Wilo Isar BOOST5 User manual

Pioneering for You
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Wilo-Isar BOOST5
4251960 • Ed.03/12/2022 4251960
en Installation and operating instructions

Isar BOOST5
http://qr.wilo.com/617

Fig. 1
Fig. 2
15 610 119 7
38 12 4
2
360°
360°
82287731
180
66
390
274
160
200
130
35 35
144
Ø40 Ø40
23 84
344
278
G1”
G1”
184

Fig. 3
Fig. 4
1 2 3
4 5 6
H –
ok
no
H +
a
b

Fig. 5
Fig. 6 Fig. 7
Fig. 8
1 2 3
SELF-PRIMING
(factory setting)
NOT SELF-PRIMING

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Installation and operating instructions • Wilo-Isar BOOST5 • Ed.03/12/2022 7
Contents
1 General ........................................................................................8
1.1 About this document ........................................................... 8
1.2 Copyright ............................................................................... 8
1.3 Subject to modifications...................................................... 8
2 Safety...........................................................................................8
2.1 Symbols .................................................................................. 8
2.2 Personnel qualifications....................................................... 9
2.3 Danger in the event of non-observance of the safety in-
structions ............................................................................... 9
2.4 Safety consciousness on the job ........................................ 9
2.5 Safety instructions for the operator................................... 9
2.6 Safety instructions for installation and maintenance work
...............................................................................................10
2.7 Unauthorised modification of components and use of
unauthorised spare parts ...................................................10
2.8 Improper use........................................................................10
3 Use .............................................................................................10
3.1 Application...........................................................................10
4 Description of the product......................................................11
4.1 Description...........................................................................11
4.2 Technical data .....................................................................11
4.3 Type key...............................................................................12
4.4 Dimensions ..........................................................................12
4.5 Scope of delivery.................................................................12
4.6 Description of control panel..............................................13
5 Transport and interim storage................................................14
6 Installation and electrical connection....................................14
6.1 Expansion card connection ...............................................15
7 Installation ................................................................................15
7.1 Receipt of the product .......................................................15
7.2 Hydraulic connection..........................................................15
7.3 Hydraulic connections........................................................16
7.4 Working pressure adjustment...........................................16
7.5 Inflating the expansion tank .............................................17
7.6 Self-priming operation ......................................................18
8 Commissioning .........................................................................18
8.1 Filling and starting ..............................................................18
8.2 Alarm codes .........................................................................19
9 Maintenance..............................................................................20
10 Faults, causes and remedies....................................................20
11 Spare parts ................................................................................20
12 Disposal .....................................................................................21

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8 Installation and operating instructions • Wilo-Isar BOOST5 • Ed.03/12/2022
1 General
1.1 About this document The installation and operating instructions are an integral part of the product. Read these
instructions before carrying out any work and keep them at hand at all times. Strict adher-
ence to these instructions is a precondition for the correct installation and application of
the product. Comply with all indications and signs that appear on the product.
The language of the original installation and operating instructions is English. All other lan-
guages of these instructions are translations of the original installation and operating in-
structions.
1.2 Copyright The manufacturer has intellectual property rights for these installation and operating in-
structions. The reproduction of their contents in any form is forbidden. They may not be
disseminated or used for competitive purposes or passed on to a third party.
1.3 Subject to modifications The manufacturer reserves the right to make technical modifications to the product or its
individual components. The figures used may differ from the original product and are inten-
ded for illustrative purposes only.
2 Safety This chapter contains essential instructions that must be followed
during the different phases of the pump’s service life. Non-ob-
servance of these instructions may constitute a danger to per-
sons, the environment and the product, and may invalidate the
warranty. Non-observance may lead to the following hazards:
•Injuries due to electrical, mechanical and bacteriological factors
and electromagnetic fields.
•Damage to the environment due to leakage of hazardous ma-
terials.
•Damage to the installation.
•Failure of important product functions.
Also comply with the indications and safety instructions in
other chapters!
2.1 Symbols Symbols:
WARNING
General safety symbol
WARNING
Electrical risks
NOTICE
Notes
Warnings:
DANGER
Imminent danger.
May result in death or severe injuries if the hazard is not prevented.

