Wilo Isar BOOST5 Installation and Operating Manual

1 Safety

1.1 About this manual

This manual is part of the product. Adhering to the manual is a prerequisite for correct handling and use:

• Read the manual carefully before any activity.
• Keep the manual accessible at all times.
• Pass the manual on to the next owner.
• Respect all product information.
• Respect all markings on the product.

The language of the original operating manual is German. All other languages of this manual are translations of the original operating manual.

Failure to follow the manual can lead to personal injury or property damage. The manufacturer is not liable for damages resulting from the following:

• Use other than intended.
• Incorrect operation.

1.2 Copyright

WILO SE © 2024

Distribution and reproduction of this document, use and disclosure of its content are prohibited unless expressly permitted. Infringement entails liability for damages. All rights reserved.

1.3 Reservation of changes

Wilo reserves the right to change the stated data without notice and does not guarantee technical inaccuracies or omitted data. The illustrations used may differ from the original and serve only for illustrative representation of the product.

1.4 Exclusion of warranty and liability

Wilo does not provide warranty service and is not liable, especially in the following cases:

• Insufficient product dimensioning due to incorrect or faulty data provided by the operator or client.
• Non-compliance with this manual.
• Use contrary to intended purpose.
• Improper storage or transport.
• Incorrect installation or disassembly.
• Insufficient maintenance.
• Unauthorized repair.
• Unsuitable foundations.
• Chemical, electrical, or electrochemical influences.
• Wear and tear.

1.5 Marking of safety instructions

Safety instructions in this installation and operating manual are marked as follows:

• Personal injury: Safety instructions begin with the corresponding symbol and have a grey background.
• Property damage: Safety instructions begin with a signal word and are presented without a symbol.

Signal words

• DANGER! Non-compliance can lead to death or very serious injury!
• WARNING! Non-compliance can lead to (very serious) injury!
• CAUTION! Non-compliance can lead to property damage, possibly complete destruction.
• NOTICE! Useful information for handling the product.

Symbols

The following symbols are used in this manual:

• ⚠️ General warning symbol
• ⚡ Danger of electric shock
• ⓘ Notice

Observe the warnings located directly on the product and keep them legible:

• Warning and fault messages
• Type plate
• Direction of rotation arrow / flow symbol
• Connection legend

1.6 Personnel qualification

Personnel must:

• Be trained on local accident prevention regulations.
• Read and understand the installation and operating manual.

Personnel must have the following qualifications:

• Work on electrical systems: Work on electrical systems must be carried out by a qualified electrician.
• Installation/Disassembly: Qualified personnel must be trained in working with the necessary tools and fastening materials.
• Operation: Operation must be carried out by persons trained in the functions of the entire system.
• Maintenance work: Qualified personnel must be familiar with the handling of operating materials used and their disposal.

1.7 Work on electrical system

Definition of "Qualified Electrician"

A qualified electrician is a person with appropriate professional training, knowledge, and experience who can recognize and prevent hazards arising from electricity.

The operator is responsible for defining the scope of responsibility, competence, and control of personnel. If personnel lack the necessary knowledge, they must be trained and instructed. If necessary, the product manufacturer can provide this service on behalf of the operator.

The product must not be operated by persons (including children) with limited physical, sensory, or mental abilities who have not been instructed in its operation by a person responsible for their safety.

Children must be supervised to ensure they do not play with the product.

• Work on electrical systems must only be carried out by a qualified electrician.
• Applicable directives, standards, and regulations, as well as the requirements of local energy companies regarding connection to the local power grid, must be observed.
• Disconnect the product from the mains before starting any work and secure it against re-energization.
• The connection must be protected by a residual current device (RCD).
• The product must be grounded.
• Have defective cables replaced immediately by a qualified electrician.

1.8 Assembly/disassembly work

Wear protective equipment:

• Safety footwear
• Cut-resistant gloves
• Safety helmet (when using lifting equipment)

When working, observe the laws and regulations on occupational safety and accident prevention applicable at the installation site.

• Disconnect the product from the mains and secure it against unauthorized re-energization.
• All rotating parts must be stopped.
• Close the shut-off valve in the inlet and pressure pipe.
• Ensure adequate ventilation in enclosed spaces.
• Ensure that there is no risk of explosion during welding or work with electrical equipment.

