Wilo Wilo-COE-2-MHIL User manual

Wilo-COE-2-MHIL
Pioneering for You
4 096 656-Ed.4 / 2016-02-Wilo
en Installation and operating instructions
fr Notice de montage et de mise en service
it Istruzioni di montaggio, uso e manutenzione
es Instrucciones de instalación y funcionamiento
pt Manual de Instalação e funcionamento
el  Οδηγίεςεγκατάστασηςκαιλειτουργίας

Fig. 1
Fig. 2 Fig. 3
Fig. 4 Fig. 5
10
1
2
3
8
9
6
4
5
7
11
4
23
5
1
1
3
1
1
2
Fig. 6 Fig. 7
3
2
5
6
4
2

Fig. 8
1
2
Pression marche
On pressure Pressione marcia
Presión conectada Com pressão
Πίεση ενεργή
Pression arrêt
Off pressure
Pressione sentenza
Presión desconectada
Sem pressão
Πίεση ανενεργή
00
1
2
3
4
5
6
7
8
9
10
1
1,3
0,3
3,6
10,6
2345678910 11 12
0,3
0,9
1,8
5,2
234567
1
3
4
6
4/12 bars 10/15 bars
Pression arrêt
Off pressure
Pressione sentenza
Presión desconectada
Sem pressão
Πίεση ανενεργή
Pression marche
On pressure Pressione marcia
Presión conectada Com pressão
Πίεση ενεργή

4WILO SE 02/2016
English
1. General
The installation and operating instruction is an
integral part of the product and must be kept
readily available near the place where the product
is installed. Strict adherence to these instructions
is a precondition for the installation and proper
use of the product. The installation and operating
instruction corresponds to the relevant version of
the product and the underlying safety standards
valid at the time of going to print.
2. Safety
This instruction contains important information
which must be followed when installing and oper-
ating. For this reason, this operating instruction
must, without fail, be read by the service techni-
cian and the responsible operator before installa-
tion and commissioning.
Both the general safety instructions in the "Safety
precautions" section and those in subsequent
sections indicated by danger symbols should be
carefully observed.
2.1 Symbols used in this operating instruction
Symbols
General symbol for danger.
Warning of electrical danger.
NOTE: ....
Signals
DANGER! Extremely dangerous situation.
The non-observance could cause death or seri-
ous injuries.
WARNING! The user may suffer from injuries
(serious). The mention «Warning» involves
that personal (serious) injuries may happen
when precautions are not observed.
ATTENTI N! Damage could be caused to the
pump or installation. The mention «Attention»
is used to indicate that by ignoring the relevant
safety instructions, damage could be caused to
the pump or its operation.
REMARK! Useful remark for product handling. Any
possible difficulty is mentioned.
2.2 Staff training
The personnel installing the pump must have the
appropriate qualifications for this work.
2.3 Risks incurred by failure to comply with the
safety precautions
Failure to comply with the safety precautions
could result in personal injury or damage to the
pump or installation. It could also invalidate any
claims for warranty.
In particular, lack of care may lead to problems
such as:
• failure of important pump or machinery functions,
• failure of the maintenance and repairing process
recommended,
• danger to persons due to electrical, mechanical
and bacteriological influences material damages.
2.4 Safety precautions for the operator
Existing regulations for the prevention of acci-
dents must be followed.
Dangers caused by electrical energy are to be
excluded. Local or general rules issued by the IEC,
VDE, etc. as well as the local electricity supply
companies are to be observed.
2.5 Safety information for inspection and assembly
The user must ensure that all inspection and
installation works are carried out by authorised
and qualified specialists who have carefully stud-
ied these instructions.
Works on the pump or installation should only be
carried out when the machine has been brought
to a standstill.
2.6 Unauthorized modification and manufacture of
spare parts
Alterations to the pump or installation may only
be carried out with prior manufacturer's consent.
The use of original spare parts and accessories
authorized by the manufacturer will ensure safe-
ty. The use of any other parts may invalidate
claims invoking the liability of WILO for any con-
sequences.
2.7 Unauthorized operating methods
The operating safety of the pump or installation
supplied can only be guaranteed if it is used in
accordance with chapter 4 of the operating
instruction. The limiting values given in the cata-
logue or data sheet must neither be exceeded
nor allowed to fall below those specified.
3. Transport and storage
The booster is supplied on a pallet and is film-
wrapped to protect it against moisture and dust.
• The equipment must be transported by means of
authorised load devices.
• Transport straps must be placed round the steel
base frame.
• The manifolds will not withstand loads and
should not be used to secure loads in transit.
ATTENTI N! Loading the pipes in transit can
result in leaks.
When the product is delivered, check it for any
damage in transit. If any defect is found, inform
the delivery company (forwarding agent).
ATTENTI N!
If the product is installed later on, store it in a dry
place. Protect it from impacts and any outside
influences (moisture, frost, etc.).
andle the product with care.

