Wilo Wilo-Rexa PRO-S User manual

Pioneering for You
·
Wilo-Rexa PRO-S
6092606 • Ed.01/2022-03
en Installation and operating instructions

Rexa PRO-S
http://qr.wilo.com/415
Rexa PRO
https://qr.wilo.com/772

en
Installation and operating instructions • Wilo-Rexa PRO-S • Ed.01/2022-03 3
Table of contents
1 General information...................................................................4
1.1 About these instructions ..................................................... 4
1.2 Digital instructions................................................................ 4
1.3 Copyright ............................................................................... 4
1.4 Subject to change................................................................. 4
1.5 Exclusion from warranty and liability.................................4
2 Safety...........................................................................................4
2.1 Identification of safety instructions................................... 4
2.2 Personnel qualifications....................................................... 6
2.3 Personal protective equipment........................................... 6
2.4 Electrical work .......................................................................7
2.5 Monitoring devices ............................................................... 7
2.6 Fluids hazardous to health................................................... 8
2.7 Transport................................................................................ 8
2.8 Use of lifting equipment......................................................8
2.9 Installing/dismantling........................................................... 8
2.10 During operation ................................................................... 9
2.11 Clean and disinfect ............................................................... 9
2.12 Maintenance tasks................................................................ 9
2.13 Operating fluid ....................................................................10
2.14 Operator responsibilities....................................................10
3 Transportation and storage.....................................................10
3.1 Delivery.................................................................................10
3.2 Transport..............................................................................11
3.3 Storage .................................................................................11
4 Application/use.........................................................................12
4.1 Intended use........................................................................12
4.2 Improper use........................................................................12
5 Product description..................................................................12
5.1 Description...........................................................................12
5.2 Materials...............................................................................13
5.3 Technical data .....................................................................13
5.4 Type key...............................................................................13
5.5 Operation in an explosive atmosphere ............................14
5.6 Scope of delivery.................................................................14
5.7 Accessories ..........................................................................14
6 Installation and electrical connection....................................14
6.1 Personnel qualifications.....................................................14
6.2 Installation types.................................................................15
6.3 Operator responsibilities....................................................15
6.4 Installation ...........................................................................15
6.5 Electrical connection..........................................................18
7 Commissioning .........................................................................21
7.1 Personnel qualifications.....................................................21
7.2 Operator responsibilities....................................................21
7.3 Direction of rotation check for three-phase AC motor
...............................................................................................22
7.4 Operation in an explosive atmosphere ............................22
7.5 Before switching on............................................................23
7.6 Switching on and off ..........................................................23
7.7 During operation .................................................................23
8 Shut-down/dismantling...........................................................24
8.1 Personnel qualifications......................................................24
8.2 Operator responsibilities.....................................................24
8.3 Shut-down............................................................................24
8.4 Removal.................................................................................25
9 Maintenance and repair............................................................26
9.1 Personnel qualifications......................................................26
9.2 Operator responsibilities.....................................................27
9.3 Operating fluid......................................................................27
9.4 Maintenance intervals .........................................................27
9.5 Maintenance measures .......................................................28
9.6 Repairs ...................................................................................30
10 Faults, causes and remedies ....................................................31
11 Spare parts.................................................................................34
12 Disposal......................................................................................34
12.1 Oils and lubricants................................................................34
12.2 Protective clothing ..............................................................34
12.3 Information on the collection of used electrical and elec-
tronic products .....................................................................34
13 Appendix....................................................................................34
13.1 Tightening torques ..............................................................34
13.2 Frequency converter operation..........................................35
13.3 Ex rating.................................................................................36

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4 Installation and operating instructions • Wilo-Rexa PRO-S • Ed.01/2022-03
1 General information
1.1 About these instructions These instructions form part of the product. Compliance with the instructions is essential
for correct handling and use:
•Read the instructions carefully before all activities.
•Keep the instructions in an accessible place at all times.
•Observe all product specifications.
•Observe the markings on the product.
The language of the original operating instructions is German. All other languages of these
instructions are translations of the original operating instructions.
1.2 Digital instructions The digital version of the instructions is available on the following product page:
https://qr.wilo.com/00415
1.3 Copyright WILO SE © 2022
The reproduction, distribution and utilization of this document as well as the communica-
tion of its contents to others without express authorization is prohibited. Offenders will be
held liable for the payment of damages. All rights reserved.
1.4 Subject to change Wilo shall reserve the right to change the listed data without notice and shall not be liable
for technical inaccuracies and/or omissions. The illustrations used may differ from the ori-
ginal and are intended as an example representation of the device.
1.5 Exclusion from warranty and liabil-
ity
Wilo shall specifically not assume any warranty or liability in the following cases:
•Inadequate configuration due to inadequate or incorrect instructions by the operator or
the client
•Non-compliance with these instructions
•Improper use
•Incorrect storage or transport
•Incorrect installation or dismantling
•Insufficient maintenance
•Unauthorised repairs
•Inadequate construction site
•Chemical, electrical or electrochemical influences
•Wear
2 Safety This section contains basic information about the individual
stages in the life cycle of the pump. Failure to observe this in-
formation leads to:
•Danger to persons
•Danger to the environment
•Property damage
•Loss of claims for damages
2.1 Identification of safety
instructions
These installation and operating instructions set out safety in-
structions for preventing personal injury and damage to property.
These safety instructions are shown differently:
•Safety 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.

