Wilo RexaBloc RE Series User manual

6078738 Ed01-12/2015 WH
Pioneering for You
Wilo-RexaBloc RE
de Einbau- und Betriebsanleitung
en Installation and operating instructions
fr Notice de montage et de mise en service
it Istruzioni di montaggio, uso e manutenzione
sv Monterings- och skötselanvisning
tr Montajvekullanmakılavuzu
sl Navodila za vgradnjo in obratovanje
hu Beépítési és üzemeltetési utasítás
pl Instrukcjamontażuiobsługi
cs Návodkmontážiaobsluze
ru Инструкцияпомонтажуиэксплуатации
lt Montavimo ir naudojimo instrukcija
ro Instrucţiunidemontajşiexploatare

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InstallationandoperatinginstructionsWilo-RexaBlocRE 29
English
1. Introduction 30
1.1. Aboutthisdocument 30
1.2. Personnelqualications 30
1.3. Copyright 30
1.4. Subjecttochangesproviso 30
1.5. Warranty 30
2. Safety 31
2.1. Instructionsandsafetyinstructions 31
2.2. Generalsafety 31
2.3. Drive 32
2.4. Electricalwork 32
2.5. Safetyandmonitoringequipment 32
2.6. Conductduringoperation 32
2.7. Fluids 32
2.8. Operatorresponsibilities 32
2.9. Standardsandguidelinesused 33
2.10. CEmarking 33
3. Productdescription 33
3.1. Intendeduseandeldsofapplication 33
3.2. Set-up 33
3.3. Operationinanexplosiveatmosphere 34
3.4. Operationwithfrequencyconverters 34
3.5. Operatingmodes 34
3.6. Technicaldata 34
3.7. Typekey 34
3.8. Scopeofdelivery 34
3.9. Accessories 35
4. Transportandstorage 35
4.1. Delivery 35
4.2. Transport 35
4.3. Storage 35
4.4. Returndelivery 35
5. Installation 36
5.1. General 36
5.2. Installationtypes 36
5.3. Installation 36
5.4. Electricalconnection 38
5.5. Operatorresponsibilities 38
6. Commissioning 38
6.1. Electricalsystem 39
6.2. Rotationcontrol 39
6.3. Operationinpotentiallyexplosiveareas 39
6.4. Operationwithfrequencyconverters 39
6.5. Commissioning 39
6.6. Conductduringoperation 40
7. Decommissioning/disposal 40
7.1. Decommissioning 40
7.2. Removal 40
7.3. Returndelivery/storage 41
7.4. Disposal 41
8. Maintenanceandrepair 41
8.1. Operatinguid 41
8.2. Maintenanceintervals 42
8.3. Maintenancework 42
8.4. Repairs 43
9. Troubleshootingandpossiblesolutions 45
10. Appendix 46
10.1. Tighteningtorques 46
10.2. Spareparts 46

30 WILOSE12-2015V05DINA4
English INTRODUCTION
1. Introduction
1.1. About this document
Thelanguageoftheoriginaloperatinginstruc-
tionsisGerman.Allotherlanguagesofthese
instructions are translations of the original oper-
atinginstructions.
Thismanualisdividedintoindividualsections,
whicharelistedinthetableofcontents.Each
section has
aheadingwhichclearlydescribesitscontent.
AcopyoftheECdeclarationofconformityis
acomponentoftheseoperatinginstructions.
Ifatechnicalmodicationismadeonthedesigns
namedtherewithoutouragreement,thisdecla-
rationlosesitsvalidity.
1.2. Personnel qualications
Allpersonnelwhoworkonorwiththehydraulics
mustbequaliedforsuchwork;electricalwork,
forexample,mayonlybecarriedoutbyaqualied
electrician.Allpersonnelmustbeoflegalage.
Operatingandmaintenancepersonnelmustalso
observenationalaccidentpreventionregulations.
It must be ensured that personnel have read and
understood the instructions in this operating and
maintenancehandbook;ifnecessary,thismanual
must be ordered from the manufacturer in the
requiredlanguage.
Thehydraulicsisnotintendedforusebypersons
(includingchildren)withlimitedphysical,sensory
ormentalcapacitiesorwithouttherelevant
experienceorknowledge,unlesstheyaresuper-
visedbyapersonresponsiblefortheirsafetyand
receiveinstructionsfromthispersononhowto
usethehydraulics.
Childrenmustbesupervisedinordertoensure
thattheydonotplaywiththehydraulics.
1.3. Copyright
Thisoperatingandmaintenancemanualhasbeen
copyrightedbythemanufacturer.Theoperating
andmaintenancemanualisintendedforuseby
installation, operating and maintenance person-
nel.Itcontainstechnicalregulationsanddraw-
ingswhichmaynotbereproducedordistributed,
eithercompletelyorinpart,orusedforpurposes
ofcompetitionwithouttheexpressconsentof
themanufacturerorsharedwithothers.Theil-
lustrationsusedmaydifferfromtheoriginaland
areonlyintendedasanexemplaryrepresentation
ofthehydraulics.
1.4. Subject to changes proviso
Themanufacturerreservestherighttomake
technicalmodicationstosystemsorcompo-
nents.Thisoperatingandmaintenancemanual
referstothehydraulicsshownonthetitlepage.
1.5. Warranty
Ingeneral,thespecicationsinthecurrent"gen-
eraltermsandconditions"applyforthewarranty.
Youcanndthesehere:
www.wilo.com/legal
Anydeviationsmustbecontractuallyagreedand
shallthenbegivenpriority.
1.5.1. General
Themanufacturerisobligedtocorrectanyde-
fectsfoundinthehydraulicsitsells,providedthat
thedefectsmeetoneormoreofthefollowing
requirements:
• Thedefectsarecausedbythematerialsused
orthewaytheproductwasmanufacturedor
designed.
• Thedefectswerereportedinwritingtothe
manufacturerwithintheagreedwarrantyperiod.
• Thehydraulicswasusedonlyasprescribed.
• Allmonitoringdevicesareconnectedandwere
testedbeforecommissioning.
1.5.2. Warranty period
Thedurationofthewarrantyperiodisstipulated
inthe"generaltermsandconditions".
Anydeviationsmustbecontractuallyagreed.
1.5.3. Spare parts, attachments and modications
Onlygenuinesparepartsfromthemanufacturer
maybeusedforrepairs,replacements,attach-
mentsandmodications.Unauthorizedadd-ons
andmodicationsortheuseofnon-originalspare
partscanseriouslydamagethehydraulicsand/or
injurepersonnel.
1.5.4. Maintenance
Theprescribedmaintenanceandinspection
workshouldbecarriedoutregularly.Thiswork
mayonlybecarriedoutbyqualied,trainedand
authorisedpersonnel.
1.5.5. Damage to the product
Damageandmalfunctionsthatendangersafety
mustbeeliminatedimmediatelybytrainedper-
sonnel.Thehydraulicsmayonlybeoperatedifit
isinperfectworkingorder.
Ingeneral,repairsshouldonlybecarriedoutby
Wilocustomerservice.
1.5.6. Disclaimer
Nowarrantyclaimswillbeacceptedorliability
willbeassumedforhydraulicsdamageifanyof
thefollowingitemsapply:
• Themanufacturerdeemsthatinformationpro-
videdbytheoperatororcustomerisinsufcient
or incorrect
• Non-compliancewithsafetyinstructionsand
workinginstructionsasspeciedinthisoperating
and maintenance manual
• Improper use
• Incorrect storage and transport
• Improperassembly/dismantling
• Insufcientmaintenance
• Incorrect repairs
• Inadequateconstructionsiteorconstructionwork
• Chemical,electrochemicalandelectricalinu-
ences
• Wear

