling. The motor can be used for continuous
duty both immersed and non-immersed, also as part of dry well installation. The con-
nection cable has bare cable ends.
Motor fittings overview
Asynchronous motor Permanent magnet motor
FKT20.2 FKT27.x FKT20.2...-P
Design type Asynchronous Asynchronous Synchronous
Max. efficiency category (based on IEC60034) IE3 IE3 IE5
Operation with frequency converter o o ! (Wilo-EFC)
Digital Data Interface o − •
Immersed operating mode S1 S1 S1
Non-immersed operating mode S1 S1 S1

en Product description
12 WILO SE 2019-10
Asynchronous motor Permanent magnet motor
FKT20.2 FKT27.x FKT20.2...-P
Dry well installation operating mode S1 S1 S1
Upper rolling bearings: permanently lubricated,
low-maintenance
• • •
Lower rolling bearings: permanently lubricated,
low-maintenance
• • •
Connection cable sealed as longitudinally wa-
tertight
• • •
! = Required/mandatory, • = Standard, o = Optional, − = Not available
4.1.3 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
The cooling system version is one of two types, depending on the motor size:
ƒFKT 20.2: The sealing chamber and the cooling system form a one-chamber system.
The sealing chamber and the cooling system are filled with P35 coolant.
ƒFKT 27.x: The sealing chamber and the cooling system form a two-chamber system.
The sealing chamber is filled with medicinal white oil and the cooling system is filled
with P35 coolant.
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 leakage chamber is empty ex works.
4.1.4 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 by the motor shaft. The waste heat is transferred directly to the fluid via
the cooling flange. The cooling system is not pressurised when in cold state.
4.1.5 Material The following materials are used in the standard version:
ƒPump housing: grey cast iron
ƒImpeller: grey cast iron
ƒMotor housing: grey cast iron
ƒSeal on the motor side:
–"G" = Carbon/ceramic or SiC/SiC
–"K" = SiC/SiC
ƒSeal on the fluid side: SiC/SiC
ƒStatic seal: FKM (ASTMD1418) or NBR (nitrile)
The precise details of the materials used are shown in the respective configuration.
4.2 Digital Data Interface
NOTICE
Note the instructions for the Digital Data Interface!
Read the separate instructions for the Digital Data Interface and comply with them.
The Digital Data Interface is a communication module with integrated web server that
has been integrated in the motor. It is accessed and controlled in an Internet browser
using a graphical user interface. The user interface enables easy pump configuration,
control and monitoring. Different sensors may have been installed in the pump for this
purpose. External signal transmitters may also input additional system parameters in
the control. The Digital Data Interface is capable of the following, depending on the
system mode:
ƒPump monitoring.
ƒControlling the pump with a frequency converter.
ƒControlling the complete system with up to four pumps.

Product description en
Installation and operating instructions Wilo Motor FKT 20.2, 27.1, 27.2:, EMU FA, Rexa SUPRA, Rexa SOLID 13
4.3 Monitoring devices Overview of monitoring devices
Asynchronous motor Permanent mag-
net motor
FKT20.2 FKT20.2 FKT27.x FKT20.2...-P
Internal monitoring devices
Digital Data Interface − • − •
Terminal/motor compartment Humidity − − • −
Motor winding: Bimetallic strip • − • −
Motor winding: PTC o • (+ 1...3x Pt100) o • (+ 1...3x Pt100)
Motor bearings: Pt100 o o o o
Sealing chamber: conductive sensor − − − −
Sealing chamber: capacitive sensor − • − •
Leakage chamber: Float switch • − • −
Leakage chamber: capacitive sensor − • − •
Vibration sensor − • − •
External monitoring devices
Sealing chamber: conductive sensor o − o −
• = Standard, − = Not available, o = Optional
All the monitoring devices fitted must always be connected!
4.3.1 Motor without Digital Data Inter-
face 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.
Motor winding monitoring
Thermal motor monitoring protects the motor winding from overheating. A temper-
ature limiter with a bimetallic strip is fitted as standard. Once the activation temper-
ature has been reached, deactivation with reactivation lock must take place.
Optionally, the temperature can also be measured using a PTC sensor. Thermal motor
monitoring can also be designed as temperature control. This allows two temperatures
to be measured. Once the low activation temperature has been reached, an automatic
reactivation can be initiated after the motor has cooled down. The unit is forced to de-
activate with reactivation lock once the high activation temperature has been reached.
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.
4.3.2 Motor with Digital Data Interface
NOTICE
Note the instructions for the Digital Data Interface!
Read the separate instructions for the Digital Data Interface and comply with them.

