INSTALLATION, OPERATION AND MAINTENANCE MANUAL

FOR
DE-WATERING PUMP

Gulf Nations for Construction Materials

CUSTOMER NAME :
Co.
2x150 TPH Cement Grinding Unit, Shuaiba
PLANT LOCATION :
Industrial Area, Kuwait

FLSMIDTH CONTRACT NUMBER : 8001529004

FLSMIDTH EQUIPMENT NUMBER : 531.SJ220 & 532.SJ220

FLSMIDTH DOCUMENT NUMBER : 60173166 Ver.1.0

Ver. By Date Description

1 M&P 13-Aug-18 ORIGINAL RELEASE
 Operating and Maintenance Manual
for WILO products

Product : Submersible waste water pump

Type :
Motor :
Order no. :
Machine no. :

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Thank you for using WILO-EMU submersible pump.

 Carefully read through and fully understand the User’s Instruction Manual before
installation and operation.
 Keep User’s Instruction Manual in proper and easy access place any time for pump
install technician, operator and maintenance technician.
 When damage observed on the product, please contact with authorized local dealers or
sales representative.

This is the safety alert symbol. Paying constant attention to safety is

always extremely important

Warning about hazards or unsafe practices which could

result in severe personal injury or death.

Warning about hazards that will or can cause minor

personal injury or product or property damage.

Content
I. SAFETY INSTRUCTIONS ……………………………………………………..……………..…….....2
II. Pump Identification………………………………………………………………….……………………….4
III. INSTALLATION………………………………………...................................................4
IV. PUMP OPERATION…………………………………………………………………………………..…………5
V. MAINTENANCE…………………………………………………………………………………….............6
VI. REPAIR PARTS………………………………………………………………………………………...........9
VII. TROUBLESHOOTING…………………………………………………………………………..……...........11

I. SAFETY INSTRUCTIONS

Warning about hazards or unsafe practices which could

result in severe personal injury or death.

● Use Breaker and ensure the ground wire (Green) is properly grounded by a qualified
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 electrician before operation to avoid fire or personal injury that may be caused by power
leakage in the event of motor failure.
● Do not lift, Carry or Hang pump by the electrical cables. Damage to the electrical cable
can cause Shock, Burn or death.
● Do not enter the pond during pump operation to avoid personal casualties in case of
leakage.
● Disconnect the power before servicing.
● The pump is designed for use with inflammable liquids and a non hazardous
environment.
● Do not strain, modify, or any excessive force to the power cable, it can damage the cable
and cause short circuit and even lead to electrocution or fire.
● Do not install the pump into any location classified as hazardous environment.

Warning about hazards that will or can cause minor

personal injury or product or property damage.

● If in a climate where the fluid in the casing could freeze, never leave liquid in the pump
casing. Drain the casing complete. During winter months and cold weather, the liquid
could freeze and damage the pump casing.
● Do not run the equipment dry or start the pump without the casing flooded.
● The pump shaft MUST turn clockwise when viewed from the motor end. It is absolutely
essential that the rotation of the motor be checked before installation and starting the
pumps. Incorrect rotation of the pump can unscrew the impeller nut and cause severe
damage to pumping assembly.
● The applicable pumping liquid temperature should be 0~40 , and the pump may be
damaged if exceeding such range.
● Vent sewage and septic tank according to local requirements or standards.
● Check proper oil level in seal chamber periodically. Check for water in the seal housing
periodically.

※ This Company places heavy emphasis on product quality and safety, however, this
Manual does not fully cover all safety matters. For this reason, the user or the maintenance
person must pay special attention to their own safety as well.

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 II.Pump Identification
Check carefully items received against Pump Nameplate show on pump, and to be sure
that model, output (motor horsepower), Voltage are all correct. Don’t operate pump if any
of Nameplate information does not match to your specification.

III. INSTALLATION

Pump Mount
 All pumps as a free standing unit. Set the pump on the floor of the basin.
 Several series of pumps may install on Guide Rail System for ease lift out inspection
and service. Guide rails allow removal of the pump without disturbing the piping or
require personnel to enter the wetwell. (Contact with local dealer or manufacturer for
appropriate Guide Rail System)
 Install the Guide Rail on hard level surface cement, asphalt, etc. Never place the pump
directly on earth, clay or gravel surfaces.