InstallationandoperatinginstructionsWilo-RexaBlocRE 31
SAFETY English
Thismeansthemanufacturer’sliabilityexcludes
allliabilityforpersonalinjury,materialdamageor
nanciallosses.
2. Safety
Thissectionlistsallthegenerallyapplicable
safetyinstructionsandtechnicalinformation.
Inaddition,alltheothersectionscontainspecic
safetyinstructionsandtechnicalinformation.
Allinstructionsandinformationmustbeobserved
andfollowedduringthevariousphasesofthe
hydraulics’slifecycle(installation,operation,
maintenance,transportetc.)!Theoperatoris
responsibleforensuringthatallpersonnelfollow
theseinstructionsandguidelines.
2.1. Instructions and safety instructions
Thismanualusesinstructionsandsafetyinstruc-
tionsforpreventinginjuryanddamagetoprop-
erty.Toclearlyidentifythemforpersonnel,the
instructionsandsafetyinstructionsaredistin-
guishedasfollows:
• Instructionsappearinboldandreferdirectlyto
theprecedingtextorsection.
• Safetyinstructionsareslightlyindentedandbold
andalwaysstartwithasignalword.
• Danger
Seriousorfatalinjuriescanoccur!
• Warning
Seriousinjuriescanoccur!
• Caution
Injuriescanoccur!
• Caution(instructionwithoutsymbol)
Substantialpropertydamagecanoccur.
Irreparabledamageispossible!
• Safetyinstructionsthatrefertopersonalinjury
appearinblackandarealwaysaccompaniedby
asafetysymbol.Danger,prohibitionorinstruc-
tionsymbolsareusedassafetysymbols.
Example:
Dangersymbol:Generalhazard
Dangersymbol,forexample,electricalcurrent
Prohibitionsymbol,forexample,Keepout!
Instructionsymbol,forexample,wearprotec-
tive clothing
Thesafetysymbolsusedconformtothegenerally
applicable directives and regulations, such as DIN
andANSI.
• Safetyinstructionsthatonlyrefertomate-
rialdamageareprintedingrey,withoutsafety
symbols.
2.2. General safety
• Wheninstallingorremovingthehydraulics,never
workaloneinroomsandsump.Asecondperson
mustalwaysbepresent.
• Thehydraulicsmustalwaysbeswitchedoff
beforeanyworkisperformedonit(assembly,
dismantling,maintenance,installation).Thedrive
forthehydraulicsmustbedisconnectedfrom
theelectricalsystemandsecuredagainstbeing
switchedonagain.Allrotatingpartsmusthave
cometoastandstill.
• Theoperatorshouldinformhis/hersuperiorim-
mediatelyshouldanydefectsorirregularities
occur.
• Theend-usermustshutdowntheequipmentim-
mediatelyifdefectsoccurthatrepresentasafety
risk.Theseinclude:
• Failureofthesafetyand/ormonitoringdevices
• Damage to important parts
• Damagetoelectricalequipment,cables,and
insulation.
• Toolsandotherobjectsshouldbekeptintheir
designatedplacessothattheycanbefound
quickly.
• Sufcientventilationmustbeprovidedinen-
closedrooms.
• Whenweldingand/orworkingwithelectronic
devices,makesurethereisnoriskofexplosion.
• Onlyuseliftinggearwhichislegallydenedas
suchandofciallyapproved.
• Theliftinggearmustbekeptsafelyandmustbe
suitablefortheconditionsofuse(weather,hook-
ingunit,load,etc.).
• Mobileequipmentforliftingloadsshouldbe
usedinsuchawaythatitisguaranteedtoremain
stableduringoperation.
• Whenusingmobileequipmentforliftingnon-
guided loads, take action to prevent tipping,
shifting,sliding,etc.
• Measures should be taken to ensure that no
personiseverdirectlybeneathasuspended
load.Furthermore,itisalsoprohibitedtomove
suspendedloadsoverworkplaceswherepeople
arepresent.
• Ifmobileequipmentisusedforliftingloads,a
second person should be present to coordinate
theprocedureifrequired(forexample,ifthe
operator’seldofvisionisblocked).
• Theloadtobeliftedmustbetransportedsothat
no-onewillbeinjuredifthereisapowerfailure.
Furthermore,ifsuchworkisbeingcarriedout
outdoors,itmustbecancellediftheweather
conditionsworsen.

32 WILOSE12-2015V05DINA4
English SAFETY
These instructions must be strictly observed.
Non-observance can result in injury or substan-
tial material damage.
2.3. Drive
Thehydraulicshasastandardizedconnection
angeforinstallinganIECstandardmotor.
See the technical data for the performance data
(e.g.size,construction,hydraulicratedpower,
speed)neededtoselectamotor.
2.4. Electrical work
ELECTRICAL hazard!
Incorrectly performed electrical work can
result in fatal injury! This work may only be
carried out by a qualied electrician.
Themotormustbeconnectedinaccordancewith
the information in the operating and maintenance
manualforthemotor.Thegoverninglocaldirec-
tives,standardsandregulations(e.g.VDE0100)
aswellastherequirementsofthelocalenergy
supplycompanymustbeobserved.
Thepersonoperatingthemotormustknow
whereitissuppliedwithpowerandhowtocutoff
thesupply.Amotorprotectionswitchmustbein-
stalledon-site.Itisadvisabletoinstallaresidual-
currentdevice(RCD).Ifthereisapossibilitythat
peoplecancomeintocontactwiththemotorand
theuid,theconnectionmustbeequippedwith
anadditionalresidual-currentdevice(RCD).
Thehydraulicsmustalwaysbeearthed.Ina
standardsystem,thehydraulicsisearthed
throughthemotor'sconnectiontothemains.Al-
ternatively,thehydraulicscanbeearthedthrough
aseparateconnection.
2.5. Safety and monitoring equipment
CAUTION!
Never operate the hydraulics if the built-on
monitoring devices have been removed or
damaged, or if they do not work.
NOTE
Alsonotealltheinformationintheoperating
andmaintenancemanualforthemotor!
Thehydraulicsisnotttedwithmonitoring
equipmentasstandard.
Optionally,thesealingchambercanbemonitored
withanexternalpencilelectrode.
Allexistingmonitoringdevicesmustbeconnect-
edbyanelectricianandcheckedtoensurethat
theyfunctioncorrectlybeforecommissioning.
Personnel must be informed about the installed
systemsandhowtheywork.
2.6. Conduct during operation
BEWARE of burns!
The housing parts can heat up to well above
40°C. There is a risk of burns!
• Never touch parts of the housing with your
bare hands.
• After switching them off, let the hydraulics
cool down to ambient temperature.
• Wear heat-resistant protective gloves!
Duringoperationofthehydraulics,alwaysfollow
thelocallyapplicablelawsandregulationsfor
worksafety,accidentpreventionandhandling
electricalmachinery.Tohelpensuresafeworking
practice,theresponsibilitiesofemployeesshould
beclearlyspeciedbytheoperator.Allpersonnel
are responsible for ensuring that regulations are
observed.
During operation, all gate valves in the inlet line
andpressurepipemustbecompletelyopen.
If the slide valves on the suction and pres-
sure sides are closed during operation, the
uid in the hydraulics housing is heated up by
the pumping movement. This heating creates
strong pressure in the hydraulics housing. The
pressure can result in the hydraulics exploding.
Before switching on the hydraulics, ensure that
all the slide valves are open and open any closed
slide valves.
2.7. Fluids
Eachuiddiffersinrespectofcomposition,cor-
rosiveness,abrasiveness,drymattercontentand
inmanyotheraspects.Generally,thehydraulics
canbeusedformanyapplications.Pleasenote
thatifrequirementschange(density,viscosityor
generalcomposition),thiscanalsoaffectmany
parametersofthehydraulics.
Whenusingorreplacingthehydraulicstopumpa
differentuid,observethefollowingpoints:
• Theuidcanbecontaminatedbyoilfromthe
sealing chamber if the mechanical seal is defec-
tive.
Pumping drinking water is not permitted!
• Hydraulicsthathasbeenoperatedtopump
contaminatedwatermustbecleanedthoroughly
beforebeingusedtopumpotheruids.
• Hydraulicsthathasbeenoperatedtopumpuids
containingfaecesand/oruidsthatarehazard-
oustohealthmustbegenerallydecontaminated
beforebeingusedtopumpotheruids.
First clarify whether the hydraulics may be used
to pump other uids!
2.8. Operator responsibilities
2.8.1. Integration into the existing safety concept
Theoperatorshallensurethattheunitisinte-
gratedintotheexistingsafetyconceptandthat
itcanbeswitchedoffinanemergencyusingthe
existingsafetyshutdowns.

