Wilo Isar BOOST5

1 Safety

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.
• Pass the instructions on to a subsequent owner.
• Observe all product specifications.
• Observe the markings on the product.

The language of the original operating instructions is German. All other languages for these instructions are translations of the original operating instructions.

Failure to observe the instructions will result in danger to persons or damage to property. The manufacturer is not liable for damage caused by:

• Improper use.
• Incorrect operation.

1.2 Copyright

WILO SE © 2025

The reproduction, distribution, and utilization of this document, in addition to communication of its contents to others without express consent, is prohibited. Offenders will be held liable for payment of damages. All rights reserved.

1.3 Subject to change

Wilo reserves 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 original and are intended as an exemplary representation of the product.

1.4 Exclusion from warranty and liability

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

1.5 Identification of safety instructions

In these installation and operating instructions, safety instructions are displayed as follows:

• Danger to persons: Safety instructions are preceded by a corresponding symbol and are shaded in grey.
• Damage to property: Safety instructions start with a signal word and are displayed without a symbol.

Signal words:

• DANGER! Failure to follow the instructions will result in serious injuries or death!
• WARNING! Failure to follow the instructions can lead to (serious) injury!
• CAUTION! Failure to follow the instructions can lead to potentially irreparable property damage.
• NOTICE! Useful information on handling the product

Symbols:

• [!] General danger symbol
• [⚡] Danger caused by electric voltage
• Notes: Follow all information that appears on the product and ensure that it remains permanently legible:
• Warning and hazard notices
• Rating plate
• Direction of rotation arrow/symbol for direction of flow [?]
• Labelling of connections

1.6 Personnel qualifications

Personnel must:

• be instructed about locally applicable regulations governing accident prevention,
• have read and understood the installation and operating instructions.

Staff must have the following qualifications:

• Electrical work: Electrical work must be performed by a qualified electrician.
• Installation/dismantling work: The installation/dismantling must be carried out by a qualified technician who is trained in the use of the necessary tools and fixation materials.
• The product must be operated by persons who have been instructed on how the complete system functions.
• Maintenance tasks: The technician must be familiar with the use of operating fluids and their disposal.

Definition of "qualified electrician": A qualified electrician is a person with appropriate technical education, knowledge and experience who can identify and prevent electrical hazards. The operator must confirm and ensure the field of authority, the competence and the monitoring of the personnel. If the personnel do not possess the necessary knowledge, they must be trained and instructed. If required, this can be carried out by the product manufacturer at the operator's request. The product must not be operated by persons (including children) with limited physical, sensory or mental capabilities unless they have been trained in the use of the product by a person responsible for their safety. Children must be supervised to ensure that they do not play with the product.

1.7 Electrical work

• Electrical work must be performed by a qualified electrician.
• Nationally applicable guidelines, standards and regulations as well as specifications issued by the local energy supply companies for connection to the local power supply system must be observed.
• Before commencing work, disconnect the product from the mains and secure it against being switched on again.
• The connection must be secured by means of a residual-current device (RCD).
• The product must be earthed.
• Have defective cables replaced immediately by a qualified electrician.

1.8 Installation / Dismantling

• Wear protective equipment:
• Safety shoes
• Safety gloves for protection against cuts
• Safety helmet (when using lifting equipment)
• Locally applicable laws and regulations on work safety and accident prevention must be complied with.
• Disconnect the device from the mains and secure it against being switched on again without authorisation.
• All rotating parts must be at a standstill.
• Close the gate valve in the inlet and in the pressure pipe.
• Provide adequate aeration in enclosed spaces.
• Make sure that there is no risk of explosion when carrying out any type of welding work or work with electrical devices.

1.9 Maintenance tasks

• Wear protective equipment:
• Sealed safety glasses
• Safety shoes
• Safety gloves for protection against cuts
• Locally applicable laws and regulations on work safety and accident prevention must be complied with.
• The procedure described in the installation and operating instructions for shutting down the product/unit must be strictly observed.
• Only original parts from the manufacturer may be used for maintenance and repairs. The use of any non-original parts releases the manufacturer from any liability.
• Disconnect the device from the mains and secure it against being switched on again without authorisation.
• All rotating parts must be at a standstill.
• Close the gate valve in the inlet and in the pressure pipe.
• Store tools at the designated locations.
• After completing work, reattach all safety and monitoring devices and check that they function properly.