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Installation and operating instructions • Wilo-Rexa PRO-S • Ed.01/2022-03 5
•Safety instructions relating to property damage start with a
signal word and are displayed without a symbol.
CAUTION
Type and source of the danger!
Consequences or information.
Signal words
•DANGER!
Failure to observe the safety instructions will result in serious
injuries or death!
•WARNING!
Failure to follow the instructions can lead to (serious) injuries!
•CAUTION!
Failure to follow the instructions can lead to property damage
and a possible total loss.
•NOTICE!
Useful information on handling the product
Markups
✓Prerequisite
1. Work step/list
⇒Notice/instructions
▶Result
Identifying cross references
The name of the section or table is in inverted commas [“ ”]. The
page number follows in square brackets [].
Symbols
These instructions use the following symbols:
Danger caused by electric voltage
Danger of bacterial infection
Danger of explosion
Danger caused by explosive atmosphere
General warning symbol
Warning – risk of cutting injuries
Warning – hot surfaces

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6 Installation and operating instructions • Wilo-Rexa PRO-S • Ed.01/2022-03
Warning – high pressure
Working alone is prohibited! A second person must be
present.
Useful information
2.2 Personnel qualifications •Personnel have been instructed on locally applicable regula-
tions governing accident prevention.
•Personnel have read and understood the installation and oper-
ating instructions.
•Electrical work: qualified electrician
Person with appropriate technical training, knowledge and ex-
perience who can identify and prevent electrical hazards.
•Installation/dismantling work: trained sewage technology pro-
fessional
Fixation and pipework in wet well and dry well installation, lift-
ing equipment, basic knowledge of wastewater facilities
•Maintenance work: trained sewage technology professional
Application/disposal of operating fluids used, basic engineering
knowledge (installation/dismantling)
•Lifting work: trained specialist for the operation of lifting
devices
Lifting equipment, lifting gear, attachment points
Children and persons with limited abilities
•Persons under the age of 16: Use of this product is prohibited.
•Persons under the age of 18: Supervise them during use of the
product (supervisor)!
•Persons with limited physical, sensory or mental capacities: Use
of this product is prohibited!
2.3 Personal protective
equipment
The protective equipment specified is the minimum requirement.
Observe the requirements of the work regulations.
Protective equipment: Transport, installation, removal and
maintenance
•Safety shoes: Protection class S1 (uvex 1 sport S1)
•Protective gloves (EN388): 4X42C (uvex C500 wet)
•Safety helmet (EN397): Conforms to standards, protection
against lateral deformation (uvex pheos)
(If lifting equipment is used)
Protective equipment: Cleaning work
•Protective gloves (ENISO374-1): 4X42C + Type A (uvex pro-
tector chemical NK2725B)
•Safety goggles (EN166): (uvex skyguard NT)
–Labelling frame: W 166 34 F CE

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Installation and operating instructions • Wilo-Rexa PRO-S • Ed.01/2022-03 7
–Labelling disc: 0-0.0* W1 FKN CE
* Protection level according to EN170 not relevant for this
work.
•Breathing protection mask (EN149): Half mask 3M series 6000
with filter 6055 A2
Article recommendations
The branded products in the parentheses constitute non-binding
suggestions. Similar products from other brands can also be used.
Adherence to the standards mentioned is required.
WILO SE does not assume any liability for the adherence of the
aforementioned products to the corresponding standards.
2.4 Electrical work •Electrical work must be carried out by a qualified electrician.
•Disconnect device from the mains and secure it against being
switched on again without authorisation.
•Observe applicable local regulations when connecting to the
mains power supply.
•Comply with the requirements of the local energy supply com-
pany.
•Train personnel on how to make electrical connections.
•Train personnel on the options for switching off the device.
•Observe the technical information in these installation and op-
erating instructions as well as on the rating plate.
•Earth the device.
•Observe provisions for connection to the electrical switching
system.
•Comply with the specifications on electro-magnetic compatib-
ility when using electronic start-up controllers (e.g. soft starter
or frequency converter). If required, take special measures into
account (e.g. shielded cables, filters, etc.).
•Replace defective connection cables. Contact customer service.
2.5 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/mo-
tor protection switch with temperature compensation, differen-
tial triggering and anti-reactivation device in accordance with the
local regulations. In case of sensitive mains, make provision for
the installation on-site of other protective equipment (e.g. over-
voltage, undervoltage or phase failure relay, etc.).

