Wilo Isar BOOST5

Safety Information

About This Manual

This manual is an integral part of the product. Following its instructions is essential for correct use and proper operation. Always read the manual carefully before starting any work, keep it accessible, and pass it on to the next owner. Comply with all product information and markings.

The original manual is in German; other language versions are translations. Non-compliance can lead to personal injury or material damage. The manufacturer is not liable for damage caused by improper use or operation.

Copyright

WILO SE 2025. Unauthorized distribution, reproduction, use, or disclosure of this document is prohibited and may result in claims for damages. All rights reserved.

Subject to Change

Wilo reserves the right to change data without prior notice and is not responsible for inaccuracies or incompleteness. Illustrations may differ from the original and serve only as examples.

Exclusion of Warranty and Liability

Wilo is not liable for warranty claims in cases of:

• Insufficient dimensioning due to incorrect or incomplete information from the user or client.
• Non-compliance with this operating manual.
• Improper use.
• Incorrect storage or transport.
• Incorrect assembly or disassembly.
• Inadequate maintenance.
• Unauthorized repair.
• Unsuitable foundation.
• Influence of chemical, electrical, or electrochemical factors.
• Wear and tear.

Safety Recommendations

The following safety instructions and recommendations are used in this manual:

• Danger to persons: Safety recommendations are marked with a corresponding symbol and highlighted in grey.
• Material damage: Safety recommendations begin with a warning word and are presented without a symbol.

Warning Texts

• [DANGER!] Non-compliance leads to death or severe injury!
• [WARNING!] Non-compliance can lead to (severe) injury!
• [CAUTION!] Non-compliance can lead to material damage, possibly total loss!
• [NOTICE!] Useful tip for operating the product.

Symbols

The following symbols are used in this manual:

• General danger symbol: [!]
• Danger due to electrical voltage: [⚡]
• Information: [i]

Observe the information on the product and keep it legible:

• Information regarding warnings and hazards.
• Nameplate.
• Arrow indicating direction of rotation / flow direction symbol.
• Connection markings.

Personnel Qualifications

Personnel must:

• Be familiar with applicable local health and safety regulations.
• Read and understand this installation and operating manual.

Personnel must have the following qualifications:

• Electrical Work: Electrical work must only be performed by qualified electricians.
• Assembly/Disassembly: Personnel must be trained in the use of necessary tools and mounting materials.
• Operation: Operation must be carried out by persons trained in the operation of the entire unit.
• Maintenance Work: Personnel must be familiar with the handling and disposal of operating materials used.

Definition of a "Qualified Electrician": A qualified electrician is a person with appropriate specialist training, knowledge, and experience who can recognize and avoid electrical hazards.

The user is responsible for the scope of responsibility, competence, and supervision of personnel. If personnel lack the required knowledge, they must be trained and instructed. Such training can be provided by the product manufacturer upon request.

The product must not be operated by persons (including children) with reduced physical, sensory, or mental capabilities unless they have been instructed by a person responsible for their safety. Ensure the product is not used as a toy by children.

Electrical Work

• Electrical work must be performed by a qualified electrician.
• Comply with current national directives, standards, and regulations, as well as local utility guidelines for connection to the local electrical grid.
• Disconnect the product from the power supply and secure it against re-energization before starting any work.
• Connection must be protected by a residual current device (RCD).
• The product must be grounded.
• Immediately arrange for the replacement of damaged cables by qualified electricians.

Assembly/Disassembly

PPE required:

• Safety shoes
• Protective gloves for cuts
• Safety helmet (when using lifting equipment)

Comply with applicable local safety and accident prevention regulations.

Disconnect the product from the power supply and secure it against unauthorized re-energization.

All rotating parts must be stopped.

Close the shut-off valve on the inlet and pressure line.

Ensure adequate ventilation in enclosed spaces.

Exclude the risk of explosion during any welding work or work with electrical equipment.

Maintenance Work

PPE required:

• Safety goggles
• Safety shoes
• Protective gloves for cuts

Comply with applicable local safety and accident prevention regulations.

Strictly follow the procedure described in the installation and operating manual for stopping and switching off the product/unit.

Only use original manufacturer parts for maintenance and repairs. The use of non-original parts voids manufacturer liability.

Disconnect the product from the power supply and secure it against unauthorized re-energization.

All rotating parts must be stopped.

Close the shut-off valve on the inlet and pressure line.

Tools must be stored in designated areas.

After completing work, reconnect all safety and control devices and check their proper function.

Product Description

Overview

A compact, quiet, and highly efficient pump system with an electric motor. It features intelligent and intuitive product control. System pressure is maintained at a constant level by regulating the pump's rotational speed based on consumption. The product controls hydraulic and electrical operating parameters and protects against malfunctions.