2 Product description

2.1 Description

• Compact, quiet and high-performance pump system.
• Electrical system with intelligent and intuitive product control.
• The system pressure is kept constant by adjusting the pump speed according to usage.
• The product controls the hydraulic and electrical operating parameters and protects against malfunctions.

Product Overview (Fig. 1)

• 1: Refill opening cap
• 2: Extension card
• 3: Fuse (12 A)
• 4: Input/Output cable entry
• 5: Drainage screw plug
• 6: Venting screw
• 7: Diaphragm expansion tank closure
• 8: Discharge/suction port cover
• 9: Discharge / suction port handle grip
• 10: Height-adjustable feet (vibration dampening)
• 11: Suction port
• 12: Mains cable
• 13: Rotatable connection elbow
• 14: Discharge port
• 15: Control panel

2.2 Description of control panel

The control panel features LEDs and buttons for operation and status indication.

• 1: LEDs: "Operating status"
• Pressure setting display
• Operation
• Fault or alarm
• 2: Operating buttons: "+" and "-"
• 3: Operating button: "On/Off"
• 4: LED: "System status" (green and red)

2.2.1 Description of operating modes

• System ready for operation: System is switched on and not in operation. "Operating status" LEDs are switched off. "System status" LED lights up green permanently.
• System in operation: System is switched on and in operation. "Operating status" LEDs run in a cycle. "System status" LED lights up green permanently.
• System switches itself off: System shuts down. "Operating status" LEDs run in a cycle. "System status" LED flashes green.
• System fault/alarm: Unit is switched on but not ready for operation. "Operating status" LEDs are switched off. "System status" LED lights up red permanently.

2.3 Type key

Example: Wilo-Isar BOOST5-E-3-2G

• Wilo: Brand name
• Isar BOOST: Pressure-boosting system
• 5: Household use
• E: Integrated pump control
• 3 or 5: Rated volume flow in m³/h
• 2G: 2nd generation

2.4 Technical data

2.5 Dimensions

The product dimensions are approximately 390 mm (length) × 276 mm (width) × 343 mm (height). The connection ports are G1". The unit features height-adjustable feet for vibration dampening.

2.6 Scope of delivery

• Pressure-boosting system
• 2 G1" hydraulic connections
• Handle grip for discharge ports
• Gaskets
• Installation and operating instructions

3 Application/use

3.1 Intended use

Wilo-Isar BOOST5 is an automatic pressure-boosting system with variable speed function, including:

• A highly efficient self-priming electric pump.
• A diaphragm expansion tank.
• Pressure and volume flow sensors.
• A non-return valve in the suction port.

The pressure-boosting system is designed for increasing the pressure of clean water in residential buildings and for irrigation, sprinkling in agriculture. Water is supplied from wells, springs, tanks, or the municipal water supply network.

NOTICE: Observe local regulations for all drinking water applications.

3.2 Improper use

Only for DE: The product must not be used for drinking water applications within Germany. Connection to the municipal water supply network is not permitted.

4 Transportation and storage

4.1 Delivery

• After delivery, check product and packaging for defects (damage, completeness).
• The transport company or the manufacturer must be notified of any defects the day the shipment is received, and the damage noted on the freight documentation.
• Claims cannot be asserted if the notification of defects takes place at a later date.

4.2 Transport

CAUTION: Property damage due to wet packaging!

Wet packaging may tear. If unprotected, the product may fall on the ground and be irreparably damaged.

• Carefully lift wet packaging and replace it immediately.
• Only transport the product in the packaging provided.
• If the outer packaging is damaged or no longer present, apply suitable protection from humidity and dirt.
• Remove the outer packaging only once the system is on site.

4.3 Storage

CAUTION: Property damage due to improper storage!

Moisture and certain temperatures damage the product.

• Protect the product against moisture and mechanical damage.
• Avoid temperatures outside the range of -10 °C to +60 °C.

5 Installation and electrical connection

5.1 Installation location

• The installation site must be dry, well-ventilated, and protected from frost.
• Observe ambient temperatures, see technical data.
• Select installation location according to product dimensions.
• Connections must be freely accessible.
• Avoid vibrations or mechanical loads from the connected piping.