5WILO SE 02/2016
English
4. Application
The booster is designed for boosting and main-
taining the pressure when the water supply net-
work is not well dimensioned or does not exist.
It is used for water supply in high-rise apart-
ments, hospitals, offices and industrial buildings.
Non aggressive clear fluids (potable water, water
containing glycol...).
A control box is used to control, monitor and
protect the boosting system.
The booster is either supplied from the public
water mains or from a mains collection tank.
In case of pressure deviations more than 1 bar in
the suction pipe it is recommended to use a pres-
sure relief valve. The pressure downstream of the
pressure relief valve (back-pressure) is the basis
for the total head calculation of the booster.
5. Product data
5.1 Type key
Wilo-COE-2-M IL-304-EM/BC
Booster name
2 : number of pumps
M IL : Type of pump (M IL)
304 : nominal output and number
of stages (3 m3/h 4 stages)
EM : Single-phase
DM : Three-phase
Control box name
5.2 Technical data
- Maximum operating pressure: 10 bars
- Maximum ambient temperature: 0 à +40°C
- Maximum water temperature: +55°C
- Three-phase supply voltage: 230/400V
(±10%) - 50 z
220/380V
(±10%) - 60 z
- Single-phase supply voltage: 220V (±10%)
50/60 z
230V (±10%)
50/60 z
- Nominal current: see type plate
5.3 Scope of delivery
- Booster.
- Installation and operating instruction of the
booster.
5.4 Accessories
as required
- Diaphragm pressure tank (Fig. 1, pos. 11)
- Dry running kit or tank
as option
- Insulation valves
- Vibration compensators
- Pressure relief valve
- Counterflanges according to manifold diameter
6. Description and operation
6.1 General description
The booster is a compact installation that is sup-
plied completely piped-up and ready to connect.
The only connections that have to be made are
for suction and delivery pipe and also the power
mains.
Every accessory ordered is delivery separately.
The relevant instructions or standards must be
observed for the connection to the public water
supply mains. Regulations from the water com-
panies must be included when appropriate. Local
conditions (e.g. a supply pressure that is too high
or fluctuates considerably and which might
require the installation of a pressure relief valve)
must also be observed.
6.2 Product description
6.2.1 The booster (Fig. 1)
1. Control box
2. Pressure switches
3. Pressure gauge
4. Multistage horizontal pumps M IL
5. Filling plug
6. Draining plug
7. Support and fixing frame
8. Suction manifold
9. Delivery manifold
10. Non-return valve
11. Tank (not delivered)
NOTE: each pump is fitted with insulation valves
on suction side and insulating valves and non-
return valves on delivery side.
6.2.2 Control box
• Ensure complete automatic operation of the
booster.
• Tightness, protection class IP 54.
• Thermal protection of the motors set in factory
according to nominal voltage mentioned on
motors.
• External safety and starting switch of the booster.
n front side (Fig. 2)
An electronic board:
1. LED power ON.
2. LED pump ON (one per pump).
3. LED pump fault (one per pump).
4. 3-position rotary switch (one per pump): AUTO
– O - AND.
5. LED dry-running.
Inside (Fig. 3)
1. Main switch with power supply connection terminals.
2. Motor magnetic circuit-breaker.
3. Transmitter with connection block for external
devices (pressure switch, float switch…).
4. Contactor.
5. Motor thermal protection relay.