InstallationandoperatinginstructionsWilo-RexaBlocRE 33
PRODUCTDESCRIPTION English
2.8.2. Recommended monitoring equipment
Thehydraulicsisdrivenbyastandardmotor.
Standardmotorarenotoverow-proof.We
thereforerecommendusinganalarmswitchgear
torecordmajorleakage.Intheeventofamajor
dischargeofuid(e.g.faultypiping),themotor
mustswitchoff.
2.8.3. Sound pressure
NOTE
Alsonotealltheinformationintheoperating
andmaintenancemanualforthemotor!
CAUTION: Wear ear defenders!
According to applicable laws and regula-
tions, ear protection must be worn if the
sound-pressure level is 85dB(A) or more! The
end-user must make sure that this is complied
with!
Thehydraulicsgeneratesasound-pressurelevel
ofapprox.70 dB(A)to80 dB(A)duringopera-
tion.
However,theactualsound-pressurelevel
dependsonseveralfactors.Theseinclude,for
example,theinstallation,xationofaccessories
andpiping,thedutypointetc.
We recommend that the operator takes an ad-
ditionalmeasurementattheworkplaceoncethe
hydraulicsisrunningatitsdutypointandunder
alloperatingconditions.
2.9. Standards and guidelines used
ThehydraulicsissubjecttovariousEuropean
directivesandharmonisedstandards.SeetheEC
declarationofconformityforpreciseinformation
aboutthese.
In addition, various standards are used as a basis
for operating, assembling and dismantling the
hydraulics.
2.10. CE marking
TheCEmarkingisattachedtotheratingplatefor
thehydraulics.
3. Product description
Thehydraulicsismanufacturedwithgreatcare
andissubjecttoconstantqualitycontrols.
Trouble-freeoperationisguaranteediftheyare
installedandmaintainedcorrectly.
3.1. Intended use and elds of application
DANGER – explosive uids!
It is strictly prohibited to pump explosive
uids (gasoline, kerosene etc.). The hydraulics
is not designed for these uids.
TheWilo-RexaBlocRE…sewagehydraulicsissuit-
ableforpumping:
• Wastewater
• Sewagecontainingfaeces
• Sludgeswithupto8%drymatter(dependingon
type)
Thesewagehydraulicsmustnot be used for
pumping:
• Drinkingwater
• Fluidscontaininghardcomponentssuchasstone,
wood,metal,sandetc.
• Highlyammableandexplosiveuidsinpure
form
Theintendeduseincludescomplyingwiththese
instructions.Anyotheruseisconsideredtobe
outsidetheintendeduse.
3.2. Set-up
TheWilo-RexaBlocREaresewagehydraulicswith
aangedIECstandardmotorinmonoblocdesign
forstationarydrywellinstallation.
Fig. 1: Description
1 Hydraulics 6
Sealing chamber
monitoring(optionally
available)
2 Bearing bracket 7 Ventingscrew
3 IECstandardmotor 8Drainagescrew
4 Suction connection 9 Support
5Pressure connection
A "Bareshaft"design(hydraulicswithoutmotor)
BUnit(hydraulicswithangedmotor)
3.2.1. Version
Asstandard,aunitconsistingofhydraulicswitha
angedmotorisdelivered.
Alternatively,a"bareshaft"designcanbedeliv-
ered.Inthiscase,theoperatorhastoprovidea
suitablemotorandinstallitonsite.
3.2.2. Hydraulics
Hydraulicshousingandbearingbracketasaself-
containedunit,withchannelimpellerorvortex
impeller,axialsuctionportandradialpressure
port.Theconnectionsareconguredasange
connections.
Bearingbracketwithsealontheuidandmotor
sides,aswellassealingchamberandleakage
chamberforreceivinguidingressthroughthe
seal.Thesealingchamberislledwithenviron-
mentallyharmlessmedicinalwhiteoil.
The hydraulics is not self-priming, in other
words, the uid must ow in either automati-
cally or with supply pressure.
3.2.3. Monitoring equipment
Asanoption,thesealingchambercanbemoni-
toredbyanexternalpencilelectrode.Thissignals
ifthereiswateringressintothesealingchamber
throughthemechanicalsealontheuidside.

34 WILOSE12-2015V05DINA4
English PRODUCTDESCRIPTION
3.2.4. Seal
Sealingontheuidsideisachievedbyabidirec-
tionalmechanicalseal.Sealingonthemotorside
isachievedbyarotaryshaftseal.
3.2.5. Materials
• Hydraulichousing:EN-GJL-250
• Impeller:EN-GJL-250
• Bearinghousing:EN-GJL-250
• Shaft:1.4021
• Staticgaskets:NBR
• Seal
• Onuidside:SiC/SiC
• Onmotorside:NBR
• Motorhousing:EN-GJL-250
3.2.6. Drive
ThehydraulicsisdrivenbyIECstandardmotors
in"B5"construction.Formoreinformationabout
themotorandthemonitoringequipmentpresent,
see the installation and operating instructions for
themotor.
3.3. Operation in an explosive atmosphere
Thehydraulicsmustnotbeoperatedinanexplo-
siveatmosphere!
3.4. Operation with frequency converters
NOTE
Alsonotealltheinformationintheoperating
andmaintenancemanualforthemotor!
Operationonafrequencyconverterispossible.
Thefollowingparametersmustbeobserved:
• Themaximumspeedmustnot exceed1450rpm.
• Continuousdutywithavolumeowof
Qopt<0.7m/sshouldbeavoided.
• Thecircumferentialspeedmustnot fall below a
minimumof13m/s.
NOTE
Thecircumferentialspeedcanbecalculatedas
follows:v = n · d · π / 60,000
Key:
- n = speed in rpm
- d = impeller diameter in mm
-v=circumferentialspeedinm/s
3.5. Operating modes
See the rating plate or installation and operat-
ing instructions for the motor to see the possible
operatingmodes.
3.5.1. Operating mode S1 (continuous duty)
Themotorcanoperatecontinuouslyattherated
loadwithoutexceedingthepermissibletempera-
ture.
3.5.2. Operating mode S2 (short-time duty)
Themaximumoperatingperiodforthemotoris
speciedinminutes,e.g.S2-15.Thepausemust
last until the machine temperature no longer dif-
fersfromthetemperatureofthecoolantbymore
than2K.
3.5.3. Operating mode S3 (intermittent operation)
Thisoperatingmodedenesacombinationof
periodsofoperationandstandstillofthemotor.
WithS3operation,thevaluesgivenarealways
calculatedbasedonaperiodof10minutes.
Example: S3 25%
Operatingtime25%of10min=2.5min/stand-
stilltime75%of10min=7.5min
3.6. Technical data
Thefollowingtechnicaldatacanbefoundonthe
ratingplate.
Max.deliveryhead: Hmax
Max.volumeow: Qmax
Ratedpowerrequiredfrom
hydraulics: P2
Pressureconnection: X-]
Suctionconnection: [-X
Fluidtemperature: t
Sizeofstandardmotor: Typekey
Standardspeed: n
Weight: Mhydr
The total weight is calculated from the weight
of the hydraulics and the weight of the motor
(see rating plate on motor).
3.7. Type key
Example: Wilo-RexaBloc RE 08.52W-260DAH132M4
RE Series
08 Sizeofpressureconnectione.g.08=DN80
52 Internalperformancecoefcient
W
Impeller shape
W=Vorteximpeller
E = Single-channel impeller
260 Impeller diameter in mm
D
Flangeconnections
D = DN connection
A=ANSIconnection
A
Material version
A=standardversion
Y = special version
H
Typeofinstallation
V=vertical
H = horizontal
132M Size of standard motor
4Numberofpolesforthenecessaryhydraulics
speed
3.8. Scope of delivery
• Version:
• Unit:Sewagehydraulicswithbuilt-onstandard
motor
• "Bareshaft"version:Sewagehydraulicswithout
motor

