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High-efficiency Circulator Pump

Calio Pro / Calio Pro Z

Installation/Operating Manual

Summary of Contents for Calio Pro

Page 1: ...High efficiency Circulator Pump Calio Pro Calio Pro Z Installation Operating Manual...

Page 2: ...contents provided herein must neither be distributed copied reproduced edited or processed for any other purpose nor otherwise transmitted published or made available to a third party without the man...

Page 3: ...13 3 5 Disposal 13 4 Description 15 4 1 General description 15 4 2 Product information as per Regulation No 1907 2006 REACH 15 4 3 Designation 15 4 4 Name plate 16 4 5 Design details 17 4 6 Configurat...

Page 4: ...42 7 2 4 Dynamic Control 44 7 2 5 Open loop control 46 7 3 Functions 47 7 3 1 Dual pump operation DUAL 47 7 3 2 Protective functions 48 7 3 3 Saving data 48 7 3 4 Error messages 48 7 4 Additional fun...

Page 5: ...ssary Discharge line The pipeline which is connected to the discharge nozzle Pump set Complete pump set consisting of pump drive additional components and accessories Suction lift line suction head li...

Page 6: ...to claim under warranty 1 2 Target group This operating manual is aimed at the target group of trained and qualified specialist technical personnel Section 2 3 Page 9 1 3 Other applicable documents T...

Page 7: ...serious injury Electrical hazard In conjunction with one of the signal words this symbol indicates a hazard involving electrical voltage and identifies information about protection against electrical...

Page 8: ...rection arrow Markings for connections Name plate The operator is responsible for ensuring compliance with all local regulations not taken into account 2 2 Intended use The pump set must only be opera...

Page 9: ...of any and all rights to claims for damages Non compliance can for example have the following consequences Hazards to persons due to electrical thermal mechanical and chemical effects and explosions...

Page 10: ...n it has been disconnected from the power supply de energised The pump set must have cooled down to ambient temperature Pump pressure must have been released and the pump must have been drained When t...

Page 11: ...nd without slack Observe the information on weights centre of gravity and fastening points Observe the applicable local occupational safety regulations and accident prevention regulations Use tested a...

Page 12: ...red prior to putting the pump into storage If commissioning is to take place some time after delivery we recommend that the following measures be taken for pump set storage Store the pump set in a dry...

Page 13: ...following web site www ksb com certificate_of_decontamination 3 5 Disposal DANGER Strong magnetic field in the pump rotor area Danger of death for persons with pacemaker Interference with magnetic dat...

Page 14: ...t marked with the adjacent symbol must not be disposed of in household waste at the end of its service life Contact your local waste disposal partner for returns If the used electrical or electronic e...

Page 15: ...not chemically and mechanically aggressive to the pump materials 4 2 Product information as per Regulation No 1907 2006 REACH For information as per chemicals Regulation EC No 1907 2006 REACH see http...

Page 16: ...44 XXXX1 12 Made in Turkey Fig 3 Name plate example 1 Type series size 7 Material number 2 Supply voltage frequency 8 Current input 3 Thermal class 9 Power input 4 Enclosure 10 Temperature class 5 Pre...

Page 17: ...nged Operating modes Constant pressure control Proportional pressure control Dynamic Control Open loop control with 3 speed levels Automatic functions Continuously variable speed adjustment depending...

Page 18: ...s lubricated and cooled by the fluid handled The electronic system housing is equipped with a plug type connector Depending on the design the pump set is fitted with high quality ceramic bearings or c...

Page 19: ...ms are included in the scope of supply Pump set Sealing elements Plug type connector to power supply Installation operating manual Single pump Two piece thermal insulation shell single pump Twin pump...

Page 20: ...the pump set Observe the permissible ambient conditions and the pump set s type of enclosure Observe the permissible ambient temperatures Ambient temperatures 0 C are not permitted In the event of out...

Page 21: ...pump set with the electronic system housing pointing downwards Undo the hexagon socket head cap screws Then turn the electronic system housing CAUTION Air entering the pump Damage to vertically instal...

Page 22: ...he display must always be in a readable position Positioning must be effected with the pump set removed from the system 1 Fig 7 Turning the electronic system housing 1 Undo four hexagon socket head ca...

Page 23: ...n the pipe union hand tight with a suitable tool Flanged pump 1 Position the pump set as indicated in an easily accessible place An arrow on the pump casing and thermal insulation shell indicates the...

Page 24: ...g Damage to the pump Flush the piping prior to commissioning or replacing the pump Remove any foreign matter NOTE Installing check and shut off elements in the system is recommended depending on the t...

Page 25: ...Heat build up at motor housing and electronic system housing Pump overheating Do not insulate the motor housing and electronic system housing Heating application The supplied thermal insulation shell...

Page 26: ...ge at the motor terminals Prevent the fluid from flowing back by closing the shut off elements DANGER Heat damage to the cable sheath Danger from electric shock Make sure the cables are never laid in...

Page 27: ...al AC DC sensitive residual current device to DIN VDE 0160 is recommended Conventional residual current devices might either fail to trip or trip erroneously Discharge current per pump 3 5 mA 5 6 1 Co...

Page 28: ...ction is positioned correctly 1 Click Fig 11 Fastening the contact insert to the plug housing 1 Projection 8 Screw the union nut and joint ring onto the thread at the plug housing Tightening torque 1...

Page 29: ...of the terminal wiring compartment 3 Prepare the cable gland that belongs to the DUAL terminal pair 4 Guide the dual connection cable through the cable gland and into the connection space 5 Screw the...

Page 30: ...2 Fig 15 Wiring diagram for the general fault message 1 No general fault message or no power supply alarm not active 2 General fault message pump rotor not rotating alarm active NC NC contact normally...