6WILO SE 02/2016
English
6. Transformer board with protections for control
circuit.
Supply board (Fig. 4)
1. Primary transformer fuses.
2. Secondary transformer fuses.
3. Voltage selector switch.
Transmitter (Fig. 5, 6, 7)
Fig. 5. Connection board for external devices.
Fig. 6. Transmitter.
Fig. 7. Bypass transmitter.
Pressure switches for automatic operation
(Fig. 8)
Both pressure switches allow automatic ON/OFF
switching of both pumps. They are standard.
1. Setting nut for pump stop pressure – high pres-
sure (PF).
2. Deviation setting nut.
6.2.3 Diameter of the manifolds
COE 2-M IL series 3/5 m3/h: threaded manifolds
2"
6.2.4 Lack of water protection
The booster needs to be fitted with a dry-run-
ning protection device:
• Connection to public water supply: pressure
switch to be assembled on the suction manifold
and connected to the control box.
• Connection to a tank: float switch to be installed
on the tank and connected to the control box.
6.3 Product function
6.3.1 perating
The control box ensures the automatic operation
of the booster.
When the pressure drops and reaches the setting
value defined for the pressure switch P1, pump 1
starts. If the pressure drops further and reaches
the setting value of the pressure switch P2,
pump 2 starts.
Then the pressure increases and reaches the set-
ting value of the pressure switch 2, pump 2
stops. When pressure reaches the setting value
of the pressure switch P1, pump 1 stops.
In case of failure from the transmitter it can be
replaced by the module bypass de permutation.
There is no more pump change, pressure switch
1 monitors pump 1 whereas the pressure switch
2 monitors pump 2.
Pump change
To get the same using and operating time for all
the pumps, a pump cycling for the starting order
is defined after each stop of the main pump.
perating mode
A 3-position rotary switch on the front part (Fig.
2, pos. 4) allows to select 3 operating modes per
pump:
- Position O: The pump is OFF.
- Position AND: The pump is operating in contin-
uous mode as long as the switch is maintained in
this position. When releasing it, the switch is
back to position O.
- Position AUTO: All control functions of the
booster are operative.
Magnetic fault
A magnetic circuit breaker (Fig. 3, pos. 2) pro-
tects the motors against shortcircuit.
Heat fault
A thermal relay is used as protection against
motor overload (Fig. 3, pos. 5).
6.3.2 Input (Fig. 5)
1 and 2. Lack of water: a pressure switch (contact
NO) or a float switch protects the booster
against lack of water, an input ON/OFF is dedi-
cated to this sensor.
5 seconds are needed to start again the booster
after closing the contact (water back).
6.3.3 Signalling (Fig. 2)
Information per booster
1. Power ON: mains voltage signalling
(fixed yellow LED).
5. Lack of water: lack of water signalling
(fixed red LED).
Information per pump
2. Pump ON: pump operating indication
(fixed green LED).
3. Pump alarm: pump fault indication (red LED)
when thermal relay is switched on (motor over-
load).
7. Installation
7.1 Local
Install the booster in a room that provides an
easy access, well ventilated and frost-proof.
Be sure that the dimension of the technical room
door is adequate to enter a booster.
Adequate space must be provided for mainte-
nance work. An easy access to the installation
shall be ensured from at least two sides.
7.2 Assembling
Assembling on well smooth and horizontal floor
with fixing per foundation bolts. Plan insulating
material (cork or reinforced rubber) under the
concrete pad to avoid any emission of water cir-
culating noise.
7.3 Hydraulic connection
ATTENTI N! Observe the requirements from the
water supply companies and the local rule into
force.
- The connection of the suction and delivery man-
ifolds can be made either on the right or left
hand sides of the installation. It is recommended
to close the ports that are not used with thread
caps.
- Valves must be fitted on the manifolds to easily
separate the booster if need be.
- The installation must be fitted with at least one
diaphragm pressure tank to be assembled on the