1.9 Maintenance work

Wear protective equipment:

• Sealed safety goggles
• Safety footwear
• Cut-resistant gloves

• When working, observe the laws and regulations on occupational safety and accident prevention applicable at the installation site.
• The procedure for shutting down the machine/system described in the installation and operating manual must be followed unconditionally.
• Only original manufacturer's parts may be used for maintenance and repair. The use of non-original parts exempts the manufacturer from any liability.
• Disconnect the product from the mains and secure it against unauthorized re-energization.
• All rotating parts must be stopped.
• Close the shut-off valve in the inlet and pressure pipe.
• Store tools in their designated places.
• After completing work, all control devices must be reinstalled and their function checked.

2 Product Description

2.1 Description

• Compact, quiet, and high-performance pumping system.
• Electrical unit with intelligent and intuitive control.
• The system's constant pressure is maintained by adjusting the pump speed depending on consumption.
• The product controls hydraulic and electrical operating parameters and protects against malfunction.

2.2 Control panel description

Fig. 2: Control panel

• LED: "Operating status"
  • Display of pressure setting
  • Operation
  • Error or alarm
• Control buttons "+" and "–"
• Control button: "On/Off"
• LED: "Device status" (green and red)

2.2.1 Description of operating states

Device ready for operation

• The device is switched on but not in operation.
• LED for "Operating status" are off.
• LED for "Device status" is permanently green.

Device in operation

• The device is switched on and in operation.
• LED for "Operating status" light up all around.
• LED for "Device status" is permanently green.

Device is switched off

• The device is switched off.
• LED for "Operating status" light up all around.
• LED for "Device status" flashes green.

Device error/alarm

• The device is switched on but not ready for operation.
• LED for "Operating status" are off.
• LED for "Device status" is permanently red.

2.3 Type key

Example: Wilo-Isar BOOST5-E-3

2.4 Technical data

2.5 Dimensions

Fig. 3: Dimensions

Diagram showing the product dimensions with measurements in mm. Key dimensions include overall height (344 mm), width (274 mm), depth (390 mm), and connection sizes (G1").

2.6 Scope of delivery

Fig. 4: Scope of delivery

• Pressure boosting device
• 2 G1" hydraulic connections
• Discharge connection bracket
• Seal
• Installation and operating manual

3 Use

3.1 Intended use

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

• A highly efficient self-priming pump with an electric motor,
• A diaphragm expansion tank,
• Pressure and flow sensors,
• A check valve in the suction connection.

The pressure boosting device is used to increase the pressure of clean water in residential buildings and for agricultural irrigation and sprinkling.

Water supply is provided from wells, springs, tanks, or the public water supply network.

NOTICE

• For all uses with drinking water, observe local regulations.

3.2 Use contrary to intended purpose

WRAS and ACS certificates are available for all Wilo-Isar BOOST5 pressure boosting devices.

For Germany (DE) only:

In Germany, the product must not be used for drinking water applications. Connection to the public water supply is not permitted.

4 Transport and Storage

4.1 Delivery

• Upon delivery, immediately check the product and packaging for any defects (damage, completeness).
• Existing defects must be noted on the transport documents and reported to the shipping company or manufacturer on the same day of delivery.
• We cannot accept claims for defects reported later.

4.2 Transport

CAUTION

Risk of property damage due to wet packaging!

Wet packaging may tear. The product may fall uncontrollably and be destroyed.

• Carefully lift wet packaging and replace it immediately!
• Transport the product only in its supplied packaging.
• If the packaging is damaged or missing, use suitable protection against moisture and dirt.
• Remove packaging only at the installation site.

4.3 Storage

CAUTION

Risk of property damage due to improper storage!

Moisture and certain temperatures can damage the product.

• Protect the product from moisture and mechanical damage.
• Must not be exposed to temperatures outside the range of -10 to +60 °C.

5 Installation and Electrical Connection

5.1 Installation location

• The installation location must be dry, well-ventilated, and protected from frost. The product is not designed for outdoor installation.
• Observe ambient temperatures, see technical data.
• Select the installation location according to the product dimensions.
• Connections must be freely accessible.
• Avoid vibrations or mechanical stress on the connected piping.

5.2 Hydraulic connection

WARNING

Risk of injury due to incorrect installation.