InstallationandoperatinginstructionsWilo-RexaBlocRE 35
TRANSPORTANDSTORAGE English
• Transportshacklebuiltontopressureportasat-
tachment point
• Installationandoperatinginstructions:
• Unit:separateinstructionsforhydraulicsand
motor
• "Bareshaft"version:Instructionsforhydraulics
• CE-declaration
3.9. Accessories
• Connectioncable,soldbythemetre
• Externalpencilelectrodeforsealingchamber
control
• Levelcontroldevices
• Fixationaccessoriesandchains
• Switchgear,relaysandplugs
4. Transport and storage
NOTE
Alsonotealltheinformationregardingtrans-
port and storage in the operating and mainte-
nancemanualforthemotor!
4.1. Delivery
Ondelivery,checkimmediatelythattheship-
mentiscompleteandundamaged.Ifanyparts
aredamagedormissing,thetransportcompany
orthemanufacturermustbenotiedontheday
ofdelivery.Claimsmadeafterthisdatecannotbe
recognised.Damagetopartsmustbenotedon
thefreightdocumentation.
4.2. Transport
Onlytheappropriateandapprovedfastening
devices,transportationandliftingequipmentmay
beused.Thesemusthavesufcientload-bearing
capacitytoensurethatthehydraulicscanbe
transportedsafely.Ifchainsareusedtheymust
besecuredagainstslipping.
Thepersonnelmustbequaliedforthetasksand
mustfollowallapplicablenationalsafetyregula-
tionsduringthework.
Thehydraulicsisdeliveredbythemanufactureror
shippingagencyinsuitablepackaging.Thisnor-
mallyprecludesthepossibilityofdamageoccur-
ringduringtransportandstorage.Thepackaging
should be stored in a safe place for reuse if the
productisfrequentlyusedatdifferentlocations.
Note the additional information in the operating
and maintenance manual for the motor regard-
ing transport.
4.3. Storage
Newlysuppliedhydraulicsarepreparedsothat
theycanbestoredforatleast1year.Thehydrau-
licsshouldbecleanedthoroughlybeforetheyare
putintotemporarystorage.
Note the additional information in the operating
and maintenance manual for the motor regard-
ing storage.
Thefollowingshouldbetakenintoconsideration
forstorage:
• Placethehydraulicsonarmsurfaceandsecure
itagainstslippingandfallingover.Sewagehy-
draulicsarestoredhorizontally.
DANGER due to falling over!
Never set the hydraulics down if unsecured.
If the hydraulics falls over, this may lead to
injuries!
• Ourhydraulicscanbestoredattemperatures
downto-15°C.Thestoreroommustbedry.We
recommend a frost-protected room for storage
withatemperaturebetween5°Cand25°C.
• Thehydraulicsmustnotbestoredinroomsin
whichweldingworkiscarriedout,becausethe
resulting gases or radiation can damage the elas-
tomercomponentsandcoating.
• Suction and pressure connections must be sealed
securelytopreventcontaminationgettingin.
• Thehydraulicsmustbeprotectedfromdirect
sunlight,heat,dust,andfrost.Heatorfrostcan
causeseriousdamagetoimpellersandcoatings!
• Theimpellersshouldbecheckedatregularinter-
vals.Thispresentsjammingofthebearingsandit
renewsthelmoflubricationonthemechanical
seal.
BEWARE of sharp edges!
Sharp edges may form on the impeller and
on the openings of the suction and pressure
ports. There is a risk of injury! Wear the nec-
essary protective clothing, such as protective
gloves.
• Ifthehydraulicshasbeenstoredforalongperiod
of time, it should be cleaned of impurities such as
dustandoilresiduebeforecommissioning.Check
thattheimpellersmovefreelyandcheckthe
housingcoatingsfordamage.
Prior to commissioning, the ll level in the seal-
ing chamber should be checked and topped up,
if necessary!
Damaged coatings must be repaired immedi-
ately. Only an intact coating fulls its intended
purpose.
Please note that elastomer parts and coatings
becomebrittleovertime.Iftheproductistobe
storedforlongerthan6months,werecommend
checking these parts and replacing them as nec-
essary.ConsultWilocustomerservicefordetails.
4.4. Return delivery
Hydraulicsthatarereturnedtothefactorymust
beproperlypackaged.Thismeansthatimpuri-
tieshavebeenremovedfromthehydraulicsand
that it has been decontaminated if used to pump
uidsthatarehazardoustohealth.
Forshipping,thepartsmustbepackedintear-
proofplasticbagsofsufcientsizeinsucha
mannerthattheyaretightlysealedandleak-
proof.Furthermore,thepackagingmustprotect

36 WILOSE12-2015V05DINA4
English INSTALLATION
thehydraulicsfromdamageduringtransporta-
tion.Ifyouhaveanyquestions,pleasecontact
Wilocustomerservice!
5. Installation
In order to prevent damage to the product or seri-
ousinjuryduringinstallation,thefollowingpoints
mustbeobserved:
• Installationwork–assemblyandinstallation
ofthehydraulics–mayonlybecarriedoutby
qualiedpersons.Thesafetyinstructionsmustbe
followedatalltimes.
• Thehydraulicsmustbeinspectedfortransport
damagebeforeanyinstallationworkiscarried
out.
5.1. General
Fordesignandoperationoftechnicalsewage
systems,observethepertinentlocalregulations
anddirectivesforsewagetechnology(suchas
thoseofsewagetechnologyassociations).
Notethat,instationaryinstallations,pressure
surgescanoccurincaseswherewaterispumped
withlongerdischargepipes(especiallywith
steadyascentsorsteepterrain).
Pressure surges can result in destruction of the
hydraulics/systemandnoisepollutionduetoap
knock.Pressuresurgescanbepreventedbyap-
plyingsuitablemeasures(e.g.non-returnvalves
withanadjustableclosingtimeorspecialrouting
ofthedischargepipeline).
Airpocketsinthehydraulicsorpipingsystem
must be avoided at all costs and must be removed
usingasuitableventilationsystem.
Protectthehydraulicsfromfrost.
5.2. Installation types
• Horizontalstationarydrywellinstallation
5.3. Installation
NOTE
Alsonotealltheinformationregardinginstalla-
tion in the operating and maintenance manual
forthemotor!
Thefollowinginformationshouldbetakeninto
considerationwheninstallingthehydraulics:
• Thisworkmustbecarriedoutbyaqualied
personandelectricalworkmustbecarriedoutby
anelectrician.
• Theoperatingspacemustbeclean,dryandfree
fromfrost,anddesignedforthehydraulicsin
question.
• Whenworkinginpumpchambers,asecondper-
sonmustbepresentforsafetyreasons.Ifthereis
ariskofpoisonousorasphyxiatinggasesforming,
thenecessaryprecautionsmustbetaken.
• Ensurethatliftingequipmentcanbettedwith-
outanytrouble,sincethisisrequiredforassembly
andremovalofthehydraulics.Itmustbepossible
toreachthehydraulicssafelyintheiroperating
andstoragelocationsusingtheliftingequip-
ment.Themachinemustbepositionedonarm
bearingsurface.Fortransportingthehydraulics,
theload-carryingequipmentmustbesecuredto
theprescribedattachmentpoints.Whenusing
chains, these must be connected to the attach-
mentpointusingashackle.Liftinggearmustbe
technicallyapproved.
• Structural components and foundations must be
ofsufcientstabilityinordertoallowtheproduct
tobexedsecurelyandfunctionally.Theoperator
or the supplier is responsible for the provision of
thefoundationsandtheirsuitabilityintermsof
dimensions,stabilityandstrength!
• Neverletthehydraulicsrundry.Airpocketsare
tobeavoidedatallcosts.Appropriateventilation
systemsmustbeprovided.
• Checktheavailableconsultingdocumentation
(installation plans, design of operating space,
inletconditions)iscompleteandcorrect.
• Please observe all regulations, rules and legal
requirementsforworkingwithandunderneath
heavysuspendedloads.Wearappropriateprotec-
tiveclothing/equipment.
• Please also observe the applicable national acci-
dent prevention regulations and trade association
safetyprovisions.
5.3.1. Attachment points
Toraiseandlowerthehydraulics,theymustbe
fastenedatthespeciedattachmentpoints.We
differentiateherebetweentheunitandthe"bare
shaft"version.
Fig. 2: Attachment points
A "Bareshaft"version
BUnit
1 Transportshackle
Denition of symbols
Attachhere!
Shacklemustbeused!
Liftingequipment:Chainpermitted
Liftingequipment:Wireropeornylonrope
permitted
Liftingequipment:Transportstrappermitted
Useofahookforattachmentisprohibited!