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Installation and operating instructions • Wilo-Isar BOOST5 • Ed.03/12/2022 9
WARNING
Non-observance may result in (very) severe injury.
CAUTION
The product risks becoming damaged. “Caution” is used when there is a
risk to the product if the user does not observe procedures.
NOTICE
Note containing useful information for the user about the product. It as-
sists the user in the case of an issue.
2.2 Personnel qualifications The installation, application and maintenance personnel must
have the appropriate qualifications to complete this work. The
operator must ensure the personnel’s areas of responsibility,
terms of reference and their supervision. If the personnel are not
in possession of the necessary knowledge, they are to be trained
and instructed. If necessary, this training can be carried out by the
product’s manufacturer on the operator’s behalf.
2.3 Danger in the event of
non-observance of the
safety instructions
Non-observance of the safety instructions may constitute a
danger to persons, the environment and the product/unit. Non-
observance of the safety instructions also results in the loss of
any claims to damages. More specifically, non-observance can re-
sult in the following risks:
•danger to persons from electrical, mechanical and bacteriolo-
gical influences,
•damage to the environment due to leakage of hazardous ma-
terials,
•damage to property,
•failure of important product/unit functions,
•failure of required maintenance and repair processes.
2.4 Safety consciousness on
the job
The existing directives for accident prevention must be adhered
to. Danger from electrical current must be eliminated. Local dir-
ectives or general directives [e.g. IEC, VDE etc.] and instructions
from local energy supply companies must be respected.
2.5 Safety instructions for
the operator
This device is not intended for use by persons (including children)
with reduced physical, sensory or mental capabilities, or a lack of
experience or knowledge, unless they are monitored or have been
given detailed instructions concerning use of the device by a per-
son responsible for their safety.
Children must be supervised to ensure that they do not play with
the device.

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10 Installation and operating instructions • Wilo-Isar BOOST5 • Ed.03/12/2022
•If hot or cold components of the product or installation pose a
danger, it is the customer’s responsibility to guard them against
being touched.
•Guards protecting against touching moving components (such
as the coupling) must not be removed whilst the product is in
operation.
•Hazardous fluids (i.e. which are explosive, toxic or hot) which
have leaked (e.g. from the shaft seals) must be disposed of so
that they pose no danger to persons or to the environment.
National statutory provisions must be respected.
•Danger from electrical current must be eliminated. Local direct-
ives or general directives [e.g. IEC, VDE etc.] and instructions
from local energy supply companies must be respected.
2.6 Safety instructions for
installation and mainten-
ance work
The operator must ensure that all maintenance and installation
work is carried out by authorised and qualified personnel, who are
sufficiently informed from their own detailed study of the install-
ation and operating instructions. Work on the product/unit must
only be carried out when at a standstill. The procedures described
in the installation and operating instructions for deactivating the
product/installation must always be complied with.
Immediately on conclusion of the work, all safety and protective
devices must be put back in position and recommissioned.
2.7 Unauthorised modifica-
tion of components and
use of unauthorised
spare parts
Unauthorised modification of components and use of unauthor-
ised spare parts will impair the safety of the product/personnel,
and will render the manufacturer’s declarations regarding safety
void. Modifications to the product are only permissible following
consultation with the manufacturer.
Original spare parts and accessories authorised by the manufac-
turer ensure safety. The use of other parts absolves the manufac-
turing company of any and all liability.
2.8 Improper use The operational reliability of the supplied product is only guaran-
teed for conventional use in accordance with Chapter4 of the In-
stallation and operating instructions. The limit values must on no
account fall below or exceed the values specified in the cata-
logue/data sheet.
3 Use
3.1 Application Wilo-Isar BOOST5 is an automatic pressure-boosting system with a variable speed function
including:
•a high-efficiency self-priming electric pump,
•an expansion tank,
•pressure and volume flow sensors,
•a non-return valve.
Pump system designed for clean water pressure-boosting in the housing and agriculture
sectors.

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Installation and operating instructions • Wilo-Isar BOOST5 • Ed.03/12/2022 11
Supply from a well, water source, reservoir, city network,
For irrigation, sprinkling, pressure-boosting etc.
NOTICE
Local regulations must be observed for all drinking water ap-
plications.
WARNING
In Germany, this product must not be used in drinking water
applications. Connection to the municipal water supply net-
work is not authorised.
The WRAS certificate is available for all Wilo-Isar BOOST5 pressure-boosting systems.
4 Description of the product
4.1 Description •Compact, silent and high-performance pump system.
•Electric system offering smart and intuitive product control:
maintains constant system pressure by adjusting pump speed based on water demand,
controls hydraulic and electric operating parameters and protects the pump from anom-
alies.
Fig.1
1. Main on/off switch
2. Gland
3. Control panel
4. Filler screw
5. Expansion tank screw
6. Vent screw
7. Drainage screw
8. Discharge connection bent
9. Suction connection bent
10. Power supply cable
11. Damping feet
12. Connection fixation valves
4.2 Technical data
Maximum utilisation pressure
Maximum operating pressure 5.5bar
Maximum suction pressure 4.5bar
Maximum volume flow See plate
Delivery head Max. See plate
suction geodesic head 8m
Start-up pressure 1bar
Temperature range
Fluid temperature 0°C to +40°C
Ambient temperature 0°C to +40°C
Electrical data
Voltage 1 ~ 230V AC
Frequency 50Hz
Power consumed See plate
Rated current See plate
Alarm relay contact Max 0.3A at 230VAC/Max 1A at 30VDC