Page 31: ...and into the connection space 5 Screw the union nut and joint ring on hand tight 6 Wire the electric cable to the terminal pair of the general fault message relay See wiring diagram for the general f...

Page 32: ...ge lines closed Hot fluids escaping Never operate the pump with the shut off elements in the suction line and or discharge line closed Only start up the pump set against a slightly or completely open...

Page 33: ...fied minimum pressure for operating the pump set Always operate the pump set within the permissible operating range The system piping and the pump set have been primed with the fluid to be handled 1 F...

Page 34: ...0 starts per 24 hours 6 2 2 Ambient temperature CAUTION Operation outside the permissible ambient temperature Damage to the pump set Observe the specified limits for permissible ambient temperatures O...

Page 35: ...applications Danger of poisoning Never use the pump for drinking water or foodstuff applications CAUTION Unsuitable fluids Damage to the pump Never use the pump to handle corrosive combustible or exp...

Page 36: ...ent in the discharge line 2 Switch off the pump set For prolonged shutdown periods CAUTION Risk of freezing during prolonged pump shutdown periods Damage to the pump Drain the pump and the cooling hea...

Page 37: ...escaping fluid As soon as the work is completed properly re install and re activate any safety relevant devices and protective devices For returning the equipment to service observe the sections on c...

Page 38: ...ved the control unit will revert to the previous settings All settings are made using the control element on the housing front The control element comprises three control pushbuttons Table 14 Overview...

Page 39: ...hts up when this operating mode is active Proportional pressure Control operating mode Symbol lights up when this operating mode is active ECO Dynamic Control operating mode Symbol lights up when this...

Page 40: ...tionally be selected for underfloor heating systems for example If noises are audible at low flow rates select the Proportional pressure Control operating mode p v The setting of the discharge head se...

Page 41: ...1 Hmin Hmax 2 HS 2 H Fig 18 Constant pressure Control function Setting H Hmax HS Hmin Q Fig 19 Constant pressure Control settings Table 17 Selecting Constant pressure Control and the setpoint co Step...

Page 42: ...characteristic curve See type series booklet Control curve too low undersupply Control curve too high increased energy input If the system characteristic curve is unknown Dynamic Control is recommende...

Page 43: ...ive operating mode Step 2 Selecting the Proportional pressure Control operating mode Press the control buttons or until the symbol for Proportional pressure Control flashes Press the control button to...

Page 44: ...is higher than the minimum characteristic curve5 4 The control system shifts the control curve downward and power input is reduced automatically To ensure sufficient supply the pump set switches to a...

Page 45: ...flashing symbol indicates the active operating mode co Step 2 Selecting Dynamic Control Press the control buttons or until the symbol for Dynamic Control flashes Press the control button to confirm t...

Page 46: ...Step 1 Activating the setting mode Press and hold the control button for 3 seconds The flashing symbol indicates the active operating mode Step 2 Selecting the Open loop Control operating mode Press...

Page 47: ...p changeover If a pump set used in dual pump operation has been replaced the operating hours per pump set can be balanced out with the intelligent pump changeover function Regular pump changeover take...

Page 48: ...off 7 3 4 Error messages Function The pump set outputs warnings and alerts as a sequence of numbers and a combination of symbol and LED on the display Warnings Fig 26 Pump set status Warning The disp...

Page 49: ...w is caused by an externally forced flow Check the hydraulics of the system system schematic piping layout Fit a check valve if required 51 The temperature limit inside the pump set has been reached T...

Page 50: ...e pump set cool down Verify the permissible temperature ranges of the fluid temperature and the ambient temperature Section 6 2 Page 34 53 Excessive temperature inside the pump set Pump set has been s...

Page 51: ...the additional function setting mode Press and hold the control button for 10 seconds The additional functions setting mode is active The symbol flashes HL Step 2 Activating the setting mode Press th...

Page 52: ...ss the process is cancelled and venting has to be re started Table 25 Activating disabling venting Step 1 Activating the additional function setting mode Press and hold the control button for 10 secon...

Page 53: ...deactivating the test alert Step 1 Activating the additional function setting mode Press and hold the control button for 10 seconds The additional functions setting mode is active The symbol flashes...

Page 54: ...rol button The pump size and the current firmware version are briefly shown on the display The display then changes automatically to its normal operating display 7 5 Resetting to factory settings Rese...

Page 55: ...ertificate of decontamination for the pump 8 3 Removing the pump set from the piping DANGER Pump acting as a generator when running in reverse Danger to life from hazardous induction voltage at the mo...

Page 56: ...Keep a safety distance of at least 0 3 m from electronic components WARNING Hot surface Risk of injury Allow the pump set to cool down to ambient temperature CAUTION Strong magnetic field in the pump...

Page 57: ...energise the pump set and make sure the pump set cannot be started up unintentionally 2 Disconnect the plug type connector from the pump set 3 Lever out the contact insert with a suitable tool as show...

Page 58: ...ts up service mode activated Disconnect the power supply Then re establish the power supply Check the power supply and fuses Disconnect the plug power cable or press the control buttons and simultaneo...

Page 59: ...EN 10 Related Documents 10 1 Sectional drawing with list of components 102 310 230 81 59 818 Fig 30 Sectional drawing Table 31 List of components Part No Description Part No Description 102 Volute ca...

Page 60: ...8 Fluid handled Density 35 I Installation at site 20 Intended use 8 K Key to safety symbols markings 7 M Manual functions 17 N Name plate 16 O Operating limits 34 Operating modes 17 Other applicable d...

Page 61: ......

Page 62: ...KSB SE Co KGaA Johann Klein Stra e 9 67227 Frankenthal Germany Tel 49 6233 86 0 www ksb com 1157 820 01 EN...

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KSB Calio Pro, Installation & Operating Manual

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