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20

Wilo-WiBooster - Installation and Operation Manual

FAULT

CAUSE

REMEDIES

Switching frequency too high or 

fluttering

Intake pressure fluctuates severely

Check intake pressure, if necessary take measures to stabilise supply pressure 

(e.g. pressure reducer)

Intake pipe blocked 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

Inlet pipe incorrectly installed

Check inlet pipe, if necessary change pipe guide

Check valve closed at pressure 

sensor

Inspect, open check valve if necessary

No diaphragm pressure vessel 

present (optional or accessory)

Retrofit a diaphragm pressure vessel

Supply pressure at existing 

diaphragm pressure vessel incorrect

Check supply pressure and correct if necessary

Valve on existing diaphragm pressure 

vessel closed

Check valve and open if necessary

Existing diaphragm pressure vessel 

defective

Check the diaphragm pressure vessel and replace if necessary

Set switching difference too small

Check setting and correct if necessary

Pump(s) produces no or too little 

pressure

Major fluctuations in Intake pressure

Check intake pressure, if necessary take measures to stabilise supply pressure 

(e.g. pressure reducer)

Intake pipe blocked 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

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 repaired

Non-return valve leaking

Check, if necessary replace seal or replace non-return valve

Non-return valve blocked

Check, if necessary remove blockage or replace non-return valve

Gate valve in system closed or not 

sufficiently open

Check, open the check valve completely if necessary

Low-water level switch has triggered Check intake pressure

Direction of motor rotation false

Check direction of rotation and correct by changing over phases if necessary

Turn-to-turn fault in motor

Check, if necessary replace motor or have repaired

Dry-running protection system 

switches off, although water is 

present

Major fluctuations in Intake pressure

Check intake pressure, if necessary take measures to stabilise supply pressure 

(e.g. pressure reducer)

Nominal diameter of inlet pipe too 

small

Check the inlet pipe, increase the crosssection for the inlet pipe if necessary

Inlet pipe incorrectly installed

Check inlet pipe, if necessary change pipe guide

Volume flow too large

Check pump data and default values and correct if necessary

Electrodes incorrectly connected or 

supply pressure switch incorrectly 

set

Check installation or setting and correct

Low-water level switch defective

Check, if necessary replace the lowwater level switch

Dry-running protection does not 

switch off, although water low

Electrodes incorrectly connected or 

supply pressure switch incorrectly 

set

Check installation or setting and correct

Low-water level switch defective

Check, if necessary replace the lowwater level switch

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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