en Product description
14 WILO SE 2019-10
The Digital Data Interface evaluates all available sensors. Use the graphical user inter-
face of the Digital Data Interface to display current values and set the limit parameters.
A warning message or alarm signal is output upon exceeding the limit parameters. The
motor winding additionally features PTC sensors to enable secure pump deactivation.
4.4 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:
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.
4.5 Operation with frequency con-
verter
4.5.1 Asynchronous motor It is possible to operate asynchronous motors at the frequency converter. The fre-
quency converter must feature the following connections at a minimum:
ƒBimetallic strip and PTC sensor
ƒMoisture probe
ƒPt100 sensor (if motor bearing monitoring is available!)
Refer to section entitled "Frequency converter operation [}55]" for additional re-
quirements and comply with these!
If the motor features a Digital Data Interface, also guarantee the following prerequis-
ites:
ƒNetwork: Ethernet 10BASE-T/100BASE-TX, IP-based
ƒProtocol support: Modbus TCI/IP
Refer to the separate instructions for the Digital Data Interface for detailed require-
ments!
4.5.2 Permanent magnet motor Guarantee the following conditions when operating permanent magnet motors:
ƒFrequency converter with connection for PTC sensor
ƒNetwork: Ethernet 10BASE-T/100BASE-TX, IP-based
ƒProtocol support: Modbus TCI/IP
Refer to the separate instructions for the Digital Data Interface for detailed require-
ments!
Permanent magnet motors have been approved for operation with the following fre-
quency converters:
ƒWilo-EFC
Other frequency converters on request!
4.6 Operation in an explosive atmo-
sphere
Asynchronous motor Permanent magnet motor
FKT 20.2 FKT 27.x FKT 20.2...-P
Approval according to IEC-Ex o − o
ATEX approval o o o
FM approval o o o
CSA-Ex approval − − −
Key
− = Not available/possible, o = Optional, • = Standard
For use in explosive atmospheres, the pump must be marked as follows on the rating
plate:
ƒ“Ex” symbol of the corresponding approval

Product description en
Installation and operating instructions Wilo Motor FKT 20.2, 27.1, 27.2:, EMU FA, Rexa SUPRA, Rexa SOLID 15
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.
4.7 Rating plate The following section provides 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
URated voltage
UEMF Inductive voltage
fFrequency
fop Max. operating frequency
Cos φ Motor efficiency
SF Service factor
OTSOperating mode: immersed
OTEOperating mode: non-immersed
AT Starting mode
IM org Impeller diameter: original
IM korr Impeller diameter: corrected
*The date of manufacture is stated in accordance with ISO8601: JJJJWww
ƒJJJJ = year

en Product description
16 WILO SE 2019-10
ƒW = abbreviation for week
ƒww = calendar week
4.8 Type key Type keys vary between individual hydraulics. The following section lists individual type
keys.
4.8.1 Hydraulics type key: EMU FA Example: Wilo-EMU FA 15.52-245E
FA Sewage pump
15 x10 = Nominal diameter of pressure connection
52 Internal performance coefficient
245 Original impeller diameter
(for standard variants only, omitted for configured pumps)
D
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
4.8.2 Hydraulics type key: Rexa SUPRA Example: Wilo-Rexa SUPRA-V10-736A
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
4.8.3 Hydraulics type key: Rexa SOLID Example: Wilo-Rexa SOLID-Q10-768A
SOLID Sewage pump with SOLID impeller
Q
Impeller shape:
T = Closed two-channel impeller
G = Half-open single-channel impeller
Q = Half-open two-channel impeller
10 x10 = Nominal diameter of pressure connection
76 Internal performance coefficient
8Characteristic curve number
A
Material version:
A = Standard version
B = Corrosion protection 1
D = Abrasion protection 1
X = Special configuration
4.8.4 Motor type key: FKT motor Example: FKT 20.2M-4/32GX-P5
FKT Self-cooling motor with separate cooling circuit
20 Size
2Configuration version

