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Wilo-WiBooster - Installation and Operation Manual
5.3
Function of Wilo-WiBooster pressure boosting system
Wilo-WiBooster pressure boosting systems are equipped
with non-self-priming, horizontal, close-coupled,
end-suction centrifugal pumps as a standard. These are
supplied with water via the suction manifold pipe. The
pumps increase the pressure and pump the water to the
consumer via the discharge manifold pipe. To do this, they
are switched on, off, or speed-controlled depending on the
demand of the system. Depending on demand, the control
unit switches the pumps on or off, or changes the speed of
the pumps, until the set control parameters are reached.
(A more precise description of the control mode and the
control process is given later in this document).
The total delivery volume of the system is distributed over
several pumps (cascading). The system output is adapted
very precisely to the actual demand and the pumps are
operated in the most favorable power range in each
case. This design delivers a high level of efficiency and
an economical energy consumption for the system. The
first pump that starts up is called the base load pump. The
remaining pumps needed to reach the system operating
point are called peak load pumps. If the system is configured
to supply potable water, one (or two in the case of a
Quadraplex) pump(s) can be designated as a standby pump.
To ensure that all the pumps are used equally, the control
unit exchanges the pumps continuously based on least
amount of hours used (e.g. the order of switching on and off
the base load/peak load or duty-standby pump functions
change regularly).
The optional hydropneumatic pressure vessel performs
a buffer function for the pressure sensor and prevents
unnecessary control system oscillation of on/off starts. It
also mitigates and reduces the frequency of starts and
switching of the base load pump as a result of minor
pressure drops in the consumer’s piping system.
The
optional NSF-61 tank is strongly recommended for the
booster set
– in addition to your system-sized storage tank
– as it helps to prevent water hammer. System-sized tanks
are also available from Wilo USA.
CAUTION!
To protect the axial face seal or slide bearing, do not allow
the pumps to run dry. Dry run may cause the pump seal to
fail and leak!
Protection against low water level/suction pressure is
monitored by a suction pressure transducer mounted on
the side of the suction manifold. The suction transducer
monitors the supply pressure that is being provided 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 non-pressurized storage tank), the
suction transducer should be sufficient for the application. If
low pressure issues occur (not common), a level-dependent
switch can be used in lieu of the supplied pressure
transducer (provided by others). It should be inserted in the
storage tank as a dry run protection device and wired to the
control panel accordingly (please refer to the wiring diagram
located in the panel door). In addition, a change from the
PLC input will have to take place in order to change the
analog input to digital.
WARNING!
Use only materials approved for use in potable water
systems!
5.4
Scope of delivery
• Wilo-WiBooster Pressure boosting system.
• Installation and operating instructions of the Wilo-
WiBooster pressure booster.
• Electrical circuit diagram as required.
• Additional sheet with the frequency converter factory
settings as required.
5.5
Optional Accessories
Accessories must be ordered separately if needed. The
optional accessories included in the Wilo range are:
• Optional, non-ASME, NSF-61 tanks are available for the
booster through WILO USA.
• Larger diaphragm pressure vessels available (both non-
ASME rated and ASME rated) are also available through
WILO USA.
Control panel options must be ordered separately if needed
and placed at the time of the initial order. The control panel
options included in the Wilo range are:
• Dome light - Red (Failure)
• Dome light - Green (Running)/Red (Failure)
• Dome light - Green (Running)/Amber (Yellow)/Red
(Failure)
• Dome light - Green (Running)/Amber (Yellow)/Red
(Failure)/ White (Running)
• Run/Fault lights
• 3 Phase surge protection - 208v-230v 3 phase, Delta,
3-wire with ground
• 3 Phase surge protection - 460v 3 phase, Delta, 3-wire
with ground
• 3 Phase surge protection - 208v-230v, 3 phase, Wye,
3-wire with ground
• 3 Phase surge protection - 277v-480v, 3 phase, Wye,
3-wire with ground
• 3 Phase surge protection - 347v -600v, 3 phase, Wye,
3-wire with ground
• BACnet gateway (MS/TP and IP)
• LONworks gateway
• CANopen gateway Card
• Interior panel light
• NEMA 3R adder in lieu of NEMA 12 panel
575VAC to 460VAC Transformers, Type 1:
• Aluminum Coiled Transformers
• 15 kVA vented transformer – 3 phase – 600v delta
- 480Y/277 150C RISE
• 30 kVA vented transformer – 3 phase – 480v delta
- 480Y /277 150C RISE
• 45 kVA vented transformer – 3 phase – 600v delta
- 480Y /277 150C RISE
• Copper Coiled Transformers
• 15 vented transformer – 3 phase – 600v delta -
480Y/277 150C RISE
• 30 vented transformer – 3 phase – 600v delta -
480Y/277, 150C RISE
• 45 vented transformer – 3 phase – 600v delta -
480Y/277 150C RISE
• 3R weather shield for transformers