Product Overview Diagram

Figure 1: Product Overview

• 1. Filling port closure
• 2. Expansion card
• 3. Fuse (12 A)
• 4. Cable entry/exit
• 5. Drain plug closure
• 6. Bleed screw
• 7. Expansion tank closure
• 8. Inlet/outlet connection cover
• 9. Inlet/outlet connection bracket
• 10. Height-adjustable feet (vibration-damping)
• 11. Suction connection
• 12. Mains cable
• 13. Swiveling connection elbow
• 14. Pressure connection
• 15. Control panel

Control Panel Description

Figure 2: Control Panel

• 1. LED Status Lights: Indicate operating status, pressure setting, operation, or error/alarm.
• 2. Operation Buttons: [+] and [-]
• 3. Operation Button: [ON/OFF]
• 4. System Status LED: Green and Red.

Operating Status Descriptions

Unit Ready to Operate: Unit is switched on but not running. "Operating Status" LEDs are off. "System Status" LED is solid green.

Unit Operating: Unit is switched on and running. "Operating Status" LEDs flash in sequence. "System Status" LED is solid green.

Unit Switching Off: Unit is switching off. "Operating Status" LEDs flash in sequence. "System Status" LED flashes green.

Error/Alarm System: Unit is switched on but not ready to operate. "Operating Status" LEDs are off. "System Status" LED is solid red.

Type Designation

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

Technical Data

Dimensions Diagram

Figure 3: Dimensions

Scope of Delivery

• Pressure boosting system
• 2 x G1" hydraulic connections
• Inlet/outlet connection bracket
• Seals
• Installation and operating manual

Application/Use

Intended Use

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

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

The pressure boosting system is designed to increase the pressure of clean water in residential buildings, for irrigation, and sprinklers in agriculture. Water supply can be from wells, springs, tanks, or the public water supply.

[NOTICE!] Comply with local regulations regarding all drinking water applications.

WRAS and ACS certifications are available for all Wilo-Isar BOOST5 pressure boosting systems.

Non-intended Use

For Germany: The product must not be used in Germany for drinking water applications. Connection to the public water supply is not permitted.

Transport and Storage

Delivery

• Upon delivery, immediately check the condition (damage, completeness).
• Report any defects to the transport company or manufacturer. Claims for defects reported after this period will not be accepted.

Transport

[CAUTION!] Damage caused by wet packaging! Wet packaging can tear, causing the product to fall and be damaged. Handle wet packaging carefully and replace it immediately!

1. Transport the product only in its supplied packaging.
2. If additional packaging is missing or damaged, ensure adequate protection against moisture and dirt.
3. Remove additional packaging only at the installation site.

Storage

[CAUTION!] Material damage due to improper storage! Moisture and certain temperatures can damage the product. Protect the product from moisture and mechanical damage. Avoid temperatures outside the range of -10°C to +60°C.

Installation and Electrical Connection

Installation Location

• The installation location should be dry, well-ventilated, and frost-protected.
• Observe ambient temperatures as specified in the Technical Data.
• Choose an installation location that accommodates the product's dimensions.
• Connections must be easily accessible.
• Avoid vibrations or mechanical stresses caused by connected piping.

Hydraulic Connection

[WARNING!] Risk of injury due to incorrect installation. Installation must be carried out exclusively by qualified personnel. Comply with accident prevention regulations. Comply with local regulations.

Figure 4: Hydraulic Connections

Avoid elbows and sharp bends in suction lines. The suction line must be pressure-resistant. For push-fit connectors, use a seal (internal application). Ensure automatic push-fit connectors are leak-proof to prevent air ingress. Check the suction line for leaks from the strainer to the pump and the check valve.

Figure 5: Hydraulic Connections

1. Use pressure-stable connection pipes.
2. Avoid excessive kinking of connection pipes.
3. Position the product horizontally using the adjustable feet.
4. Remove the covers from the inlet and suction connection brackets.
5. Remove the brackets from the inlet and suction connections.
6. Connect pressure-resistant connection pipes to the hydraulic connections (scope of delivery). Inner diameter of connection pipe: G1".
7. Fit the suction and pressure connections with seals.
8. Mount the brackets for the inlet and suction connections.
9. Mount the covers on the inlet and suction connection brackets.

Electrical Connection

[DANGER!] Risk of electric shock! Improper electrical connection can lead to electric shock. Electrical work must be performed by a qualified electrician. Comply with accident prevention regulations. Comply with local regulations.

• Install a residual current device (30 mA, Type A).
• Check the installation for compliance with regulations.
• Verify that the supply voltage matches the data on the nameplate.

Connecting Expansion Card

[DANGER!] Risk of electric shock! Before any work, disconnect the plug from the electrical supply. Electrical work must be performed by a qualified electrician. Comply with local regulations.

Figure 6: Expansion Card Connections

1. Remove the cover mounting screws.
2. Partially remove the cover to access the expansion card terminal strip.

Commissioning

Operating Modes

The product can operate in suction mode (pump above water level) and discharge mode (pump below water level).

[CAUTION!] Material damage due to dry running! Dry running damages mechanical seals. Fill and vent the pump before operation.

Filling the Product

Figure 7: Suction Mode

Figure 8: Load Mode

Figure 9: Filling

Figure 10: Operation Button [+] and [-]

Figure 11: Operation Button [ON/OFF]

To Fill:

1. Remove the filling port closure and bleed screw.
2. Fill the product with water (approx. 1.5 l) until water flows from the vent opening (Fig. 9).
3. Reinstall the filling port closure and bleed screw.
4. Open shut-off valves (pos. 1, 2).
5. Connect the mains plug to the electrical supply.