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8 Installation and operating instructions • Wilo-Rexa PRO-S • Ed.01/2022-03
Residual-current device (RCD)
•Install a residual-current device (RCD) in accordance with the
regulations of the local energy supply company.
•If people can come into contact with the device and conductive
fluids, install a residual-current device (RCD).
2.6 Fluids hazardous to
health
Hazardous germs form in sewage or in stagnant water. There is a
danger of bacterial infections!
•Wear protective equipment!
•Clean and disinfect the product thoroughly after removal!
•Inform all persons about the pumped fluid and the danger it
poses!
2.7 Transport •Locally applicable laws and regulations on work safety and ac-
cident prevention must be complied with.
•Always carry the product by the handle!
2.8 Use of lifting equipment If lifting equipment (lifting device, crane, chain hoist…) is used,
observe the following points:
•Wear a safety helmet according to EN397!
•Comply with local regulations on the use of lifting equipment.
•The technically correct use of the lifting equipment is the oper-
ator’s responsibility!
•Lifting gear
–Use legally specified and approved lifting gear.
–Select lifting gear based on the attachment point.
–Attach lifting gear to the attachment point according to local
regulations.
•Lifting equipment
–Check it functions properly before use!
–Sufficient bearing capacity.
–Ensure stability during use.
•Lifting operation
–Do not jam the product when lifting and lowering it.
–Do not exceed the max. permissible bearing capacity!
–If necessary (e.g. blocked view), assign a second person to
coordinate.
–No one should stand under suspended loads!
–Do not move loads over workplaces where persons are
present!
2.9 Installing/dismantling •Locally applicable laws and regulations on work safety and ac-
cident prevention must be complied with.
•Disconnect device from the mains and secure it against being
switched on again without authorisation.
•All rotating parts must stop.

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Installation and operating instructions • Wilo-Rexa PRO-S • Ed.01/2022-03 9
•Ensure enclosed spaces have sufficient ventilation.
•When working in enclosed spaces, a second person must be
present for safety reasons.
•Toxic or asphyxiating gases may build up in enclosed spaces or
buildings. Observe protective measures in accordance with
work regulations, e.g. carry a gas detector with you.
•Clean the device thoroughly.
•If the product has been used in fluids that are hazardous to
health, disinfect the product!
2.10 During operation •Demarcate and cordon off the working area.
•No persons are allowed in the working area during operation.
•Depending on the process, the product is activated and deac-
tivated using separate controls. The product may automatically
be activated following power cuts.
•If the motor emerges, the motor housing can heat up to above
40°C (104°F).
•Superior must be informed immediately of any faults or irregu-
larities.
•The product must be switched off immediately if faults occur.
•Never reach into the suction port. The rotating parts can crush
and sever limbs.
•Open all gate valves in the inlet and pressure pipe.
•Ensure minimum water submersion by using dry-running pro-
tection.
•Sound-pressure level depends on several factors (installation,
duty point, etc.). Measure the current noise level under operat-
ing conditions. Wear hearing protection at noise levels of
85dB(A) and over. Demarcate the working area!
2.11 Clean and disinfect •If a disinfectant is used, wear protective equipment according
to the manufacturer’s instructions!
•Inform all persons about the disinfectant and how to use it cor-
rectly!
2.12 Maintenance tasks •Disconnect device from the mains and secure it against being
switched on again without authorisation.
•Clean the device thoroughly.
•If the product has been used in fluids that are hazardous to
health, disinfect the product!
•Carry out maintenance work in a clean, dry and well-lit place.
•Only carry out maintenance tasks described in these installation
and operating instructions.
•Only original parts of the manufacturer may be used. The use of
any non-original parts releases the manufacturer from any liab-
ility.
•Collect any leakage of fluid and operating fluid immediately and
dispose of it according to the locally applicable guidelines.

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10 Installation and operating instructions • Wilo-Rexa PRO-S • Ed.01/2022-03
2.13 Operating fluid The following white oils are used:
•ExxonMobile: Marcol52
•ExxonMobile: Marcol82
General remarks
•Absorb leakages immediately.
•If major leakages occur, contact customer service.
•If the seal is defective, the oil enters the pumped fluid.
First aid measures
•Skin contact
–Rinse skin areas thoroughly with soap and water.
–If skin irritation occurs, consult a doctor.
–In case of contact with open skin, consult a doctor!
•Eye contact
–Remove the contact lenses.
–Rinse eye thoroughly with water.
–If eye irritation occurs, consult a doctor.
•Inhalation
–Remove from the contact area!
–Create air exchange!
–If the respiratory tract becomes irritated or there is dizziness
or nausea, consult a doctor immediately!
•Ingestion
–Consult a doctor immediately!
–Do not induce vomiting!
2.14 Operator responsibilities •Provide installation and operating instructions in a language
which the personnel can understand.
•Make sure that the personnel have received the required train-
ing for the specified work.
•Provide protective equipment. Ensure that the protective
equipment is worn by personnel.
•Ensure that safety and information signs mounted on the
device are always legible.
•Train the personnel on how the system operates.
•Fit dangerous components within the system with an on-site
guard.
•Demarcate and cordon off the working area.
•Measure the noise level. At noise levels of 85dB(A) and over,
wear hearing protection. Demarcate the working area!
3 Transportation and storage
3.1 Delivery •After receiving the shipment, check it immediately for defects (damage, completeness).
•Defects must be noted on the freight documentation.
•Defects must be notified to the transport company or the manufacturer on the day of
receipt of shipment.