WILO SE 02/2016
English
delivery manifold, 18 and 24 litre capacities (Fig.
1), just beside the booster for higher capacities.
- The existing pipes must be installed free from
stresses. Compensators or flexible connecting
pipes are recommended for this purpose in order
to avoid stresses on the pipe connections and
minimise the transmission of vibrations to the
building installation.
Connection to public water supply
Be sure the installation can withstand the maxi-
mum pump pressure at zero flow plus the public
water mains pressure. Otherwise connect the
pressure relief valve to the booster outlet.
We recommend to install a pressure relief and
regulating valve on the booster inlet, on the
water supply inlet to avoid any pressure varia-
tions at the booster inlet.
Connection on load to a tank
Be sure the installation can withstand the maxi-
mum pump pressure at zero flow plus the public
water mains pressure. Otherwise connect the
pressure relief valve to the booster outlet behind
the tank.
Connection on suction to a tank
Be sure that the losses of head do not exceed the
suction capacity of the pumps. It is recommend-
ed to use a foot-strainer valve with a pipe whose
dimension is equal to or higher than the suction
nominal diameter.
7.4 Electrical connection
WARNING! The electrical connection must be
performed according to the local regulations by
an electrical installation engineer approved by
the local utility.
To make the electrical connection, the corre-
sponding installation and operating instructions
and attached electrical circuit diagrams must be
observed. General points to be considered are
listed below:
• the type of current and voltage of the mains
connection must comply with the data on the
type plate and the circuit diagram of the control
unit.
• as protection measure, the booster must be
earthed according to the regulations (i.e. accord-
ing to the local regulations and circumstances) ;
the connections intended for this purpose are
identified accordingly (see circuit diagram).
Power supply cable
The electric supply cable shall be correctly
dimensioned according to the total booster
power (see type plate).
Connecting the control box on a voltage differ-
ent from the one mentioned in the description is
not possible (see chapter 5.2. technical data).
NOTE: for any further details an electric diagram
is available inside the control box.
ATTENTI N! Do not forget to connect the earth
terminal.
Lack of water protection
An input ON/OFF (250V 2A) (Fig. 5) protects the
booster against lack of water, a pressure switch
(Normally Open) or a float switch shall be con-
nected to this input.
ATTENTI N! Do not apply external voltage to the
terminals.
8. Commissioning
ATTENTI N! Never let the booster run as dry
over a few seconds. Dry running may damage the
mechanical seal.
Before switching on for the first time, check that
the customer's wiring has been done correctly,
particularly the earthing.
ATTENTI N! Tighten all the supply terminals
before starting the booster.
8.1 Tank inflating
With no water in the tank pressurize the tank to
a pressure 0.3 bar lower than the starting pres-
sure of the pumps.
ATTENTI N! Do not exceed the maximum value
of tank first-inflating.
8.2 Filling - Degazing
Connection to public water supply or on load to
a tank
- Check the water supply origin (adequate water
level in the tank).
- Open the booster supply valve to get water
inside.
- Open the filling plugs (Fig. 1, pos. 5) of the
pumps and wait as long as water is getting inside
before closing them again.
- Keep the switch (Fig. 2, pos. 4) on " AND" to
check priming. If need be test the pumps one
after the other.
Connection on suction to a tank
- Close the delivery valve.
- Open the suction valve.
- Screw off the filling plugs and remove them.
- With a funnel placed inside the port, fill in slowly
and completely the pumps and the suction pipes.
- After water and air exit, filling is finished.
- Screw on the filling plugs (Fig. 1, pos. 5).
- Set the switch (Fig. 2, pos. 4) on " AND" to
check priming. If need be test the pumps one
after the other.
8.3 Motor sense of rotation
The electric connection of the pumps to the
control box is performed in the factory.
Nevertheless in case of three-phase version, you
shall check the right sense of rotation as follows:
- Be sure there is water inside the booster.
- Position the pump switches (Fig. 2, pos. 4) on
"OFF".
- Disconnecting switch ON.
7