• Have installation carried out exclusively by professionally qualified personnel.
• Observe accident prevention regulations.
• Observe local regulations.

Fig. 5: Hydraulic connection

Diagram showing the hydraulic connection steps. It illustrates connecting pipes to the device using adjustable feet for leveling, removing covers, and attaching hoses.

• Use pressure-resistant connection hoses.
• Avoid excessive bending of connection hoses.
• 1. Level the product horizontally using the adjustable feet.
• 2. Remove the covers on the discharge and suction connection brackets.
• 3. Remove the discharge and suction connection brackets.
• 4. Connect the pressure-resistant connection hoses to the hydraulic connections (included in delivery). Inner diameter of connection hose: G1".
• 5. Attach the suction and discharge connection with seal.
• 6. Mount the discharge and suction connection brackets.
• 7. Mount the covers on the discharge and suction connection brackets.

5.3 Electrical connection

DANGER

Risk of fatal injury from electric shock!

Improper electrical connection can cause electric shock.

• Ensure that work on the electrical system is always carried out by a qualified electrician.
• Observe accident prevention regulations.
• Observe local regulations.

• Install a residual current device (30 mA, Type A).
• Check the proper installation of the protective earth connection.
• Check that the power supply corresponds to the data on the type plate.

5.3.1 Connection of expansion card

DANGER

Risk of fatal injury from electric shock!

Voltage from the external power supply is present even when the main switch is off!

• Disconnect the plug from the power supply before carrying out any work.
• Ensure that work on the electrical system is always carried out by a qualified electrician.
• Observe local regulations.

CAUTION

Property damage due to incorrect installation!

• Devices connected to the expansion card can only be used with a separate low voltage (SELV).
• When removing the cover, do not pull on the main switch cables.

Fig. 6: Connection of expansion card

Diagram showing the expansion card terminals and their connections.

6 Commissioning

6.1 Priming mode

CAUTION

Risk of property damage due to dry running!

Dry running of the pump damages the mechanical seals.

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

Fig. 7: Priming mode

Diagram illustrating the priming mode setup, showing water flow into the device and out through a vent.

• The product is in priming mode.
• 1. Remove the seal of the filler plug and the vent screw.
• 2. Fill the product with water (approx. 1.5 liters) until it starts to drain from the vent opening (Fig. 8).
• 3. Reinstall the seal of the filler plug and the vent screw.
• 4. Open the shut-off valve (pos. 1, 2).
• 5. Connect the power plug to the power supply.
• 6. Switch on the product using the main switch.
• 7. Press and hold the "+" and "–" control buttons simultaneously for 5 seconds (Fig. 9).
• The product switches to priming mode.
• 8. On the control panel, press the "On/Off" control button (Fig. 10).
• Priming lasts for a maximum of five minutes. Every minute, the pump automatically stops for five seconds and then restarts. This process repeats until the product is ready for operation. The LEDs flash during the process. Priming ends after five minutes or when priming is complete. The LEDs no longer flash.
• 9. If the pump does not start priming automatically, repeat the process.
• 10. On the control panel, press the "On/Off" control button.

Fig. 8: Filling

Illustration showing the filling process.

Fig. 9: Control buttons + and –

Illustration of the control panel buttons.

Fig. 10: Control button On/Off

Illustration of the On/Off button.

6.2 Deactivation of priming mode

Fig. 11: Deactivation of priming mode

Diagram showing the deactivation of priming mode.

• The product is set to priming mode ex works. If proper operation under load is guaranteed or the inlet is already under pressure, the automatic priming mode can be switched off.
• 1. Remove the seal of the vent screw.
• 2. Turn the switch to the vertical position.
• 3. Reinstall the seal of the vent screw.

6.3 Operation under load

Fig. 12: Operation under load

Diagram illustrating the setup for operation under load.

• 1. If the product is to be used for operation under load. Deactivate priming mode (see page 15).
• 2. Open the shut-off valve (pos. 1, 2).
• 3. Connect the power plug to the power supply.
• 4. Switch on the product using the main switch.
• 5. On the control panel, press the "On/Off" control button (Fig. 13).

6.4 Setting operating pressure

The LEDs for "Operating status" indicate the desired operating pressure. The operating pressure can be set between 1 bar and 5.5 bar.

