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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

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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