Piping
 All piping must be independently supported, accurately aligned and be capable of
handling semi-solids.
 Reduce the number of bends in the discharge piping to keep the outlet flow as smooth
as possible.
 All pump models covered in this manual are intended for use in a wet, flooded sump.
Due to this intended service, no suction piping is required.
 The piping must not be smaller than pump discharge.

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Electrical

Electricity is dangerous. It can burn, shock or cause death. When

installing, operating or servicing this pump, following the instruction below.
1. DO NOT splice the power cord.
2. DO NOT handle or service the pump while it is connected to the power supply
3. DO NOT operate the pump and motor unless it is properly grounded. Wire the pump
directly to a grounded terminal block in automatic float or pump control panel. Be sure
to follow all local electrical cods here the unit is installed.
4. Make sure the supply frequency and voltage corresponds to the nameplate frequency
and voltage requirements. Supply voltage must be within 10% of nameplate voltage.
Incorrect voltage can seriously damage the motor and could cause fire which would
invalidate the warranty. If in doubt consult a licensed electrician.
5. Pump must rotate in a clockwise direction (viewed from the motor end). Never operate
pump and motor in reverse. If a three phase unit runs backwards, interchange two of
three power supply wires to reverse the motor’s direction of rotation.
6. Connect the pump to its own circuit with nothing else on the same circuit.
7. Install the pump in accordance with all applicable electrical codes. Install a fused
disconnect switch or a circuit breaker.

WIRING DIAGRAMS
Use a control panel or starter sized to meet the requirements of the pump. Refer to the
appropriate wiring diagram for connection details.

IV. PUMP OPERATION

Hazardous impeller and possible unexpected starts. Rotation

of the impeller with hands can cause loss of fingers. Disconnect the
electrical power before working on or handling the pump for any
reason.

 It is absolutely essential that the rotation of the pump be checked.

 All the pumps covered in this manual turn clockwise as viewed from motor end.

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 An Automatic thermal overload protector in the motor will protect the motor from
damage due to overheating and overloading. When the motor cools down, the thermal
overload will automatically reset and start the motor. The motor protector is usually
classified into A.C. Protector and Thermal Protector.
 If the thermal overload trips frequently, check for the cause. It could be impeller block,
wrong/ low voltage, bad A.C. Protector, electrical failure in the motor.
 For Automatic operation, the pump must stop before the liquid level reach Pump
Minimum Water Level (M.W.L.)
 DO NOT allow the pump to run in a dry sump. It will void the warranty and maybe
damage the pump.

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 V. MAINTENANCE
Only qualified mechanics with proper tools and knowledge should attempt to
service this pump.

Hazardous voltage and possible unexpected starts. Disconnect the

electrical power before working on or handling the pump for any reason.
Heavy parts. Use a hoist to left and control the pump during repair.

Warning about hazards that will or can cause minor

personal injury or product or property damage. It must be very careful when
dissemble and replace new o-ring for assembling the motor and mechanical seal chamber.
In proper assembling may impair the waterproof and cause motor burn by leakage and will
void the warranty.

1. Check voltage and Amperage is corresponds to the

nameplate. Voltage must be within 10% of nameplate
Daily
voltage.
2. Check if the water flow is normal.
1. Check the insulation is lower than 10MΩ, the maintenance is
Monthly recommended. Replace new motor immediately when
insulation is lower than 1MΩ.
Inspect lubricant:
 For pumps ≦0.75KW, the item should be checked every 3000
hours or 12 months (whichever comes first).
 For pumps ≧1.5KW, the item should be checked every 6000
Annual hours or 12 months (whichever comes first).
PS: Loosen the oil plug screw and check the color of the lubricant.
If the lubricant looks unclear, please change the mechanical seal
and the lubricant immediately. Apply adhesive before re-securing
the oil plug screw to strengthen the screw against leakage.
1. Change the lubricant：
 For pumps ≦0.75KW, the item should be changed ever 4500
Biannual hours or 24 months (whichever comes first).
 For pumps ≧1.5KW, the item should be changed every 9000
hours or 24 months (whichever comes first).