InstallationandoperatinginstructionsWilo-RexaBlocRE 37
INSTALLATION English
Denition of symbols
Useofchainsasliftingequipmentprohibited
Thefollowinginformationmustbeobserved
whenattachingtheliftingequipment:
• Theliftingequipmentmustbefastenedtothe
transportshacklebyashackle.Carryingstraps,
wireropesandplasticropesorchainsmaybe
usedasliftingequipment.
• Thetransportshacklemustbedismantledafter
positioningiscomplete.
• When attached to the housing parts, the lifting
equipmentmustbefastenedinaloop.Chains
maynotbeusedhere!
5.3.2. Maintenance work
Afterastorageperiodofmorethan6months,the
followingmaintenanceworkmustbecarriedout
beforeinstallation:
• Rotate impeller
• Checkoilinthesealingchamber
Rotate impeller
1. Placethehydraulicshorizontallyonarmsurface.
Make sure that the hydraulics cannot fall over
and/or slip!
2. Carefullyandslowlyreachintothehydraulics
housing through the suction port and rotate the
impeller.
BEWARE of sharp edges!
Sharp edges can form on the impeller and the
opening on the suction port. There is a risk of
injury! Wear the necessary protective cloth-
ing, such as protective gloves.
5.3.3. Check oil in the sealing chamber (“Fig. 4: Screw
plugs”)
Thesealingchamberhasaseparateopeningfor
drainingandllingthesealingchamber.
1. Placethehydraulicshorizontallyonarmsurface.
Make sure that the hydraulics cannot fall over
and/or slip!
2. Unscrewscrewplug(D+).
3. Placeasuitabletankunderthescrewplug(D-)to
collecttheoil.
4. Unscrewscrewplug(D-)andallowtheoiltodrain
out.Iftheoilisclear,doesnotcontainanywater
andthequantitymatchesthespecication,itcan
bereused.Iftheoiliscontaminated,itmustbe
disposedofinaccordancewiththerequirements
inthe"Disposal"chapter.
5. Cleanthescrewplug(D-),renewthesealringand
screwitbackin.
6. Pourtheoilinthroughtheopening(D+)(quan-
tity:1600ml).Notetherecommendedoperating
uids.
7. Cleanthescrewplug(D+),renewthesealringand
screwitbackin.
5.3.4. Stationary dry well installation
Inthisinstallationtype,theoperatingspaceis
divided:collectortankandmachineroom.The
uidiscollectedinthecollectortankandthe
hydraulicsisinstalledinthemachineroom.The
operating space must be blocked out as per the
manufacturer'scongurationorconsultingguide.
Thehydraulicsisconnectedtothesuction-and
pressure-sidepipesystematthespeciedpoint
inthemachineroom.Thehydraulicsisnotim-
mersedintheuid.
Thesuction-andpressure-sidepipesystemmust
beself-supporting,i.e.itmaynotbesupported
bythehydraulics.Inaddition,thehydraulicscon-
nectiontothepipesystemmustbefreeofstress
andvibrations.Wethereforerecommendusing
elasticconnectionpieces(compensators).
Thefollowingoperatingparametersmustbe
compliedwith:
• Themaximum uid temperature is 70°C.
• Motor cooling–Toensuresufcientmotor
coolingbythemotorfan,theminimumdistance
totherearwallmustbecompliedwith.Seethe
operatingandmaintenancemanualforthemotor.
• Max. ambient temperature–seetheoperating
andmaintenancemanualforthemotor.
The hydraulics is not self-priming so that hy-
draulics housing must be completely lled with
the uid. Ensure that there is an appropriate
inlet pressure. Air pockets are to be avoided at
all costs. Appropriate ventilation systems must
be provided.
Fig. 3: Stationary dry well installation
1 Collectortank 6Compensator
2 Machine room 7 Hydraulics
3 Gatevalveinlet 8 Standard motor
4Gatevalvedischarge
pipeline 9Attachmentpointsfor oorxation
5Non-return valve
Work steps
1. Installingthehydraulics:about3–5h
• Checkthatthepipesystemissecuredrmly.
• Fastenliftingequipmenttothecorresponding
attachmentpointsandpositionthehydraulics
intheplannedlocation.
• Fastenhydraulicstothefoundation(6xattach-
mentpoints:4xhydraulics,2xsupport).We
recommendusinganchorboltforthisxation.
Note: The hydraulics is constructed in a "back
pull out" design. In other words, the motor,
bearing housing and impeller can be removed
as a unit without dismantling the hydraulics
housing from the piping. A minimum distance of
500mm must be ensured here between the mo-
tor fan and the rear wall.
• Loosentheliftinggearandremovethetrans-
portshacklefromthepressureport.
Keep the transport shackle for later transport.

38 WILOSE12-2015V05DINA4
English COMMISSIONING
• Connectthesuction-andpressure-sidepipe
system.Toensurethatthepipesystemis
connectedfreeofstressesandvibration,we
recommend using elastic connection pieces
(compensators).
• Routethepowersupplycables(must be pro-
videdbythecustomer)inaccordancewithlocal
requirements.
• Havetheelectricalconnectionsmadebya
qualiedelectrician.
2. Installoptionalaccessories,suchasalarmswitch-
gearfordetectingmoisture.
3. Commissioningthehydraulics:about2–4h
• Asdescribedinthe"Commissioning"section
• Openslidevalvesonsuctionandpressuresides.
• Ventthehydraulicsandpipesystem.
5.4. Electrical connection
ELECTROCUTION hazard!
Improper electrical connections can lead to
fatal electric shocks. Electrical connections
may only be carried out by a qualied electri-
cian approved by the local energy supply
company, in accordance with locally applica-
ble regulations.
NOTE
Alsonotealltheinformationregardingelectrical
connection in the operating and maintenance
manualforthemotor!
• Thecurrentandvoltageofthemainsconnection
mustbedesignedinaccordancewiththeinfor-
mation in the operating and maintenance manual
forthemotor.Seealsothespecicationsonthe
ratingplateforthemotor.
• Thepowersupplycablemustbeprovidedbythe
customer.Thecablecross-sectionandchosen
routingoptionmustcomplywithlocalstandards
andrequirements.
• Anyavailablemonitoringequipment,e.g.sealing
chamber control, must be connected and tested
toensurethatitisworkingproperly.
• Earththehydraulicsaccordingtotheregulations.
Earthingisprovidedbythemotorconnection.Al-
ternatively,thehydraulicscanbeearthedthrough
aseparateconnection.Thecrosssectionofthe
cable for the earth conductor connection must
complywithlocalregulations.
5.4.1. Check the monitoring equipment before
commissioning
Ifthevaluesdeviatefromthespecications,the
monitoringequipmentmaybefaulty.Consult
Wilocustomerservice.
Optional pencil electrode for sealing chamber
control
Before the pencil electrode is connected, it must
becheckedwithanohmmeter.Thefollowing
valuesmustbecompliedwith:
• Thisvaluemustapproachinnity.Ifthevalue
islow,thereiswaterintheoil.Alsoobservethe
instructionsoftheoptionalevaluationrelay.
5.4.2. Connecting the monitoring equipment
Connecting the pencil electrode (available as an
option) for sealing chamber control
• Thepencilelectrodemustbeconnectedviaan
evaluationrelay.Werecommendthe“NIV101/A”
relayforthis.Thethresholdis30kΩ.Whenthe
thresholdisreached,awarningmustbegivenor
theunitswitchedoff.
CAUTION!
If there is only a warning, the hydraulics could
be irreparably damaged by water ingress. We
always recommend switching the hydraulics
off!
5.4.3. Connecting the standard motor
Theinformationforconnectingthemotortothe
mains,informationconcerningexistingmonitor-
ingequipmentandconnectingthisequipment,
andconcerningpossibleactivationtypescanbe
found in the operating and maintenance manual
forthemotor.
5.5. Operator responsibilities
5.5.1. Recommended monitoring equipment
Thehydraulicsisdrivenbyastandardmotor.
Standardmotorarenotoverow-proof.We
thereforerecommendusinganalarmswitchgear
torecordmajorleakage.Intheeventofamajor
dischargeofuid(e.g.faultypiping),analarmcan
beissuedandtheunitswitchedoff.
6. Commissioning
NOTE
Alsonotealltheinformationregardingcom-
missioning in the operating and maintenance
manualforthemotor!
The“Commissioning”sectioncontainsalltheim-
portant instructions for the operating personnel
forstartingupandoperatingthehydraulics.
Thefollowingconditionsmustbeadheredtoand
monitored:
• Maximumambienttemperature(seeinstallation
andoperatinginstructionsformotor)
• Allslidevalvesonthesuction-andpressure-side
are open
These general conditions must also be checked
after a lengthy period without operation, and
any defects detected must be repaired!
Alwayskeepthismanualeitherbythehydraulics
orinaplacespeciallyreservedforit,whereitis
accessible for the entire operating personnel at
alltimes.