8WILO SE 02/2016
English
- Position the switch of pump 1 on “ AND", the
pump shall start (LED lit on the control box);
check the correct sense of rotation of the motor.
- Proceed in the same way for pump 2.
- In case of wrong direction, reverse 2 wires of the
phase.
WARNING! Before changing over the phases,
switch off the installation main switch.
- After this operation, position the pump switches
on “OFF“.
8.4 Setting description
8.4.1 Pressure switch setting (Fig. 8)
The adjustment is made by turning the nut
(pos. 1) to set the high point (stopping of pump)
and the nut (pos. 2) to adjust the low point
(starting of pump).
- Turning the nut (pos. 1) clockwise increases the
value of the hight point.
- Turning the nut (pos. 2) clockwise decreses the
value of the low point (the difference increases).
Before adjusting pressure switches PR1 and PR2 ,
choose the starting and stopping pressures (if nec-
essary, use the nomographs).
Proceed as follows:
Remove the cover of contactor PR1.
Turns the nuts (item 1 & 2)
fully clockwise without tightening them.
Set the switch of on pump to “MANU” and hold to
increase the pressure in the installation.
Release the switch at the desired pump stopping pressure
(read on pressure gauge).
Turn the nut (item 1) anticlockwise until there
is an audible click.
Open the discharge valve to lower the pressure
to the desired pump starting level
(read on pressure gauge).
Turn the nut (item 2) anticlockwise.
If there is a click.
Set the switch of one pump to
“AUTO” and hold to check
you adjustments.
adjustment OK
Put the cover
back on.
Remove the
cover of
contactor
PR2.
Commission
Adjustments
imprecise.
See § "prin-
ciple" and refi-
ne the
Adjustments.
adjustment OK
If no click.
Check your operating points
and the tank pre-pressuri-
zation pressure
(it must be 0,3 bar
less than the pump
starting pressure).
If necessary, choose 2 new
points and adjust the pre-
pressurization pressure.
NOTE : the high points (pressure – stop) of both
pumps are similar. The low points (pressure –
start) show a deviation of 0.5 bar Pf from PR2
< 0.5 Pf from PR1.
8.4.2 Setting of the motor protection
Check voltage set on thermal relays
(Fig. 3, pos. 5) by comparing with the data men-
tioned on the pump type plates. If need be reset
the value by turning the thumb wheel.
8.4.3 Float switch for connection to a tank
Set the float switch in order to keep a minimum
water level about 40 cm over the booster inlet
port to be able to resist to the strainer foot-
valve.
Be sure the electric connection is right by activat-
ing the float switch per hand to generate the
lighting of the dry running LED on the control box.

9WILO SE 02/2016
English
8.5 Start
The maximum operating pressure in the installa-
tion is equal to the pressure at zero flow of the
pumps plus the water supply pressure at booster
inlet if need be.
On the control box position the mains switch on
"I" and the button of the pumps on “Auto".
The control box now ensures the automatic
operating of the booster.
ATTENTI N! Do not let the pump operate with
delivery valve closed beyond some minutes.
9. Maintenance
- No particular maintenance is recommended for
the booster when operating.
- Motor bearings are greased for life-time.
- No maintenance for the mechanical seal when
operating.
- In long period of frost and stop of the pump, it is
recommended to drain the pump by screwing off
the bottom plug.
ATTENTI N! Fill in the pump before any new
start.
10. Faults, causes and remedies
If the fault cannot be solved, please contact
WIL customer services.
Faults Causes Remedies
One or two pumps fail to prime Air leak at suction Check tightness of all suction pipe con-
nections.
Check if the tank suction strainer is
covered with water
Foot-valve strainer not tight or obstruc-
ted
Check tightness of the valve, replace it if
necessary
Large losses of head at suction Calculate the losses of head and make
sure they are compatible with the pump
NSP
Public water pressure too low or zero If it recurs, it is recommended to use a tank
Suction head too high Be sure that the minimum water level of
the tank is compatible with the NPS of
the pumps
Suction piping obstructed or valve on
suction manifold closed
Check valve opening and clean the piping
if necessary
Pumps turn in the reverse direction
(three-phase)
Cross 2 supply wires on the motor termi-
nal blocks
One pump fails to run Thermal relay tripped The pump "fault" indicator on the control
box must be lit. Check the setting of the
current
Magnetic circuit breaker tripped Switch it again. If tripping recurs, check
the output current of the motor concer-
ned. If this current is much higher than
the one mentioned on the motor type
plate, the circuit breaker is defective and
shall be replaced
Pump shaft blocked Switch off the electric supply of the con-
trol box and then check the shaft turns
freely. If it is blocked, dismantle the
pump
Winding fault Disconnect the terminal block of the
motor concerned. Check the network at
the terminals and the stator insulation.
Replace the motor if necessary
Contactor coil blown Replace it