5.2 Hydraulic connection

WARNING: Risk of injury due to improper installation.

• Installation should only be carried out by qualified personnel.
• Comply with accident prevention regulations.
• Observe local regulations.

Hydraulic Lines (Fig. 4):

• Avoid elbows and goosenecks in the suction lines.
• Suction line must be pressure resistant.
• If automatic connectors are employed, use a seal (applied inside). To prevent air intake, the automatic connectors have to be airtight.
• Check the suction line from the strainer to the pump and the check valve for leaks.

Hydraulic Connection Steps (Fig. 5):

1. Align the product horizontally using the adjustable feet.
2. Remove the covers on the holders of the discharge and suction ports.
3. Remove the handle grip on the discharge and suction ports.
4. Connect the pressure-resistant connection pipes to the hydraulic connections (included in scope of delivery). Inside diameter of connection pipe: G1".
5. Insert suction and discharge port with gasket.
6. Fit the handle grip on the discharge and suction ports.
7. Fit the covers on the holders of the discharge and suction ports.

5.3 Electrical connection

DANGER: Danger of death due to electrical current!

Improper electrical connection can lead to electric shock.

• Have electrical work carried out by a qualified electrician.
• Comply with accident prevention regulations.
• Observe local regulations.
• Install residual-current device (30 mA, class A).
• Check earthing connection for proper installation.
• Ensure that the power supply corresponds to the specifications on the rating plate.

5.3.1 Connecting the extension card

DANGER: Risk of fatal injury due to electrical current!

• Disconnect the plug from the power supply before carrying out any work.
• Have electrical work carried out by a qualified electrician.
• Observe local regulations.

CAUTION: Property damage due to improper installation!

Device connected to the extension card must only be operated with separated extra-low voltage (SELV).

Extension Card Connections (Fig. 6):

1. Remove fastening screws on the cover.

2. To access the terminal strip of the extension card, partially remove the cover.

Input Terminal (1-2): Level message. Bypass in case of a missing signal.

6 Commissioning

6.1 Filling the diaphragm expansion tank

CAUTION: Property damage due to improper installation!

The integrated diaphragm expansion tank is prefilled ex works with nitrogen to a pressure of 1.5 bar. The maximum filling pressure is 4 bar.

• For filling, use nitrogen or air.
• Fill the diaphragm expansion tank at a system pressure of zero.
• Fill the diaphragm expansion tank according to the table.
• After each change of operating pressure, the filling pressure of the diaphragm expansion tank must be adjusted.

Filling Pressure Table:

Ensure a compressor or pump with a manometer is at hand.

Filling Process (Fig. 10):

1. Close the gate valve (Fig. 7 – Item 1, 2) at the suction and discharge sides.
2. Remove the screw at the diaphragm expansion tank closure.
3. Connect the compressor or air pump (hand pump) to the closure of the diaphragm expansion tank.
4. Fill the diaphragm expansion tank until the desired and set operating pressure is reached.

NOTICE: If necessary, install an additional diaphragm expansion tank on the discharge side to avoid pressure peaks.

6.2 Operating modes

The product can be operated in suction mode (pump above the water level) and in load mode (pump under the water level).

CAUTION: Property damage due to dry run!

If the pump runs dry, the mechanical seals will be damaged.

• Fill the pump with water and vent it before commissioning.

Load operation:

1. If the product is installed in load mode (Fig. 8), press the "On/Off" operating button once (Fig. 11). The pump starts.

Suction mode:

1. If the product is installed in suction mode (Fig. 7), press the "+" and "-" operating buttons simultaneously for 5 seconds (Fig. 10). The product switches to suction mode.
2. Press the "On/Off" operating button on the control panel (Fig. 11).
3. Suction takes a maximum of 5 minutes. During the process, the LEDs flash. Suction is stopped after 5 minutes or if the suction is completed. The LEDs no longer flash.
4. If the pump does not self-prime, repeat the procedure.

Filling the product with water (for suction mode):

• Remove the refill opening cap and the venting screw.
• Fill the product with water (approx. 1.5 l) until the water comes out of the aeration opening (Fig. 9).
• Put the refill opening cap and the venting screw back on.
• Open the gate valve (Item 1, 2).
• Connect the mains plug to the power supply.