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Installation and operating instructions • Wilo-Rexa PRO-S • Ed.01/2022-03 11
•Subsequently notified defects can no longer be asserted.
3.2 Transport
CAUTION
Soaked packaging may tear!
The product may fall on the ground if unprotected and may be damaged.
Lift wet packaging carefully and replace it immediately!
Fig.1: Attachment point
•Wear protective equipment! Observe the work regulations.
–Protective gloves: 4X42C (uvex C500 wet)
–Safety shoes: Protection class S1 (uvex 1 sport S1)
•Carry the pump by the handle!
•Protect the connection cable against water ingress. Do not immerse attached plugs in the
pumped fluid.
•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 package the used pump for transport in a
leak-proof manner.
3.3 Storage
DANGER
Danger due to fluids which are hazardous to health!
Danger of bacterial infection!
• Disinfect the pump after removal!
• Observe the specifications of the work regulations!
WARNING
Risk of injury from sharp edges on the cutting device!
The macerator has extremely sharp edges. In addition, sharp edges can
form on the suction port. There is a danger of cuts!
• Wear protective gloves!
• Do not touch the macerator!
CAUTION
Defective macerator due to objects lying around!
Hard objects can damage the macerator! When setting down, ensure that
no objects come into contact with the macerator.
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.
•Place the pump upright (vertical) on a firm bearing surface.
•Secure the pump against falling over and slipping!
•Store the pump for a maximum of one year. Consult the customer service before storing
the device for more than one year.

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12 Installation and operating instructions • Wilo-Rexa PRO-S • Ed.01/2022-03
•Storage conditions:
–Maximum: -15 to +60°C (5 to 140°F), max. humidity: 90%, non-condensing.
–Recommended: 5 to 25°C (41 to 77°F), relative humidity: 40 to 50%.
–Protect the pump from direct exposure to sunlight. Extreme heat can cause damage!
•Do not store the pump in rooms where welding work is carried out. The resulting gases
or radiation can corrode the elastomer parts and coatings.
•Seal the suction and discharge connection tightly.
•Protect the connection cable against kinking and damage. Maintain a constant bend ra-
dius!
4 Application/use
4.1 Intended use For pumping in commercial areas of:
•Sewage containing faeces
•Wastewater (with small amounts of sand)
Sewage pumping according to (DIN)EN12050
The pumps meet the requirements of EN12050-2.
4.2 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.
The submersible pumps must not be used for pumping:
•Untreated sewage
•Drinking water
•Fluids containing hard components (such as stones, wood, metal, etc.)
•Fluids containing high quantities of abrasive contents (e.g. sand, gravel).
Intended use also includes compliance with this manual. Any other use is regarded as non-
compliant with intended use.
5 Product description
5.1 Description Fully submersible grinder pump for stationary and portable wet well installation in continu-
ous operation.
1
2
3
4
5
6
7
Fig.2: Overview
1 Handle/attachment point
2 Connection cable
3 Discharge connection
4 Macerator
5 Hydraulics housing
6 Seal housing
7 Motor housing
RexaPRO-S.../M.../O
Sewage pump with radial macerator with double shear effect. Horizontal discharge port with
flange and oval connection. Hydraulics housing and impeller made of grey cast iron; macer-
ator made of hardened cutting steel. Surface-cooled 1~ motor with thermal motor monitor-
ing and moisture probe. Oil-filled sealing chamber with two mechanical seals. Motor housing
made of grey cast iron. Detachable connection cable with capacitor box and bare cable ends.
Unit with Ex-rating as standard.
RexaPRO-S.../T.../O
Sewage pump with radial macerator with double shear effect. Horizontal discharge port with
flange and oval connection. Hydraulics housing and impeller made of grey cast iron; macer-
ator made of hardened cutting steel. Surface-cooled 3~ motor with thermal motor monitor-
ing and moisture probe. Oil-filled sealing chamber with two mechanical seals. Motor housing