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12 Installation and operating instructions • Wilo-Isar BOOST5 • Ed.03/12/2022
Protection class IPX4
Motor protection Protection fuse max 12.5A
Power supply cable 1.5m
Other characteristics
Permissible fluid Clean water
Sound level 58dB(A) in sound pressure at 1m in normal operation
Dimensions (LxWxH) 390x274x344mm
Connection on the discharge side G1"
Connection on the suction side G1"
Net mass (+/-10%) 15 kg
4.3 Type key
Example: Wilo-Isar BOOST5-E-3
Wilo Brand
Isar Pressure-boosting system
BOOST Domestic use
5Built-in pump control
EControlled electronically
3 or 5 Rated volume flow in m3/h
4.4 Dimensions See Fig.2
4.5 Scope of delivery Wilo-Isar BOOST5:
•System,
•2 hydraulic connections G1",
•2 forks,
•2 O-rings,
•Installation and operating instructions.

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Installation and operating instructions • Wilo-Isar BOOST5 • Ed.03/12/2022 13
4.6 Description of control panel
1
24
3
Display
1. Operation status indicator LED
Indication of adjustment value in bar
Pump running
Error or alarm
2. Adjustment buttons “-” or “+”
3. On/Off button
4. System status LED
System on stand-by
•The system is powered and not in operation.
•Operating LEDs off.
•System status LED solid green.
System running
•System powered and pump running.
•Operating LEDs indicate adjustment value.
•System status LED solid green.

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14 Installation and operating instructions • Wilo-Isar BOOST5 • Ed.03/12/2022
System deactivated
•System powered and pump running.
•LED operating in circular mode.
•System status LED flashing green.
System error/alarm
•The system is powered and not in operation.
•Operating LEDs off.
•System status LED solid red.
5 Transport and interim storage When receiving the product, check that it has not been damaged during transport. If any
damage is found, take all necessary measures with the carrier in the time provided.
CAUTION
Risk of material damage
If the equipment delivered is to be installed at a later date, store it in a
dry place and protect it from impacts and any external influences (hu-
midity, frost etc.). Temperature range for transport and storage: -10°C
to +60°C.
Handle the product with care so as not to damage it prior to installation.
6 Installation and electrical con-
nection
All installation and electrical connection work must be carried out solely by authorised
and qualified personnel, in accordance with applicable regulations.
WARNING
Physical injuries
The applicable regulations for the prevention of accidents must be com-
plied with.
WARNING
Risk of electric shock
Hazards from electric current must be prevented.

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Installation and operating instructions • Wilo-Isar BOOST5 • Ed.03/12/2022 15
6.1 Expansion card connection
WARNING
Risk of electric shock.
Hazards from electric current must be prevented.
CAUTION
Risk of material damage
Any device attached to the expansion card must be at separated extra-
low voltage (SELV).
Do not pull the electric cables attached to the main on/off switch when
removing the cover.
•Unscrew and remove the fastening screws on the cover.
•Partly remove the cover to access the expansion card terminal block.
9-10
7-8 0 V
5-6
3-4 OUTPUT
1-2 INPUT
Terminal block key
1-2 Input LEVEL SIGNAL - bridge in ab-
sence of signal
3-4 Output ALARM SIGNAL – max 0.3A
@ 230V AC / 1A @ 30V DC
5-6 Not connected - Do not use
7-8 0 V Not connected
9-10 Not connected - Do not use
7 Installation CAUTION
Risk of material damage
Position the product horizontally and level.
Install the product in a dry, well-ventilated location protected from frost.
The product is not designed for use outdoors.
Choose a location to suit the device dimensions (Fig.3) where the connections will be ac-
cessible.
7.1 Receipt of the product Unpack the pump and recycle or dispose of the packaging in an environmentally respons-
ible manner.
7.2 Hydraulic connection
DANGER
Risk of physical injuries
The applicable regulations for the prevention of accidents must be com-
plied with.