6.3 Setting operating pressure

The "operating status" LEDs indicate the desired operating pressure. The operating pressure can be set between 1 bar and 6 bar.

• Indicate operating pressure: Press operating button "+".
• Adjust the operating pressure by 0.5 bar at a time: Press operating buttons "-" or "+".

Example:

• Press operating button "+". Operating pressure is displayed (2 bar).
• Increase the operating pressure to 3 bar by pressing the operating button "+" twice (0.5 bar + 0.5 bar). The "operating status" LEDs indicate the current operating pressure (3 bar).

6.4 Alarm codes

LED in range 1-6 flashes green + LED flashes red

• Alarm 1: Low water. If there is low water on the suction side for more than 7 seconds, the alarm is displayed.
• Check the water supply on the suction side.
• Fill pump.
• The product restarts automatically after 1 min, 15 min, 30 min, 1 hr, etc.
• Alarm 2: The pump does not reach the set pressure.
• Contact customer service.
• Alarm 4: Outlet pressure below 0.2 bar (damaged pipe).
• Eliminate the cause.
• To reset the alarm, switch the product off and back on with the "On/Off" operating button (Fig. 2, Item 3).
• Check why pressure was reset to zero.
• Alarm 5: Supply voltage too low.
• Ensure a power supply of 230 V ±10%.
• Alarm 6: Switch-off signal from the outside.
• Contact customer service.
• Example (Short-circuit): LED 1 lights up green + red LED flashes.
• Switch off unit.
• Contact customer service.
• To reset the alarm, switch the product off and back on with the "On/Off" operating button (Fig. 2, Item 3).
• Example (Overcurrent): Current consumption exceeds the permissible tolerance.
• To reset the alarm, switch the product off and back on with the "On/Off" operating button (Fig. 2, Item 3).
• If the alarm is still displayed, contact customer service.
• Alarm 3: Module temperature too high.
• Check the temperature of the fluid.
• If the fluid temperature exceeds 40 °C, contact customer service.
• If the temperature drops below the alarm threshold, the product is automatically reset.
• Alarm 4: Motor temperature too high.
• Motor temperature too high.
• Check the temperature of the fluid.
• If the fluid temperature exceeds 40 °C, contact customer service.
• If the temperature drops below the alarm threshold, the product is automatically reset.
• Alarm 5: Pressure sensor signal fault.
• Contact customer service.
• Alarm 6: Volume flow sensor signal fault.
• Contact customer service.

7 Maintenance

7.1 Diaphragm expansion tank maintenance

CAUTION: Property damage due to improper maintenance!

The product will be damaged if the diaphragm expansion tank is set improperly.

• At least once a year (Wilo recommends: every 6 months): Check the filling pressure of the diaphragm expansion tank and fill if necessary.
• Adjust the filling pressure of the diaphragm expansion tank every time the operating pressure changes.

To provide for improved access to the valve seal, the valve of the diaphragm expansion tank is offset by design. The extra space at the side serves to make installation of the pressure hose easier and to store the sealing cap.

Faults, causes and remedies

DANGER: Risk of fatal injury due to electrical current!

• Disconnect the plug from the power supply before carrying out any work.
• Have electrical work carried out by a qualified electrician.
• Observe local regulations.

WARNING: Risk of injury due to improper repair!

• Only allow repairs to be carried out by qualified personnel.

9 Spare parts

Spare parts are ordered via customer service. To avoid return queries and incorrect orders, the article number and production date must always be supplied. Subject to change without prior notice!

10 Disposal

10.1 Information on the collection of used electrical and electronic products

Proper disposal and appropriate recycling of this product avoids environmental damage and risks to personal health.

NOTICE: Disposal in domestic waste is prohibited!

In the European Union, this symbol [♻️] may be included on the product, the packaging, or the accompanying documentation. It means that the electrical and electronic products in question must not be disposed of along with domestic waste.

Please note the following points to ensure proper handling, recycling, and disposal of the used products in question:

• Hand over these products at designated, certified collection points only.
• Observe the locally applicable regulations!

Please consult your local municipality, the nearest waste disposal site, or the dealer who sold the product to you for information on proper disposal. Further recycling information at http://www.wilo-recycling.com.

Subject to change without prior notice!