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Installation and operating instructions • Wilo-Rexa PRO-S • Ed.01/2022-03 13
made of grey cast iron. Detachable connection cable with bare cable ends. Unit with Ex-rat-
ing as standard.
5.2 Materials •Pump housing: EN-GJL-250 (ASTMA48 Class35/40B)
•Impeller: EN-GJL-250 (ASTMA48 Class35/40B)
•Macerator: 1.4528/59HRC (AISI440B+Co)
•Motor housing: EN-GJL-250 (ASTMA48 Class35/40B)
•Shaft:
–Up to 2.5kW: 1.4401 (AISI316)
–From 3.9kW: Stainless steel AISI1.4021 (420)
•Seal on the motor side: C/MgSiO4
•Seal on the fluid side: SiC/SiC
•Seal, static: NBR (nitrile)
5.3 Technical data General
Date of manufacture* [MFY] See rating plate
Mains connection [U/f] See rating plate
Power consumption [P1] See rating plate
Rated power [P2] See rating plate
Max. delivery head [H] See rating plate
Max. volume flow [Q] See rating plate
Activation type [AT] Direct
Fluid temperature [t] 3…40°C (37…104°F)
Fluid temperature, short-term 60°C (140°F) for 3min
Protection class IP68
Insulation class [Cl.] F, optionally H
Speed [n] See rating plate
Max. switching frequency 60/h
Cable length 10m (33ft)
Immersion depth, max. 20m (66ft)
Operating modes
Immersed S1
Non-immersed Up to 3.9kW: S2-30min; S3 25%
from 5kW: S2-15min; S310%
Discharge connection
Flange connection DN32/40, PN10; ANSIB16.1, Size1.5, Class125
Oval connection 36mm
Extended use
Explosion protection IECEx, ATEX, FM
Operation on frequency converter Allowed
*The date of manufacture is stated in accordance with ISO8601: JJJJWww
•JJJJ = year
•W = abbreviation for week
•ww = calendar week
5.4 Type key Example: Rexa PRO-S03-112A/21T011X540/O
Rexa Submersible sewage pump
PRO Series
S Macerator
03 Nominal diameter of the discharge connection: DN32/40
112 Hydraulics type
A Material version: Standard
2 No. of poles
1 IE class

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14 Installation and operating instructions • Wilo-Rexa PRO-S • Ed.01/2022-03
T Mains connection version:
•M = single-phase current (1~)
•T = three-phase current (3~)
11 Value/10 = rated power P2 in kW
X Ex rating
5 Mains frequency: 5 = 50Hz/6 = 60Hz
40 Key for rated voltage
O Additional electrical equipment:
•O = with bare cable end
•P = with plug
5.5 Operation in an explosive atmo-
sphere Overview of Ex ratings
•IECEx certification: yes
•Approval according to ATEX: yes
•Approval according to FM: yes
•Approval according to CSA-Ex: no
Identification of Ex-rated pumps
The pump is labelled as follows on the rating plate for use in explosive atmospheres:
•“Ex” symbol of the corresponding approval
•Ex classification
Observe the explosion protection section!
IECEx certification
The pumps are suitable for operation in potentially explosive atmospheres:
•Device group: II
•Category: 2, zone 1 and zone 2
These pumps must not be used in zone 0!
ATEX approval
The pumps are suitable for operation in potentially explosive atmospheres:
•Device group: II
•Category: 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:
•Protection class: Explosionproof
•Category: Class I, Division 1
Notice: If the cabling is carried out according to Division 1, installation in Class I, Division
2 is also permitted.
5.6 Scope of delivery •Pump
•Installation and operating instructions
5.7 Accessories •Connection cable with fixed cable lengths up to max. 50m (164ft).
•External pencil electrode for monitoring the sealing chamber
•Suspension unit for wet well installation
•Pump support foot for portable installation
•Level control devices
•Fixation sets with anchor bolts
•Fixation accessories and chains
•Switchgear, relays and plugs
6 Installation and electrical con-
nection
6.1 Personnel qualifications •Electrical work: qualified electrician
Person with appropriate technical training, knowledge and experience who can identify
and prevent electrical hazards.

