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WILO_IOM_WIBOOSTER_07012019

Installation and commissioning by qualified personnel only!

1                              

About this document

These installation and operating instructions are an integral 

part of the product. They must be kept readily available at 

the place where the product is installed. Strict adherence to 

these instructions is a precondition for the proper use and 

correct operation of the product.

These installation and operating instructions correspond 

to the relevant version of the product and the underlying 

safety standards valid at the time of publication.

2                              

Safety

These operating instructions contain basic information 

concerning the installation and commissioning of the 

system and should be read by the service technician and 

responsible operator prior to proceeding. Observe the 

special safety instructions and understand the danger 

symbols throughout this document.

2.1                      

Indication of instructions

Symbols:

 General danger symbol

 Danger due to electrical voltage

 Danger due to explosion risk

 Information on handling the product or draw attention 

to possible problems.

Signal Words:

DANGER!

Acutely dangerous situation. Non-observance could result 

in death or the most serious of injuries.

WARNING!

The user can suffer (serious) injuries. ‘Warning’ implies that 

(serious) injury to persons is probable if this information is 

disregarded.

CAUTION!

There is a risk of damaging the pump/unit. ‘Caution’ implies 

that damage to the product is likely if this information is 

disregarded.

2.2                     

Personnel qualifications

The installation personnel must have the appropriate 

qualifications for this work.

2.3                     

Danger in the event of non-observance of the safety 

instructions

Non-observance of the safety instructions can result in 

risk of injury to persons and damage to pump/unit. Non-

observance of the safety instructions can result in the loss 

of any claims to damages. In detail, non-observance can, for 

example, result in the following risks:

•  Failure of important pump/unit functions

•  Failure of required maintenance and repair procedures

•  Danger to persons from electrical, mechanical and 

bacteriological influences

•  Property damage

2.4                     

Safety instructions for the operator

The existing directives for accident prevention must 

be observed. Danger from electrical current must be 

eliminated. Local directives [e.g. NEMA, IEC etc.] and local 

power supply directives companies must be followed.

2.5                 

Safety instructions for inspection and installation work

The operator must ensure that all inspection and installation 

work is carried out by authorized and qualified personnel, 

who are sufficiently informed from their own detailed study 

of the operating instructions. Work on the pump/unit should 

only be carried out when the unit is powered down, and 

lock-out/tag-out procedures are followed.

2.6                 

Unauthorized modification and manufacture of spare 

parts

Modifications to the pump/unit are only permissible after 

consultation with the manufacturer. Original spare parts 

and accessories authorized by the manufacturer ensure 

safety. The use of unauthorized parts violates warranty 

and absolves the manufacturer of responsibility for 

consequences stemming from their use.

2.7                 

Improper use

The operating safety of the supplied pump/unit is only 

guaranteed for conventional use in accordance with Section 

4 of the operating instructions. The limit values must never 

fall below or exceed those specified. 

                             

CAUTION!

If placing the unit outside, a NEMA 3R panel must be used 

in order to avoid defaulting on the factory warranty.

3                              

Transport and interim storage

The Wilo-WiBooster is supplied on a pallet, on transport 

boards or in a crate and is film-wrapped to protect it against 

moisture and dust. Transport and storage instructions 

marked on the packing must be observed. The transport 

dimensions, weights and necessary passageways or 

transport space of the unit are given in the attached 

installation plan or other documentation.

Summary of Contents for WiBooster

Page 1: ...Installation and operating instructions WILO_IOM_WIBOOSTER_07012019 Wilo WiBooster Pressure Boosting Systems...

Page 2: ...ages In detail non observance can for example result in the following risks Failure of important pump unit functions Failure of required maintenance and repair procedures Danger to persons from electr...

Page 3: ...re function and requirements comply with the following guidelines and directives NSF 61 and NSF 372 listed for drinking water certification DOE regulations The Wilo WiBooster pressure boosting system...