InstallationandoperatinginstructionsWilo-RexaBlocRE 39
COMMISSIONING English
Inordertopreventdamageorseriousinjurywhen
commissioningthehydraulics,thefollowing
pointsmustbeobserved:
• Commissioningofthehydraulicsmayonlybe
carriedoutbyqualiedandtrainedpersonnelin
accordancewiththesafetyinstructions.
• Allpersonsworkingonorwiththehydraulics
must have received, read and understood this
operatingandmaintenancemanual.
• Allsafetydevicesandemergencycut-outsmust
beconnectedandcheckedtoensurethatthey
workproperly.
• Electrical engineering and mechanical adjust-
mentsmustbemadebyqualiedpersonnel.
• Thehydraulicsissuitableforuseunderthespeci-
edoperatingconditions.
• Whenworkinginpumpchambers,asecondper-
sonmustbepresentforsafetyreasons.Adequate
ventilation must be ensured if there is danger of
poisonousgasesforming.
6.1. Electrical system
ELECTROCUTION hazard!
Improper electrical connections can lead to
fatal electric shocks. Electrical connections
may only be carried out by a qualied electri-
cian approved by the local energy supply
company, in accordance with locally applica-
ble regulations.
Thestandardmotorisconnectedtothemains
andthepowersupplycablesareroutedinaccord-
ancewiththeoperatingandmaintenancemanual
forthemotorandinaccordancewithlocallyap-
plicableregulations.
Thehydraulicsmustbeproperlyprotectedand
earthed.
Make sure all monitoring devices are connected
andhavebeentested.
6.2. Rotation control
Ifthedirectionofrotationisincorrect,thehy-
draulicswillnotperformasspeciedandmaybe
damaged.Whenyoulookatthehydraulicsfrom
thefront,theymustrotateanticlockwise(see
directionofrotationarrowonthehydraulics).
Unitsdeliveredfromthefactorywithabuilt-on
standardmotorrequireaclockwiserotatingeld
toensurethecorrectdirectionofrotation.The
rotatingeldcanbecheckedwitharotatingeld
testerbyalocalelectrician.
The hydraulics is not approved for operation
with a counter-clockwise rotating eld!
Theelectricalconnectionmustbecompletedin
accordancewiththeinformationintheoperating
andmaintenancemanualforthemotor.
There must be a test run without uid and with
the slide valve on the suction side closed!
If the direction of rotation is incorrect for direct
startmotors,2phasesmustbeswapped.Inthe
caseofstar-deltamotors,theconnectionsoftwo
windingsmustbeswapped,e.g.U1withV1and
U2withV2.
6.3. Operation in potentially explosive areas
Thehydraulicsmustnotbeoperatedinanexplo-
siveatmosphere!
6.4. Operation with frequency converters
NOTE
Alsonotealltheinformationintheoperating
andmaintenancemanualforthemotor!
Operationonafrequencyconverterispossible.
Thefollowingparametersmustbeobserved:
• Themaximumspeedmustnot exceed1450rpm.
• Continuousdutywithavolumeowof
Qopt<0.7m/sshouldbeavoided.
• Thecircumferentialspeedmustnot fall below
aminimumof13m/s.
NOTE
Thecircumferentialspeedcanbecalculatedas
follows:v = n · d · π / 60,000
Key:
- n = speed in rpm
- d = impeller diameter in mm
-v=circumferentialspeedinm/s
6.5. Commissioning
Thehydraulicsmusthavebeeninstalledproperly
asspeciedinthe"Installation"chapter.This
mustbecheckedbeforethesystemisswitched
on.
Theelectricalconnectionmusthavebeencom-
pletedinaccordancewiththeinformationinthe
operatingandmaintenancemanualforthemotor.
Intheversionwithaplug,notetheplug'sIPpro-
tectionclass.
6.5.1. Before switching on
Checkthefollowing:
• Min./max.temperatureoftheuid
• Min./max.ambienttemperature
• Suction-andpressure-sidepipesystemisfreeof
deposits and solids
• Openallslidevalvesonthepressureandsuction
sides
If the slide valves on the suction and pres-
sure sides are closed during operation, the
uid in the hydraulics housing is heated up by
the pumping movement. This heating creates
strong pressure in the hydraulics housing. The
pressure can result in the hydraulics exploding.
Before switching on the hydraulics, ensure that
all the slide valves are open and open any closed
slide valves.
• Thehydraulicshousingmustbecompletelylled
bytheuidandtheremustbenoairinthehous-
ing.Ventingisprovidedbyaventingscrewonthe
pressureport.
• Checktoensureallaccessoriesareproperlytted