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Installation and operating instructions • Wilo-Rexa PRO-S • Ed.01/2022-03 15
•Installation/dismantling work: trained sewage technology professional
Fixation and pipework in wet well and dry well installation, lifting equipment, basic
knowledge of wastewater facilities
6.2 Installation types •Vertical stationary wet well installation with suspension unit
•Vertical portable wet well installation with pump support foot
6.3 Operator responsibilities •Observe locally applicable accident prevention and safety regulations.
•Observe all regulations for working with heavy loads and under suspended loads.
•Provide protective equipment. Ensure that the protective equipment is worn by person-
nel.
•Observe local sewage technology regulations for the operation of sewage systems.
•Avoid pressure surges!
Pressure surges can occur in long pressure pipes with steep terrain. These pressure
surges can lead to the destruction of the pump!
•Ensure the cooling time of the motor depending on the operating conditions and the
size of the pump chamber.
•Structural components and foundations must be of sufficient stability in order to allow
the device to be fixed in a secure and functional manner. The operator is responsible for
the provision and suitability of the structural component/foundation!
•Check that the available consulting documents (installation plans, installation location,
inflow conditions) are complete and accurate.
6.4 Installation
DANGER
Risk of fatal injury due to dangerous lone working practices!
Work in chambers and narrow rooms as well as work involving risk of fall-
ing are dangerous work. Such work may not be carried out autonom-
ously!
• Only carry out work with another person!
•Wear protective equipment! Observe the work regulations.
–Protective gloves: 4X42C (uvex C500 wet)
–Safety shoes: Protection class S1 (uvex 1 sport S1)
–Safety helmet: EN397 Conforms to standards, protection against lateral deformation
(uvex pheos)
(When using lifting equipment)
•Prepare the installation site:
–Clean, free of coarse solids
–Dry
–Frost-free
–Disinfected
•Toxic or asphyxiating gases may build up during work:
–Observe protective measures in accordance with work regulations (gas measurement,
carry a gas detector with you).
–Ensure adequate ventilation.
–If toxic or asphyxiating gases accumulate, leave the workplace immediately!
•Always carry the pump by the handle!
•Install lifting equipment: even surface, clean, firm base. Warehouse and installation loca-
tion must be easily accessible.
•Attach chain or wire rope to handle/attachment point with a shackle. Only use lifting
gear that has been technically approved.
•All connection cables must be laid properly. The connection cables must not pose any
risk (i.e. tripping, damage during operation). Check whether the cable cross-section and
the cable length are sufficient for the selected installation type.
•Installation of switchgear: Observe information in the manufacturer’s instructions (IP
class, overflow-proof, potentially explosive atmospheres)!
•Avoid air intake into the fluid. Use baffles or deflector plates at the inlet. Install the
ventilation systems!
•Do not allow the pump to run dry! Avoid air pockets. Do not go below the minimum wa-
ter level. Installation of dry-running protection is recommended!

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16 Installation and operating instructions • Wilo-Rexa PRO-S • Ed.01/2022-03
6.4.1 Indications for double pump oper-
ation
If several pumps are used in an operating space, minimum distances between the pumps
and the wall must be complied with. Here there is a difference in the distances depending
on the type of system: Alternating operation or parallel operation.
d
A2
A1
Fig.3: Minimum distances
d Diameter hydraulics housing
A1Minimum distance from the wall:
- alternating operation: min. 0.3×d
- parallel operation: min. 1×d
A2Distance to pressure pipes
- alternating operation: min. 1.5×d
- parallel operation: min. 2×d
6.4.2 Maintenance tasks After a storage period of more than 12months, carry out the following maintenance tasks
before installation:
•Check the oil in the sealing chamber and replace it if necessary. See section “Oil change
in sealing chamber [}29]”.
6.4.3 Stationary wet well installation The pump is installed in a pump chamber or basin. A suspension unit is installed to connect
the pump to the pressure pipe. The on-site pressure pipe is connected to the suspension
unit. The pump is connected to the suspension unit via a coupling connection.
The pressure pipe must meet the following requirements:
•The connected pressure pipe is self-supporting. The pressure pipe must not be suppor-
ted by the suspension unit!
•The pressure pipe must not be smaller than the pump’s discharge connection.
•All prescribed valves (gate valves, backflow preventers…) are present.
•Pressure pipe laid frost-proof.
•Ventilation systems (e.g. air vent valves) installed. Air pockets in the pump and in the
pressure pipe can lead to delivery problems.
1
5
6
3
4
2
OFF!
S1
S2, S3
Fig.4: Wet well installation, stationary
1 Suspension unit
2 Non-return valve
3 Stop valve
4 Guide pipes (provided by the customer)
5 Lifting equipment
6 Attachment point for lifting equipment
✓Place of use prepared.
✓Suspension unit installed.
✓Coupling connection mounted on the pump.
1. Use a shackle to attach the lifting equipment to the attachment point on the pump.
2. Lift the pump and swing it over the opening of the pump chamber.
3. Slowly drain the pump and thread the guide pipes into the coupling connection.
4. Lower the pump until it sets on the suspension unit and is connected automatically.
CAUTION!Hold the connection cables slightly taut when lowering the pump!
5. Loosen the lifting gear from the lifting equipment and secure it against falling at the
pump chamber outlet.
6. Correctly route the connection cables and lead them out of the pump chamber. CAU-
TION!Do not damage the connection cables!
- No chafing or kinking.