Page 4: ...th vibration damper 2 2 to 4 Close Coupled Series 230 or 320 centrifugal pumps 3 Control panel that contains one variable frequency drive per pump 4 Suction manifold 5 Check valve 6 Isolation butterfl...

Page 5: ...5 Wilo WiBooster Installation and Operation Manual Figure 5c Figure 5d...

Page 6: ...l Figure 5e WARNING Risk of damage or bodily injury Please follow the above instructions figure 5d in order to safely remove the hydropneumatic tank from the discharge manifold for service Note The bl...

Page 7: ...rovided from the water main Its analog signal is processed by the PLC to make sure it does not fall below the suction pressure set point In the case of an indirect connection system separation through...

Page 8: ...secure the pipe clamps to the Wilo WiBooster manifolds The connection is made either on the right or left of the system depending on the site conditions It may be necessary to move blind flanges or t...

Page 9: ...ccordance to local and national electrical codes The connections intended for this purpose are identified accordingly see wiring diagram Further measures are referenced in the wiring diagram of the co...

Page 10: ...Local Codes Fuses LP J for 1 1 4 X Full Load Amps of Both Motors SHORT CIRCUIT CURRENTD Branch Circuit Protection 8199 FIELD CONNECTIONS Installer To Supply Branch Circuit NUMBER ON TERMINAL BLOCKS C...

Page 11: ...L1 L3 L2 L3 L2 L1 1L1 1L3 1L2 W V U MP3 VFD3 31 MOTOR PUMP 33 32 3 86 87 88 L3 L2 L1 2L2 2L1 AN0 AN1 AN2 AN3 ACM 0 VDC SUCTION TRANSDUCER DISCHARGE TRANSDUCER V 24 VDC 0V 0 VDC GROUND START RUN ENABLE...

Page 12: ...umps can maintain pressure efficiently and if so a pump will turn off 6 If only 1 pump is running the pump will turn off if either a Pressure is high out of band for a programmable amount of time b Sy...

Page 13: ...sets the desired output pressure of the system 04 Pump Test Run The Pump Test Run page allows for pumps to be run for a short duration 1 Enables and disables the pump test option When enabled pumps wi...

Page 14: ...s with alarm conditions in Activating this mode will allow the user to run the pumps unless regardless of conditions unless the pump failure is due to a physical failure of the pump or drive This opti...

Page 15: ...free email accounts like gmail or outlook will not work Accounts with https www smtp2go com have been verified to work 2 Port number associated with mail server Default 587 3 Email user name This is t...

Page 16: ...Sensor faults activate immediately upon an invalid value A failed low sensor fault will show a negative value of pressure A failed high sensor fault will show the max value of pressure A failed high...

Page 17: ...the internal IP address which can be found on the PLC by clicking Menu Page IP Configuration from the main page 2 If connecting to the PLC from outside the network enter the WAN address of your networ...

Page 18: ...b Max frequency Default value 60 Hz Input range 25 60 Hz 17 Pipe Fill Settings Pipe Fill Mode will only allow one pump to run until either the pressure or time requirement is met 1 Enables and disabl...

Page 19: ...ed or shut off Check inlet pipe if necessary remove blockage or open check valve Nominal diameter of inlet pipe too small Check the inlet pipe increase the crosssection for the inlet pipe if necessary...

Page 20: ...sary Inlet pipe incorrectly installed Check inlet pipe if necessary change pipe routing Air in inlet Check if necessary seal pipe Vent pumps Impellers blocked Check pump if necessary replace or have r...

Page 21: ...k pressure to the correct level Isolate see step 1 of figure 5d the pumps and system from the discharge side and upstream piping of the manifold Drain the water from the discharge manifold Check the g...

Page 22: ...WILO USA LLC 1 262 204 6600 www wilo usa com info us wilo com WILO Canada Inc 1 403 276 9456 www wilo canada com info wilo canada com WILO Mexico 52 442 167 00 32 www wilo mexico com info wilo com mx...

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