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16 Installation and operating instructions • Wilo-Isar BOOST5 • Ed.03/12/2022
7.3 Hydraulic connections
DANGER
Risk of physical injuries
The applicable regulations for the prevention of accidents must be com-
plied with.
See Fig.3
1. Adjust the feet to ensure the Wilo-Isar BOOST5 is properly level.
2. Remove the fork covers.
3. Remove the fork with force.
4. Insert the hydraulic connections.
The suction pipe has a minimum diameter of 1" and must be completely watertight.
5. Insert the forks correctly.
6. Insert the fork covers.
Installation and hydraulic connection
WARNING
Risk of electric shock
All installation and electrical connection work must be carried out solely
by approved personnel, in accordance with applicable regulations.
WARNING
During the initial phase of installation and maintenance, ensure there is
no power being supplied.
During initial installation and maintenance, ensure the system is not
pressurised.
Ensure the power supply network is equipped with protection devices, particularly a high-
sensitivity differential switch (30mA in class A) adjusted for protection against alternating
direct, pulsed unipolar and high-frequency fault currents. Also check that the connection
to the earth complies with the standards.
Check that the details on the plate are those required and adapted to the unit.
Install Wilo-Isar BOOST5 in a room:
•protected from external conditions (rain, cold, frost etc.),
•ventilated and free from excessive dust or humidity,
•in such a way that it is not exposed to harmful vibrations or mechanical stress from the
attached pipes.
7.4 Working pressure adjustment The working pressure of the Wilo-Isar BOOST5 is displayed by green LEDs that light up on
the control panel.
It ranges from 1 to 5.5bar
To adjust:
•Press the button “+” to display the working pressure.
•Press the buttons “+” or “-” to increase or reduce the working pressure.
Each time the “+” or “-” buttons are pressed, the value increases or decreases in incre-
ments of 0.5bar.
Examples:

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Installation and operating instructions • Wilo-Isar BOOST5 • Ed.03/12/2022 17
Press the button to display the working pressure. When the green LEDs are lit up as shown in
the image, the working pressure is 2bar.
•For instance, press the button “+” twice to adjust the working pressure to 3bar. The value
is increased by 1bar (0.5 + 0.5bar).
•The LEDs light up as shown in the image. The working pressure is 3bar.
7.5 Inflating the expansion tank
CAUTION
Risk of material damage
The expansion tank built into the Wilo-Isar BOOST5 is pre-inflated to
1.5bar at the factory. Optimum tank inflation ensures the smooth oper-
ation of the system and prevents premature bursting of the diaphragm.
WARNING
Risk of physical injuries
The tank must be inflated when the system pressure is zero. Maximum
inflation pressure of 4bar
CAUTION
Risk of material damage
Inflate the expansion tank to 1.5bar less than the working pressure (see
table).
Working pressure (bar) Inflation pressure (bar)
1 0.5
1.5 1
2 1.5
2.5 1.5

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18 Installation and operating instructions • Wilo-Isar BOOST5 • Ed.03/12/2022
Working pressure (bar) Inflation pressure (bar)
3 1.5
3.5 2
4 2.5
4.5 3
5 3.5
5.5 4
Inflation (Fig.7)
•Remove the screw,
•get a compressor,
•connect the compressor pipe to the filling valve,
•inflate the expansion tank to the desired pressure.
7.6 Self-priming operation
CAUTION
Risk of material damage
The pump is set to self-priming operation in the factory. If proper load operation is guaran-
teed or the supply is already pressurised, you can turn off the automatic priming function
by turning the lever (Fig.5) to the vertical position.
•Unscrew and remove the drainage screw. Risk of water leakage.
•Move the red lever into the vertical position to turn off the automatic self-priming oper-
ation.
•Screw the drainage screw back on and refill the Wilo-Isar BOOST5 with water as de-
scribed in the chapter “Filling and Starting”.
8 Commissioning
8.1 Filling and starting Filling and starting
WARNING
Qualified personnel only.
CAUTION
Risk of damaging the pump
Never run the Wilo-Isar BOOST5 dry in order to prevent damage to the
mechanical seal.
Load operation (Fig.4a)
•Open all the valves to fill the pump with water.
•Connect the plug to the mains
•Set the change-over switch to the vertical position
•Press the button to start the Wilo-Isar BOOST5
Suction operation (Fig.4b)
•Unscrew and remove the filler screw and snifter valve screw.
•Pour around 1.5litres of water until it comes out of the aeration hole (Fig.6).
•Screw the filler screw and snifter screw back on.
•Open the water valve.
•Connect the plug to the mains
•Set the change-over switch to the vertical position
•Press and hold the buttons at the same time for 5seconds.
Wilo-Isar BOOST5 enters priming mode.
•Press the On/Off switch on the control panel to start priming.