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 2. Change mechanical seal: Inspecting and replacing the
mechanical seal. Only qualified mechanics with proper tools
and knowledge should be attempting to service this pump or
contact our authorized local dealers or WILO-EMU for such
services.
1. Strongly recommended the pump to be overhaul or regular
inspection even if it is still operating. This maintaining
Every 2~5
procedure can extend pump operating life cycle.
Years
2. Pease contact your authorized local dealers or WILO- EMU for
such service.

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 VI. REPAIR PARTS

NO. PART NAME USED QTY

01 Power Cable 1
03 Upper Cover 1
16 Motor Frame 1
18 Outer Casing 1
21 Mechanical Seal 1
24 Oil Seal Bush 1
25 Oil Seal 1
26 Casing 1
27 Impeller 1
28 Casing Cover 1
30 Footing 1
31 Strainer 1
36A Flange 1
36B Flange 1
41 Handle 1
46 Impeller Key 1
47C O Ring 1
47D O Ring 1
47F Round Gasket 3
47H Out Cover 1
Packing
53B Washer 4
53E Washer 4
53G Cap Washer 1
53H Impeller 2
Washer
54A Spring Washer 8
54C Spring Washer 1
55E Screw 2
55G Screw 4
55H Screw 4
55K Screw 4
55L Long Screw 4
55M Oil Plug Screw 1
56C Bolt Nut 1
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NO. PART NAME USED QTY
01 Power Cable 1
03 Upper Cover 1
16 Motor Frame 1
19 Bearing Bracket 1
21 Mechanical Seal 1
23 M. Seal Bracket 1
25 Oil Seal 1
26 Casing 1
27 Impeller 1
28 Casing Cover 1
35 Outlet Bend 1
36 Flange 1
41 Handle 1
46 Impeller Key 1
47C O Ring 1
47D Outlet Bend 1
Gasket
47E Flange Gasket 1
53B Washer 16
53E Impeller Washer 2
54A Spring Washer 14
54B Spring Washer 6
54C Spring Washer 4
55E Screw 12
55G Screw 1
55H Screw 4
55I Screw 4
55J Screw 8
55K Screw 4
55M Oil Plug Screw 1
55N Air Vent Screw 1
56B Nut 8

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 VII. TROUBLESHOOTING

Hazardous voltage can shock, burn, or kill. Disconnect the electrical

power before attempting any service or repair work on pump.

SYMPTOM POSSIBLE CAUSE RECOMMENDED SOLUTION

Power failure Check power and correct connection
Defective cable Replace power cable.
Remove the foreign objects from impeller or
Impeller clogged
casing
Pump Not
Bad Motor Protector Replace new motor protector
Operating
The motor burn out Rewind or Replace new motor
Float switch defective Replace new float switch
Bad Control Panel Repair or replaced.
Remove the foreign objects from impeller or
Impeller Jammed
casing
Pump Stop During Check the power and make sure it corresponds
Abnormal voltage
Operation to the nameplate
Make sure liquid temperature is below 40℃、
The motor protector tripped
pump is complete submerged.
Reverse two of three leads on a three phase
Incorrect rotation
motor.
Worn and damaged impeller Replace new impeller.
Pump not Objects inside the pump or the Remove the foreign objects from impeller or
reaching design impeller casing
flow rate Remove plugged objects or replace new valves
Valves and pipe plugged
or pipes.
System head excessive Consult dealer
Cavitations Reposition liquid level control
Power cable damaged Replace new Cable
Electric Leakage Wet cable terminal Reconnect after drying out
Circuit Breaker Worn mechanical seal cause water
Activated Replace new Mechanical seals and oil seal
enter
The motor burns Replace new motor
Check the power and make sure it corresponds
Abnormal voltage
to the nameplate
Reverse two of three leads on a three phase
Incorrect rotation
motor.
Abnormal high More liquid needs to be added to the pump fluid
Amperage High viscosity liquid
to decrease its viscosity.
Objects inside the pump or the Remove the foreign objects from impeller or
impeller casing
Defective bearings Replace new bearing

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