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Installation and operating instructions • Wilo-Rexa PRO-S • Ed.01/2022-03 17
- Do not immerse the cable end in the fluid.
- Observe the bending radii.
▶Pump installed, make the electrical connection.
6.4.4 Portable wet well installation Attach the pump support foot (available separately as an accessory) to the pump. The
pump support foot allows the pump to be positioned anywhere at the place of use. A pres-
sure hose is connected on the discharge side.
•Use a hard surface or underlay at the place of use to prevent sinking on a soft bearing
surface.
•If the pump is used at the same location for a longer period of time, bolt the pump sup-
port foot to the floor. This reduces vibrations and enables quiet operation.
1
65
3
4
2
OFF!
S1
S2, S3
Fig.5: Wet well installation, portable
1 Pump support foot
2 Pipe elbow with hose connection or Storz fixed coupling
3 Storz hose coupling
4 Pressure hose
5 Lifting equipment
6 Attachment point
S* Non-immersed operating mode: Observe information on the rating plate!
✓Place of use prepared.
✓Pump support foot mounted.
✓Discharge connection prepared: Hose connection or Storz coupling fitted.
✓Soft bearing surface: solid surface available.
1. Use a shackle to attach the lifting equipment to the attachment point on the pump.
2. Lift and align the pump at the installation location.
3. Place the pump on a firm bearing surface. Avoid sinking!
4. Secure the pump against moving and falling over: Bolt the pump support foot to the
floor.
5. Lay the pressure hose and fasten it properly at the appropriate place (e.g. drainage).
6. Correctly route the connection cables. CAUTION!Do not damage the connection
cables!
- No chafing or kinking.
- Do not immerse the cable end in the fluid.
- Observe the bending radii.
▶Pump installed, make the electrical connection.
6.4.5 Level control Provide a level control on site for level-dependent control of the pump.
DANGER
Risk of explosion due to incorrect installation!
If the level control is installed within a potentially explosive area, the sig-
nal transmitter must be connected via an Ex cut-off relay or a Zener bar-
rier. There is a risk of explosion if connected incorrectly! Connection
must be carried out by a qualified electrician.
6.4.6 Dry-running protection Dry-running protection prevents the pump from being operated without fluid and air from
entering the hydraulics. For this purpose, the minimum permissible fill level is monitored
using an external control. When the minimum fill level is reached, the pump is switched off.
Furthermore, depending on the control, a visual and acoustic alarm is triggered.
The dry-running protection can be integrated into existing controls as an additional meas-
uring point. Alternatively, the dry-running protection can also work as a stand-alone shut-
off device. Depending on the system security, the pump can be restarted automatically or
manually.
Installation of dry-running protection is recommended for optimum operational reliability.

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18 Installation and operating instructions • Wilo-Rexa PRO-S • Ed.01/2022-03
6.5 Electrical connection
DANGER
Risk of fatal injury due to electrical current!
Improper conduct when carrying out electrical work can lead to death
due to electric shock!
• Electrical work must be carried out by a qualified electrician!
• Observe local regulations!
DANGER
Risk of explosion due to incorrect connection!
If the pump is used inside potentially explosive atmospheres, there is a
risk of fatal injury from explosion if the connection is incorrect! If used in
potentially explosive atmospheres:
• The connection must always be carried out by a qualified electrician.
• Always connect the pump to an electrical outlet outside the explosive
area. If the connection must be established within explosive atmo-
spheres, the connection must be carried out in an Ex-rated housing
(ignition protection class according to DINEN60079‑0)!
• Connect the equipotential bonding conductor to the earth terminal
indicated. The earth terminal is installed in the area near the connec-
tion cables. Use cable cross-sections as per locally applicable regula-
tions for the equipotential bonding conductor.
• Connect thermal motor monitoring using an Ex-certified evaluation
relay.
• The temperature limit deactivation must take place with a reactiva-
tion lock.
Reactivation must only be possible if an unlock button has been
pressed manually!
• Connect the external pencil electrode via an Ex-approved evaluation
relay with an intrinsically safe circuit.
• Observe the further information in the explosion protection section
for the electrical connection!
•Mains connection corresponds to the information on the rating plate.
•Power supply on mains side with clockwise rotating field for three-phase AC motors (3~
motor).
•Route the connection cables according to the local regulations and connect them ac-
cording to the wire assignment.
•Connect all of the monitoring devices and check their function.
•Secure the earthing in accordance with the local regulations.
6.5.1 Fuse on mains side 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 min-
imum requirement is a thermal relay/motor protection switch with temperature compensa-
tion, differential triggering and anti-reactivation device in accordance with the local regu-
lations. In case of sensitive mains, make provision for the installation on-site of other pro-
tective equipment (e.g. overvoltage, undervoltage or phase failure relay, etc.).
Residual-current device (RCD)
•Install a residual-current device (RCD) in accordance with the regulations of the local
energy supply company.
•If people can come into contact with the device and conductive fluids, install a residual-
current device (RCD).
6.5.2 Maintenance tasks •Check the insulation resistance of the motor winding.
•Check the resistance of the temperature sensors.