• Indication of operating pressure: Press the "+" control button.
• Change the operating pressure in increments of 0.5 bar: Press the "–" or "+" control buttons.

Example:

• 1. Press the "+" control button. The operating pressure (2 bar) is displayed.
• 1. Double-pressing the "+" control button (0.5 bar + 0.5 bar) increases the operating pressure to 3 bar.
• The LEDs for "Operating status" indicate the current operating pressure (3 bar).

6.5 Filling the diaphragm expansion tank

CAUTION

Premature product damage due to incorrect installation!

The integrated diaphragm expansion tank is pre-filled ex works to 1.5 bar. The maximum filling pressure is 4 bar.

• Fill the diaphragm expansion tank at zero system pressure.
• Fill the diaphragm expansion tank according to the table.
• For every change in operating pressure, adjust the filling pressure of the diaphragm expansion tank.

Fig. 14: Filling the diaphragm expansion tank

Diagram showing the process of filling the expansion tank.

• A compressor or pump with a pressure gauge is available.
• 1. Close the shut-off valve (Fig. 7 – pos. 1, 2) on the suction and discharge sides.
• 2. Remove the screw on the diaphragm expansion tank seal.
• 3. Connect the compressor or air pump (hand pump) to the diaphragm expansion tank seal.
• 4. Fill the diaphragm expansion tank until the desired and set operating pressure is achieved.

NOTICE

To prevent pressure surges, install an additional diaphragm expansion tank on the discharge side if necessary.

6.6 Alarm codes

LEDs 1-6 flashing green + LED flashing red

LEDs 1-6 lit green + LED flashing red

7 Maintenance

7.1 Maintenance of flow sensor

Release pressure in the system by closing the shut-off valves on the suction and discharge sides.

• Drain the product using the drain screw.
• 1. Remove the seal of the filler plug.
• 2. To remove the flow sensor, loosen the retaining screw.
• 3. Check the flow sensor and clean it if necessary.
• 4. Reinstall the flow sensor, ensuring correct orientation.
• 5. Reinstall the seal of the filler plug.

Fig. 15: Flow sensor

Diagram showing the flow sensor removal and reinstallation.

7.2 Maintenance of check valve suction connection

Release pressure in the system by closing the shut-off valves on the suction and discharge sides.

• Drain the product using the drain screw.
• 1. Remove the cover and bracket.
• 2. Remove the suction connection.
• 3. Remove the check valve.
• 4. Check the check valve and clean it if necessary.
• 5. Reinstall the check valve, ensuring proper seating.
• 6. Reinstall the suction connection.
• 7. Reinstall the bracket and cover.

Fig. 16: Check valve suction connection

Diagram showing the check valve removal and reinstallation.

7.3 Maintenance of diaphragm expansion tank

CAUTION

Premature product damage due to incorrect maintenance!

• At least once a year (Wilo recommends: every 6 months): Check the filling pressure of the diaphragm expansion tank and refill if necessary.
• For every adjustment of the operating pressure, adapt the filling pressure of the diaphragm expansion tank.

8 Faults, Causes, and Troubleshooting

DANGER

Risk of fatal injury from electric shock!

Voltage from the external power supply is present even when the main switch is off!

• Disconnect the plug from the power supply before carrying out any work.
• Ensure that work on the electrical system is always carried out by a qualified electrician.
• Observe local regulations.

WARNING

Risk of injury due to incorrect repair!

• Have repairs carried out exclusively by professionally qualified personnel.

9 Spare Parts

Spare parts can be ordered through customer service. To avoid follow-up questions or incorrect orders, always state the item number and date of manufacture. Technical changes reserved!

10 Disposal

10.1 Information on collection of used electrical and electronic equipment

Proper disposal and professional recycling of this product will prevent environmental damage and risks to human health.

NOTICE

Do not dispose of with household waste!

This symbol may appear on the product, packaging, or accompanying documents within the European Union. This means that affected electrical and electronic products must not be disposed of with household waste.

For proper handling of affected old products, their recycling and disposal, observe the following points:

• Hand over these products only at certified collection points designated for this purpose.
• Observe applicable local regulations!

Request information on proper disposal from your local municipal office, the nearest waste disposal facility, or the retailer where the product was purchased. Further information on recycling can be found at www.wilo-recycling.com.

Technical changes reserved!