Transportation and storage en
Installation and operating instructions Wilo Motor FKT 20.2, 27.1, 27.2:, EMU FA, Rexa SUPRA, Rexa SOLID 17
Example: FKT 20.2M-4/32GX-P5
MShaft design
4Number of poles
32 Package length in cm
GSeal version
XEx-rated
P
Motor design:
- None = Standard asynchronous motor
- E = Highly efficient asynchronous motor
- P = Permanent magnet motor
5
IE efficiency class (based on IEC 60034-30):
None = IE0 to IE2
3 = IE3
4 = IE4
5 = IE5
4.9 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
4.10 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
the maximum bearing capacity of the lifting equipment! Check that lifting equip-
ment is functioning properly before use!

en Transportation and storage
18 WILO SE 2019-10
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
Permanent magnet motors: Connection wire may be live!
Turning the rotor may mean a voltage applies at the connection wires. Insulate con-
nection wires and do not short circuit!
CAUTION
Total damage due to moisture ingress
The ingress of moisture into the connection cable damages the cable and the pump!
Never immerse the ends of the connection cable in fluid. Seal them tightly during
storage.
Newly delivered pumps can be stored for one year. Contact customer service before
storing the device for more than one year.
When storing the pump, please note the following points:
ƒPlace the pump upright (vertical) on a firm bearing surface. Secure the pump against
falling over and slipping!
ƒThe max. storage temperature is -15°C to +60°C (5°F to 140°F). The max. relative
humidity is 90%, non-condensing. We recommend frost-proof storage. Ambient
temperature: 5 to 25°C (41 to 77°F), relative humidity: 40 to 50%.
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 the connection cable against kinking and damage. Maintain a constant bend
radius!

Installation and electrical connection en
Installation and operating instructions Wilo Motor FKT 20.2, 27.1, 27.2:, EMU FA, Rexa SUPRA, Rexa SOLID 19
ƒImpellers must be turned by 180° at regular intervals (3–6months). This prevents
the bearings from jamming and renews the lubrication film on 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 mixer has to 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
ƒHorizontal stationary dry well installation
NOTICE!Horizontal installation is not possible, depending on type and perform-
ance. For this installation type, contact customer service!
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
Permanent magnet motors: Risk of fatal injury caused by inductive
voltage!
The motor generates an inductive voltage if the rotor is driven without electrical en-
ergy (e.g. when the fluid returns). In this case, the connection cable is live. There is a
risk of fatal injury caused by electric shock! Earth the connection cable prior to mak-
ing the connection and dissipate inductive voltage!
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.

en Installation and electrical connection
20 WILO SE 2019-10
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
the maximum bearing capacity of the lifting equipment! Check that lifting equip-
ment is functioning properly before use!
ƒPrepare the operating space/installation location as follows:
–Clean, free of coarse solids
–Dry
–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
that has been technically approved.
ƒUse lifting gear for lifting, lowering and transporting the pump. Do not pull the pump
by the connection cable!
ƒIt must be possible to attach the lifting equipment safely. The storage location and
the operating space/installation site must be accessible by the lifting equipment.
The set-down location must have a firm surface.
ƒRouted connection cables must enable 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 switchgears. Install the
switchgear in an overflow-proof position and away from potentially explosive atmo-
sphere areas!
ƒAvoid air intake into the fluid, use baffles or deflector plates for the inlet. Air that has
entered the system can collect in the pipe system and lead to impermissible operat-
ing conditions. Air pockets must be removed using the ventilation systems!
ƒDo not allow the pump to dry run! Avoid air pockets in the hydraulics housing or in
the pipe system. Ensure that the water never falls below the minimum level. The in-
stallation of 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.