40 WILOSE12-2015V05DINA4
English DECOMMISSIONING/DISPOSAL
6.5.2. Switching on/off
Thestandardmotorisswitchedonandoffusinga
separateoperatingpoint(on/offswitch,switch-
gear)providedbythecustomer.
See the information in the operating and main-
tenance manual for the motor.
6.6. Conduct during operation
BEWARE of burns!
The housing parts can heat up to well above
40°C. There is a risk of burns!
• Never touch parts of the housing with your
bare hands.
• After switching them off, let the hydraulics
cool down to ambient temperature.
• Wear heat-resistant protective gloves!
Duringoperationofthehydraulics,alwaysfollow
thelocallyapplicablelawsandregulationsfor
worksafety,accidentpreventionandhandling
electricalmachinery.Tohelpensuresafeworking
practice,theresponsibilitiesofemployeesshould
beclearlyspeciedbytheoperator.Allpersonnel
are responsible for ensuring that regulations are
observed.
During operation, all gate valves in the inlet line
andpressurepipemustbecompletelyopen.
If the slide valves on the suction and pres-
sure sides are closed during operation, the
uid in the hydraulics housing is heated up by
the pumping movement. This heating creates
strong pressure in the hydraulics housing. The
pressure can result in the hydraulics exploding.
Before switching on the hydraulics, ensure that
all the slide valves are open and open any closed
slide valves.
7. Decommissioning/disposal
NOTE
Alsonotealltheinformationregardingdecom-
missioning/disposalintheoperatingandmain-
tenancemanualforthemotor!
• Allworkmustbecarriedoutwiththegreatest
care.
• Properprotectiveclothingistobeworn.
• Whencarryingoutworkinbasinsand/ortanks,
the respective local protection measures must be
observed.Asecondpersonmustbepresentfor
safetyreasons.
• Liftingequipmentinperfecttechnicalcondition
andofciallyapprovedload-bearingequip-
mentmustbeusedforliftingandloweringthe
hydraulics.
RISK of fatal injury due to malfunctions!
The lifting gear and lifting equipment must
be in a technically sound condition. Work
may only commence if the lifting equipment
has been checked and found to be in perfect
working order. If it is not inspected, fatal
injuries may result.
7.1. Decommissioning
1. Switchtheelectroniccontrolfortheunitto
manualmode.
2. Closegatevalveonsuctionside.
3. Manuallyactivatetheunittopumptheremaining
quantityofuidintothedischargepipeline.
4. Switchoffthemotorandsecureitagainstbeing
switchedonagainbyunauthorisedpersons.
5. Closegatevalveonpressureside.
6. Work on removal, maintenance and storage can
nowcommence.
7.2. Removal
DANGER due to poisonous substances!
Hydraulics that pump liquids hazardous to
health must always be decontaminated before
undertaking any other work! Otherwise, there
is a risk of fatal injury! Wear the necessary
physical protection equipment!
BEWARE of burns!
The housing parts can heat up to well above
40°C. There is a risk of burns!
• Never touch parts of the housing with your
bare hands.
• After switching them off, let the hydraulics
cool down to ambient temperature.
• Wear heat-resistant protective gloves!
NOTE
Notethattheresidualuidinthehydraulics
housingwillescapeduringremoval.Suitable
collector tanks should be positioned to collect
alloftheescapinguid.
1. Haveaqualiedelectriciandisconnectthemotor
fromthemains.
2. Draintheresidualuidthroughthedrainage
screwonthehydraulics.
Attention: Collect the uid in a suitable tank
and dispose of it properly.
3. Toremovethehydraulics,youhavetoloosenthe
screwedconnectionsonthesuctionandpres-
sureportsandtheoorxationonthehydraulics
housingandonthesupport.
4. Attachtheliftingequipmenttothecorrespond-
ingattachmentpoints.To do this, you rst have
to attach the enclosed transport shackle to
the pressure port.Thehydraulicscanthenbe
removedfromtheoperatingspace.

InstallationandoperatinginstructionsWilo-RexaBlocRE 41
MAINTENANCEANDREPAIR English
5. Theoperatingspacemustbecleanedthoroughly
afterthehydraulicsisremovedandanydrips
mustbewipedup.
7.3. Return delivery/storage
Forshipping,thepartsmustbepackedintear-
proofplasticbagsofsufcientsizeinsucha
mannerthattheyaretightlysealedandleak-
proof.
For return delivery and storage please also refer
to the "Transport and storage" section!
7.4. Disposal
7.4.1. Operating uid
Oilsandlubricantsmustbecollectedinappropri-
atecontainersandproperlydisposedofinterms
ofECDirective75/439/EECaswellasincompli-
ancewiththeprovisionsofsections5aand5b
oftheGermanWasteActortheapplicablelocal
laws.
7.4.2. Protective clothing
Protectiveclothingwornforcleaningandmain-
tenanceworkistobedisposedofinaccordance
withtheGermanWasteCodeTA52402and
ECDirective91/689/EEC.
7.4.3. Product
Proper disposal of this product avoids damage to
theenvironmentandriskstopersonalhealth.
• Usetheservicesofpublicorprivatewastedis-
posal companies, or consult them for the disposal
oftheproductorpartsthereof.
• Formoreinformationonproperdisposal,please
contactyourlocalcouncilorwastedisposalofce
orthesupplierfromwhomyoupurchasedthe
product.
8. Maintenance and repair
ELECTROCUTION hazard!
There is a risk of fatal electric shocks when
performing work on electrical devices. With
all maintenance or repair work, the motor
must be disconnected from the mains by a
qualied electrician and secured against being
switched on again without permission.
NOTE
Alsonotealltheinformationregardingmainte-
nance and repair in the operating and mainte-
nancemanualforthemotor!
• Beforeanymaintenanceorrepairwork,the
hydraulicsmustbedeactivatedanddismantled
asdescribedinthe"Decommissioning/disposal"
chapter.
• Aftermaintenanceorrepairwork,thehydraulics
must be installed and connected as described in
the"Installation"chapter.
• Thehydraulicsisswitchedonasdescribedinthe
"Commissioning"chapter.
Notethefollowing:
• Allmaintenanceandrepairworkmustbecarried
outbyWilocustomerservice,authorisedservice
workshopsortrainedspecialistswiththegreatest
ofcareandinasafeworkplace.Properprotective
clothingistobeworn.
• Thismanualmustbeavailabletoandobserved
bythemaintenancestaff.Onlymaintenanceand
repairworkdescribedinthismanualmaybecar-
riedout.
Any other work and/or alterations to the
construction must only be carried out by Wilo
customer service.
• Whencarryingoutworkinbasinsand/ortanks,
the respective local protection measures must be
observedinallcases.Asecondpersonmustbe
presentforsafetyreasons.
• Liftingequipmentinperfecttechnicalcondition
andofciallyapprovedload-bearingequipment
mustbeusedforliftingandloweringthehydrau-
lics.Themaximumpermissiblebearingcapacity
mustneverbeexceeded!
Make sure the lifting gear, wire rope and safety
devices of the lifting equipment are in perfect
working order. Work may only commence if
the lifting equipment has been checked and
found to be in perfect working order. If it is not
inspected, fatal injuries may result.
• Ifammablesolventsandcleaningagentsare
used,nakedamesandsmokingareprohibited.
• Hydraulicsthatpumpliquidshazardoustohealth
mustalwaysbedecontaminated.Inaddition,
make sure that no gases that are hazardous to
healthformorarepresent.
If injuries are caused by uids or gases that
are hazardous to health, apply the rst-aid
measures specied on the notice at the working
premises and notify a doctor immediately!
• Makesurethatthenecessarytoolsandmaterials
areavailable.Orderandcleanlinessensuresafe
andsmoothworkonthehydraulics.Afterwork-
ingonthehydraulics,removeanyusedclean-
ingmaterialsandtoolsfromthepump.Storeall
materialsandtoolsintheirproperplace.
• Operatingmaterialsshouldbecollectedinsuit-
ablecontainersanddisposedofproperly.Always
wearappropriateprotectiveclothingwhenper-
formingmaintenanceandrepairwork.Thismust
alsobedisposedofproperly.
8.1. Operating uid
8.1.1. Overview of white oil
Thesealingchamberislledwithwhiteoilthatis
potentiallybiodegradable.
Whenchangingtheoil,werecommendthefol-
lowingoiltypes:
• AralAutinPL*
• ShellONDINA919
• EssoMARCOL52*or82*
• BPWHITEMOREWOM14*