Load Mode:

1. If the product is installed in load mode (Fig. 8), press the [ON/OFF] button once (Fig. 11). The pump starts.

Suction Mode:

1. If the product is installed in suction mode (Fig. 7), press the [+] and [-] buttons simultaneously for 5 seconds (Fig. 10). The product switches to suction mode.
2. Press the [ON/OFF] button on the control panel (Fig. 11). Suction takes a maximum of 5 minutes. LEDs flash during this process. Suction is complete after 5 minutes or upon successful suction. LEDs no longer flash.
3. If the pump does not self-prime, repeat the process.

Setting Operating Pressure

The "Operating Status" LEDs indicate the selected operating pressure. The operating pressure can be set between 1 bar and 6 bar.

• To display the operating pressure: Press the [+] button.
• To change the operating pressure by 0.5 bar: Press the [-] or [+] buttons.

Example:

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

Filling the Expansion Tank

[CAUTION!] Material damage due to improper installation! The integrated expansion tank is factory pre-filled with nitrogen to 1.5 bar. The maximum filling pressure is 4 bar.

• Use air or nitrogen for filling.
• Fill the expansion tank at zero system pressure.
• Fill the expansion tank according to the table.
• Adjust the filling pressure when changing the operating pressure.

Figure 12: Filling the Expansion Tank

• A compressor or pump with a manometer is available.
• Connect the shut-off valve (Fig. 7 - pos. 1, 2) on the suction and pressure sides.
• Remove the screw on the expansion tank closure.
• Connect a compressor or air pump (hand pump) to the expansion tank closure.
• Fill the expansion tank to achieve the desired and set operating pressure.

[NOTICE!] To avoid pressure fluctuations, consider installing an additional expansion tank on the pressure side.

Alarm Codes

LEDs 1-6 flash green + LED flashes red:

Alarm 1 (Dry run): If dry run occurs on the suction side for more than 7 seconds, an alarm is displayed. Check water supply on the suction side. Fill the pump. The product restarts automatically after 1 min, 15 min, 30 min, 1 hour, etc.

Alarm 2 (Pump not reaching pressure): Contact technical service.

Alarm 4 (Low supply voltage): Ensure electrical supply is 230 V ±10%.

Alarm 5 (Output pressure below 0.2 bar / damaged pipe): Eliminate the cause. To reset the alarm, switch the product off and on again using the [ON/OFF] button (Fig. 2, pos. 3). Check why the pressure has reset to zero.

Alarm 6 (External shut-off signal):

Example Dry Run: LED 1 flashes green + red LED flashes.

Alarm 3 (Over-current):

Electrical power consumption exceeds permissible tolerance. To reset the alarm, switch the product off and on again using the [ON/OFF] button (Fig. 2, pos. 3). If the alarm persists, contact technical service.

Alarm 4 (High motor temperature): Motor temperature is too high. Check the temperature of the pumped medium. If the fluid temperature exceeds 40°C, contact technical service. If the temperature drops below the alarm threshold, the product resets automatically.

Alarm 5 (High fluid temperature): Check the temperature of the pumped medium. If the fluid temperature exceeds 40°C, contact technical service. If the temperature drops below the alarm threshold, the product resets automatically.

Alarm 6 (Pressure sensor fault): Contact technical service.

Alarm 6 (Flow sensor signal fault): Contact technical service.

Example Short Circuit: LED 1 is solid green + red LED flashes.

Maintenance

Expansion Tank Maintenance

[CAUTION!] Material damage due to improper maintenance! The product can be damaged by incorrect expansion tank settings.

• At least once a year (Wilo recommends: every 6 months): Check the expansion tank's filling pressure and refill if necessary.
• Adjust the expansion tank's filling pressure whenever the operating pressure is adjusted.

For better access to the valve closure, the expansion tank valve is offset due to its construction. The space on the side allows for easy mounting of the pressure hose and storage of the sealing cap.

Faults, Causes, and Remedies

[DANGER!] Risk of electric shock! Before any work, disconnect the plug from the electrical supply. Electrical work must be performed by a qualified electrician. Comply with local regulations.

[WARNING!] Risk of injury due to improper repair! Repair must be carried out exclusively by qualified personnel.

Spare Parts

Spare parts can be ordered through technical service. To avoid queries and incorrect orders, always state the article number and production date. Technical changes reserved!

Disposal

Information on Collection of Used Electrical and Electronic Equipment

Proper disposal and recycling of this product prevent environmental damage and health risks.

[NOTICE!] Forbidden to dispose of with household waste! In the European Union, this symbol on products, packaging, or accompanying documents indicates that this electrical and electronic equipment must not be disposed of with household waste.

For proper processing, recycling, and disposal of used equipment, follow these recommendations:

• Hand over such equipment only at designated and certified collection points.
• Observe local regulations!

Information regarding statutory disposal can be obtained from the local municipality, the nearest waste disposal point, or the retailer where the product was purchased. Detailed information on recycling can be found at: http://www.wilo-recycling.com.

Technical changes reserved!