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Installation and operating instructions • Wilo-Isar BOOST5 • Ed.03/12/2022 19
NOTICE
The priming process lasts no longer than 5minutes. At the end of each
minute, Wilo-Isar BOOST5 stops the electric pump automatically for
5seconds, then restarts it. And so on until Wilo-Isar BOOST5 is primed.
During this process, the LEDs will continue to flash. The priming stage
may be brought to a close by timeout (5minutes) or the end of the prim-
ing stage. The LEDs will stop flashing. If the pump does not prime itself,
repeat the operation.
8.2 Alarm codes
Flashing green LED + flashing red LED
Alarm 1 Low water. Starts after 7seconds of no wa-
ter at the suction side. Check for water at
the suction side and fill the pump. Wilo-Isar
BOOST5 attempts automatic restart after
1min, 15min, 30min, 1h, etc.
Alarm 2 The pump does not reach the set pressure.
Contact customer service.
Alarm 3 The tank’s preload pressure is too low; in-
flate the tank to 50% of working pressure
(for instance, if working pressure is 3bar, in-
flate the tank to 1.5bar).
Alarm 4 Discharge pressure below 0.2bar (broken
pipe). Reset possible in manual mode only.
Check why the pressure was reset to zero.
Alarm 5 Supply voltage too low. Ensure 230V ±10%
of power supply.
Alarm 6 OFF signal from exterior.
Example Pump in alarm state due to low water
LED 1 flashing + red LED flashing = low wa-
ter
Continuous green LED + flashing red LED
Alarm 1 Short-circuit. Turn off the device and con-
tact customer service. Reset possible in
manual mode only.
Alarm 2 Excess current. The current absorbed ex-
ceeds the authorised tolerance. Reset pos-
sible in manual mode only. Contact customer
service if the problem persists.
Alarm 3 Excessive module temperature. Check the
temperature of the fluid being pumped. If
the fluid temperature is not above 40°C,
contact customer service. Automatic reset if
the temperature falls below the alarm level.
Alarm 4 Excessive motor temperature. Check the
temperature of the fluid being pumped. If
the fluid temperature is not above 40°C,
contact a support centre. Automatic reset if
the temperature falls below the alarm level.
Alarm 5 Invalid pressure sensor signal. Contact cus-
tomer service.
Alarm 6 Invalid volume flow sensor signal. Contact
customer service.

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20 Installation and operating instructions • Wilo-Isar BOOST5 • Ed.03/12/2022
Continuous green LED + flashing red LED
Example Pump in alarm state due to short-circuit
LED 1 continuous + flashing red LED =
short-circuit
9 Maintenance Inspection and cleaning of non-return valve (Fig.8)
•After lowering the system pressure, unscrew and remove the filler screw.
•Remove the non-return valve unit by unscrewing the fastening screw.
•Inspect and clean it.
•Reinstall the non-return valve unit. Make sure it is oriented correctly.
•Screw the filler screw back on properly.
Inspection and cleaning of non-return valve (Fig.9)
•Lower the system pressure.
•Remove the cover and fork.
•Remove the bent connection.
•Extract the non-return valve.
•Check and clean it.
•Replace the non-return valve in its housing correctly.
•Reattach the bent connection, as well as the cover and fork.
10 Faults, causes and remedies WARNING
Risk of electric shock
Danger from electrical current must be eliminated. Ensure that the
pump’s power supply is switched off and secured against unauthorised
reactivation before performing any electrical work.
Fault LED signal Remedy
The control panel does not light up LEDs turned off Check that the side switch is set to “I”.
Check the presence of mains power supply and conformity of the
residual-current device.
Pump does not start Red LED continuously lit Switch on the pump by pressing the “I/O” button.
Flashing red LED See the list of alarm codes in Section8
Green LED continuously lit System pressure does not fall below the set working pressure.
Low water alarm Flashing red LED, flashing green
LEDs in position1
Check for water at the suction side.
Ensure the suction is not obstructed.
Fill and prime the pump.
Short-circuit alarm Flashing red LED, continuous green
LEDs in position1.
Check the pump is not blocked by opening the plug at the back
of the motor and turning the shaft
Check that the cable, plug and socket are intact and there are no
leakages
Low voltage alarm Flashing red LED, flashing green
LEDs in position5.
Voltage is more than 15% lower than value indicated on signal
plate. Stabilise voltage to keep it within the limits ±15%.