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Installation and operating instructions • Wilo-Rexa PRO-S • Ed.01/2022-03 19
6.5.2.1 Checking the insulation resistance
of the motor winding
✓Insulation tester 1000V
✓Motors with capacitor: Short-circuited windings!
1. Check the insulation resistance.
⇒Measured value at initial commissioning: ≥20MΩ.
⇒Measured value at interval measurement: ≥2MΩ.
▶Insulation resistance checked. If the measured values deviate from the specifica-
tions, consult the customer service.
6.5.2.2 Test the resistor of the temper-
ature sensor
✓Ohmmeter available.
1. Measure the resistance.
⇒Measured value Bimetallic strip: 0ohms (passage).
⇒Measured value 3x PTC sensor: between 60 and 300ohm.
⇒Measured value 4x PTC sensor: between 80 and 400ohm.
▶Resistance checked. If the measured value deviates from the specification, consult
the customer service.
6.5.3 Connection of the single-phase AC
motor (1~ motor)
U1/Z1
3
U2
4
Cr
Z2
5
CS
M 1~
gn-ye
LNPE
1 2 6
3 4
gn-ye
1 2
6
2120 DK
Fig.6: Connection diagram 1~ motor
Wire Designation Terminal
1, 2 20, 21 Thermal motor monitoring
3 U1/Z1 L
4 U2 N
5 Z2 Start and operating capacitor connection
6 DK Monitoring leakage motor compartment
Green/yellow (gn-ye) PE Earth
•Connection cable with bare cable ends.
•Connection in the switchgear according to the connection diagram.
•Thermal motor monitoring:
–Sensor: Bimetallic strip
–Number of temperature circuits: 1, temperature limiter
–Connection values: max. 250V(AC), 2.5A, cosphi=1
–Threshold value: is set by sensor.
–Triggering status: If the threshold value is reached, switch off the pump!
•Monitoring leakage motor compartment:
The connection must be made via an evaluation relay (e.g. “NIV101/A”).
–Sensor: Electrode
–Connection values: max. 250V(AC), 2.5A, cosphi=1
–Threshold: 30kOhm
–Triggering status: If the threshold value is reached, switch off the pump!

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20 Installation and operating instructions • Wilo-Rexa PRO-S • Ed.01/2022-03
6.5.4 Connection of the three-phase AC
motor (3~ motor)
5
1 2
4
3
M 3~
gn-ye
WV 2120UPE
6
DK
Fig.7: Connection diagram 3~ motor: Bimet-
allic strip, direct starting
Wire Designation Terminal
1, 2 20, 21 Thermal motor monitoring
3 U L1
4 V L2
5 W L3
6 DK Monitoring leakage motor compartment
Green/yellow (gn-ye) PE Earth
•Connection cable with bare cable ends.
•Connection in the switchgear according to the connection diagram.
•Mains connection with clockwise-rotating field
•Thermal motor monitoring:
–Sensor: Bimetallic strip
–Number of temperature circuits: 1, temperature limiter
–Connection values: max. 250V(AC), 2.5A, cosphi=1
–Threshold value: is set by sensor.
–Triggering status: If the threshold value is reached, switch off the pump!
•Monitoring leakage motor compartment:
The connection must be made via an evaluation relay (e.g. “NIV101/A”).
–Sensor: Electrode
–Connection values: max. 250V(AC), 2.5A, cosphi=1
–Threshold: 30kOhm
–Triggering status: If the threshold value is reached, switch off the pump!
6.5.5 Optional equipment Information on electrical accessory connection or possible special configurations. Please
refer to the order confirmation or configuration overview for details on the special config-
uration.
6.5.5.1 Connection of three-phase AC
motor (3~ motor) with PTC sensor
5
1 2
4
3
M 3~
gn-ye
WV 1110UPE
6
DK
Fig.8: Connection diagram 3~ motor: PTC
sensor, direct starting
Wire Designation Terminal
1, 2 10, 11 Thermal motor monitoring
3 U L1
4 V L2
5 W L3
6 DK Monitoring leakage motor compartment
Green/yellow (gn-ye) PE Earth
•Thermal motor monitoring:
The connection must be made via an evaluation relay (e.g. “CM-MSS”).
–Sensor: PTC sensors
–Number of temperature circuits: 1, temperature limiter
–Connection values: max. 30V(DC)
–Threshold value: is set by sensor.
–Triggering status: If the threshold value is reached, switch off the pump!
6.5.5.2 Connection of thermal motor mon-
itoring as temperature control
Thermal motor monitoring is designed as temperature limiting (1temperature circuit) as
standard. Optionally, the thermal motor monitoring can also be designed as temperature
control (2temperature circuits):
•If the low temperature threshold is reached, switch off the pump. The pump can be re-
started automatically.
•If the high temperature threshold is reached, switch off the pump. Restarting must be
carried out manually!