42 WILOSE12-2015V05DINA4
English MAINTENANCEANDREPAIR
• TexacoPharmaceutical30*or40*
Alloiltypesmarkedwith"*"areapprovedforuse
withfoodsinaccordancewith"USDA-H1".
Filling quantities
Thellingquantityforthesealingchamberis
1600ml.
8.1.2. Overview of grease
Thefollowinglubricatinggreasecanbeusedin
accordancewithDIN51818/NLGlClass3:
• EssoUnirexN3
8.2. Maintenance intervals
Toensurereliableoperation,variousmaintenance
tasksmustbecarriedoutregularly.
Themaintenanceintervalsmustbespeciedac-
cordingtotheloadonthehydraulics.Regardless
ofthespeciedmaintenanceintervals,thehy-
draulics or installation must be checked if strong
vibrationsoccurduringoperation.
Also note the maintenance intervals and main-
tenance work for the motor. See the operating
and maintenance manual for the motor.
8.2.1. Intervals for normal operating conditions
2 years
• Visualinspectionofthecoatingandhousingfor
wear
• Functionalcheckofpencilelectrode(availableas
anoption)forsealingchambercontrol
• Oilchangeinsealingchamber
• Checktheleakagechamberforleaks
NOTE
If sealing chamber control is installed, the main-
tenanceintervalcorrespondstotheindicator!
15000 operating hours or after 10 years at the
latest
• Generaloverhaul
8.2.2. Intervals for harsh operating conditions
Underharshoperatingconditions,thespecied
maintenance intervals must be shortened accord-
ingly.Inthiscase,contactWilocustomerservice.
Ifusingthehydraulicsunderharshconditions,we
alsorecommendsigningamaintenancecontract.
Harshoperatingconditionsinclude:
• Alargeproportionofbrousmaterialorsandin
theuid
• Stronglycorrosiveuids
• Stronglygassinguids
• Unfavourabledutypoints
• Operationatriskfromwaterhammers
8.2.3. Recommended maintenance measures to en-
sure smooth operation
We recommend regular inspections of the current
consumption and the operating voltage in all
phases.Innormaloperation,thesevaluesremain
constant.Slightuctuationsdependonthechar-
acteristicsoftheuid.Thecurrentconsumption
canprovideanearlyindicationofdamageand/
ormalfunctionsintheimpeller,bearingsand/or
motor,whichcanberectied.Largervoltageuc-
tuationsstrainthemotorwindingandcancause
themotortobreakdown.Regularinspections
canthereforelargelypreventmajorsecondary
damageandreducetheriskoftotalbreakdown.
We recommend the use of remote monitoring for
regularinspections.PleasecontactWilocustomer
service.
8.3. Maintenance work
Beforecarryingoutmaintenancework:
• Disconnectthemotorfromthepowerandsecure
itagainstbeingswitchedoninadvertently.
• Allowthehydraulicstocooldownandcleanthem
thoroughly.
• Makesurethatalltheoperationally-relevant
partsareingoodcondition.
8.3.1. Visual inspection of coating and housing for
wear
Thecoatingsandhousingpartsmustnotshow
anysignsofdamage.Ifthereisvisibledamage
tothecoatings,repairthecoatingaccordingly.If
there is visible damage to housing parts, contact
Wilocustomerservice.
8.3.2. Functional check of pencil electrode (available
as an option) for sealing chamber control
Tocheckthepencilelectrode,thehydraulicshas
to be cooled to the ambient temperature and
the electrical connection for the pencil electrode
hastobedisconnectedintheswitchgear.The
monitoringequipmentcanthenbecheckedwith
anohmmeter.Thefollowingvaluesshouldbe
measured:
• Thisvaluemustapproachinnity.Ifthevalue
islow,thereiswaterintheoil.Alsoobservethe
instructionsoftheoptionalevaluationrelay.
If there are larger deviations, consult Wilo
customer service.
8.3.3. Oil change in sealing chamber
Thesealingchamberhasseparateopeningsfor
drainingandllingthechamber.
RISK of injury from hot and/or pressurised
operating uid!
After the hydraulics is switched off, the oil is
still hot and pressurised. This can cause the
screw plug to be ejected and hot oil to escape.
There is a risk of injury or burns! First allow
the oil to cool down to ambient temperature.
Fig. 4: Screw plugs
D- Drainholescrewplug
D+ Fillerholescrewplug
1. Ifyoucanplaceatankbeneaththehydraulics
tocollecttheoil,youdonotneedtoremovethe
hydraulics.

InstallationandoperatinginstructionsWilo-RexaBlocRE 43
MAINTENANCEANDREPAIR English
2. Carefullyandslowlyunscrewthescrewplug(D+).
Attention: the oil may be pressurised! This can
cause the screw to be ejected at speed.
3. Placeasuitabletankbeneaththescrewplug(D-)
tocollecttheoil.
4. Carefullyandslowlyunscrewscrewplug(D-)and
allowtheoiltodrainout.Disposeoftheoilinac-
cordancewiththerequirementsinthe"Disposal"
chapter.
5. Cleanthescrewplug(D-),renewthesealringand
screwitbackin.
6. Pourthenewoilinthroughtheholeforthescrew
plug(D+).Notetherecommendedoilsandlling
quantities.
7. Cleanthescrewplug(D+),renewthesealringand
screwitbackin.
8.3.4. Check the leakage chamber for leaks
Theleakagechamberisaself-containedchamber
and receives the leakage chamber from the seal-
ingchamberintheeventoffaults.Ifthereare
largequantitiesofwaterintheleakagechamber,
contact Wilo customer service
Fig. 5: Screw plug
L- Drainholescrewplug
1. Ifyoucanplaceatankbeneaththehydraulics
tocollecttheoil,youdonotneedtoremovethe
hydraulics.
2. Placeacollectortankunderneaththescrewplug
(L-).
3. Carefullyandslowlyunscrewscrewplug(L-)and
allowtheoiltodrainout.Disposeoftheoilinac-
cordancewiththerequirementsinthe"Disposal"
chapter.
4. Cleanthescrewplug(L-),renewthesealringand
screwitbackin.
8.3.5. General overhaul
In a general overhaul, the normal maintenance
workiscarriedoutandinadditiontheshaftseals,
O-ringsandshaftbearingsarecheckedandre-
placed,ifnecessary.Thisworkmaybeperformed
onlybythemanufactureroranauthorisedservice
workshop.
8.4. Repairs
DANGER due to poisonous substances!
Hydraulics that pump liquids hazardous to
health must always be decontaminated before
undertaking any other work! Otherwise, there
is a risk of fatal injury! Wear the necessary
physical protection equipment!
BEWARE of sharp edges!
Sharp edges can form on the impeller and the
opening on the suction port. There is a risk of
injury! Wear the necessary protective cloth-
ing, such as protective gloves.
BEWARE of burns!
The housing parts can heat up to well above
40°C. There is a risk of burns!
• Never touch parts of the housing with your
bare hands.
• After switching them off, let the hydraulics
cool down to ambient temperature.
• Wear heat-resistant protective gloves!
Beforecarryingoutrepairs:
• Haveaqualiedelectriciandisconnectthemo-
tor'spowersupplycableonthemotorandsecure
itagainstbeingswitchedoninadvertently.
• Allowthehydraulicsandmotortocooldownand
cleanthemthoroughly.
• Makesurethatalltheoperationally-relevant
partsareingoodcondition.
• AlwaysreplaceO-rings,sealsandscrewlocking
devices(springlockwashers,Nord-Lockwash-
ers).
• Thespeciedtighteningtorquesmustbecom-
pliedwith.
• Neveruseforcewhencarryingoutthiswork!
8.4.1. Use of screw locking
Screwlockingisusedonallscrews.Thismust
alwaysberenewedafterdisassembly.
Thescrewlockingcanbeappliedindifferent
ways:
• Liquidscrewlockingcompound,e.g.Loctite243
• MechanicalscrewlockingwithNord-Lockwasher
Liquid screw locking compound
Liquidscrewlockingcompoundcanbeunfas-
tenedbyapplyingincreasedforce.Ifthisisnot
possible, the connection must be heated to
about300°Cinordertobereleased.Theaffected
componentsmustbethoroughlycleanedand,
onassembly,onceagainhavethescrewlocking
compoundappliedtothem.
Mechanical screw locking
TheNord-Lockwasherisonlyusedonboltswith
strengthclass10.9whichhavebeencoatedwith
Geomet.
The Nord-Lock washer must not be used for
screw locking with stainless screws!
8.4.2. Which repair work is allowed to be performed?
• Impeller change
• Replacing the mechanical seal
• Changeofhydraulics
• Changeofmotor
8.4.3. Impeller change
Thebearinghousing,impellerandmotorare
constructedin"backpullout"design.Thismeans
that these components can be removed as a
completeunit.Thehydraulicshousingremains
installedinthepipesystem.