10 WILO SE 02/2016
English
11. Spare parts
All spare parts must be ordered through WILO
Customer Services.
In order to avoid any mistakes, please specify the
name plate data for orders.
Spare parts catalogue is available at
www.wilo.com.
Subject to technical alterations!
Faults Causes Remedies
No delivery pressure Flow higher than booster capabilities Plan to replace the booster by a more
adequate one (do not forget to contact
us in any case)
One or two pumps not primed Check that the suction strainer does not
let air in or the tank filling point is too
close from the strainer
Public water pressure lower than the
minimum pressure planned
Contact the public water supply compa-
ny or replace the booster.
Contact us
Pumps turn in the reserve direction Cross 2 supply wires at the motor termi-
nal blocks
A pump is obstructed by particles ave the pump dismantled and cleaned
Voltage of the motors too low Check the voltage on motor terminals
Contactor tripping too frequent, starting
frequency too high
Required pressure wrong set Reset it
Installation capacity too low Add a tank
No air inside the tank Pressurize the tank or replace the bladder
Tripping frequency of dry running safety
too high
Setting of dry running pressure switch-
too high
Set the pressure switch correctly
Drop of the public water supply pressure
when starting the pumps
Set the dry running pressure switch to
the minimum value. If it recurs, the public
water mains is inadequate, check the
pressure with the pressure gauge when
starting the pumps or contact the public
water mains service
Operating automatism device defective Wires disconnected Check all connections to the terminal
block of the control box
Transmitter defective Install the bypass on the transmitter base
Discharge check valve not tight Valve diaphragm destroyed Change the valves

Argentina
WILO SALMSON
Argentina S.A.
C1295ABI Ciudad
Autónoma de Buenos Aires
T [phone]
[email protected]
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WILO Australia Pty Limited
Murrarrie, Queensland, 4172
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of[email protected]
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Importacao Ltda
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Calgary, Alberta T2A 5L7
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101300 Beijing
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Ocina Comercial
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Siboney. La Habana. Cuba
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com
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Private Limited
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Lebanon
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03202 Vilnius
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1551 NA Westzaan
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0975 Oslo
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5-506 Lesznowola
T [phone]
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Portugal
Bombas Wilo-Salmson
Sistemas Hidraulicos Lda.
4475-330 Maia
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[email protected]
Romania
WILO Romania s.r.l.
077040 Com. Chiajna
Jud. Ilfov
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[email protected]
Russia
WILO Rus ooo
123592Moscow
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[email protected]
Saudi Arabia
WILO Middle East KSA
Riyadh 11465
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[email protected]
Serbia and Montenegro
WILO Beograd d.o.o.
11000 Beograd
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of[email protected]
Slovakia
WILO CS s.r.o., org. Zložka
83106 Bratislava
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[email protected]
Slovenia
WILO Adriatic d.o.o.
1000 Ljubljana
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[email protected]
South Africa
Wilo Pumps SA Pty LTD
1685 Midrand
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[email protected]
Spain
WILO Ibérica S.A.
8806 Alcalá de Henares
(Madrid)
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[email protected]
Sweden
WILO NORDIC AB
35033 Växjö
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[email protected]
Switzerland
Wilo Schweiz AG
4310 Rheinfelden
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[email protected]
Taiwan
WILO Taiwan CO., Ltd.
24159 New Taipei City
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[email protected]
Turkey
WILO Pompa Sistemleri
San. ve Tic. A.S¸
34956 İstanbul
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[email protected]
Ukraina
WILO Ukraina t.o.w.
08130 Kiew
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[email protected]
United Arab Emirates
WILO Middle East FZE
Jebel Ali Free zone – South
PO Box 262720 Dubai
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[email protected]
USA
WILO USA LLC
Rosemont, IL 60018
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[email protected]
Vietnam
WILO Vietnam Co Ltd.
Ho Chi Minh City, Vietnam
T [phone]
[email protected]
Wilo – International (Subsidiaries)
Further subsidiaries, representation and sales ofces on www.wilo.com Januar 2016

Pioneering for You
WILO SE
Nortkirchenstraße 100
D-44263 Dortmund
Germany
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www.wilo.com