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7 Operation

37 of 68

Calio

1157.821/04-EN

7 Operation

7.1 Control panel

All settings are made using the control element on the housing front. 
The control element consists of a dial and a control button. The control button is
arranged in the middle of the dial and can be pressed down.
Setpoint values can be adjusted by turning the dial in increments down to a
minimum of 0 %. The setpoint value is shown as a numerical value on the display.
10 LED segments are arranged around the dial. These segments represent setpoint
values ranging from 0 - 100 % in increments of 10 %. The LED segments light up in
blue when settings are being made at the pump. In the following example the
setpoint = 40 %.

NOTE

If set to 100 %, the performance limits may cause the actual value to be slightly
below the maximum characteristic curve, depending on the pump and operating
point.

 

 

%

II 

III 

Fig. 17: 

Control element

I

Dial

II Control button

III 10 LED segments (lit up in blue when pump settings are being made)

Settings overview

Table 14: 

Overview of settings using the control button

Menu

Time to open the corresponding menu

Details

Operating mode

Press and hold the control button
> 3 seconds

(

ð

 Section 7.2, Page 39)

Functions

Press and hold the control button
> 6 seconds

(

ð

 Section 7.3, Page 49)

Locking the control panel

Press and hold the control button
> 9 seconds

(

ð

 Section 7.1.1, Page 37)

Setback operation

Press and hold the control button
> 12 seconds

(

ð

 Section 7.3.5, Page 57)

Resetting the factory setting

Press and hold the control button
> 30 seconds

(

ð

 Section 7.4, Page 59)

7.1.1 Locking the control panel

For locking the control panel to prevent unauthorised access press and hold the
control button for 10 seconds. The current status of the control panel is shown on the
display:

H-L = control panel locked

H-O = control panel unlocked

Use the dial to change between H-L and H-O. To save the selected status press the
control button. The pump size and the current firmware version are briefly shown on
the display. The factory settings can only be reset when the control panel is unlocked.

Summary of Contents for Calio

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

Page 2: ...s 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 manufacture...

Page 3: ...n 12 3 3 Storage preservation 12 3 4 Return to supplier 13 3 5 Disposal 13 4 Description 14 4 1 General description 14 4 2 Product information as per Regulation No 1907 2006 REACH 14 4 3 Designation 1...

Page 4: ...Dynamic control 43 7 2 6 Eco Mode 44 7 2 7 Open loop control 46 7 3 Functions 49 7 3 1 Remote ON OFF digital input 49 7 3 2 External analog 0 10 V DC signal 49 7 3 3 Dual pump operation DUAL 51 7 3 4...

Page 5: ...r accessories Pump set Complete pump set consisting of pump drive additional components and accessories Setback operation Setback Operation avoids running the pump set at an unchanged control curve du...

Page 6: ...m 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 Table 1 O...

Page 7: ...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 voltage...

Page 8: ...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 operated in t...

Page 9: ...ture of warranty cover and 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 chemic...

Page 10: ...onnected 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 taking the pump set...

Page 11: ...damage in writing immediately 3 2 Transport DANGER The pump set could slip out of the suspension arrangement Danger to life from falling parts Always transport the pump set in the specified position O...

Page 12: ...nated or damaged openings and connections Leakage or damage to the pump Clean and cover pump openings and connections as required prior to putting the pump into storage If commissioning is to take pla...

Page 13: ...riers electronic devices components and instruments Uncontrolled magnetic attraction forces between magnet equipped components tools or similar Keep a safety distance of at least 0 3 m WARNING Fluids...

Page 14: ...sive fluids which are 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 19...

Page 15: ...201920 XXXX1 Table 6 Key to the production number Code Description 291349XX Material number A Version of EU Declaration of Conformity 2019 Year of production 20 Week of production XXXX1 Consecutive nu...

Page 16: ...al value of the differential pressure Dual pump operation Peak load operation Setback operation External start stop Deblocking function Self venting function Soft start Full motor protection with inte...

Page 17: ...otating assembly is lubricated and cooled by the fluid handled The lubricating system high quality graphite bearings and precision balanced rotor ensure smooth running and a long service life The inte...

Page 18: ...he model the following items are included in the scope of supply Pump set Two piece thermal insulation shell single pump 2 gaskets Installation operating manual 4 9 Dimensions and weights For dimensio...

Page 19: ...fluid to be handled matches the description of suitable fluids Section 6 2 5 1 Page 35 5 3 Installing the pump set DANGER Leakage at the pump Hot fluids escaping Fit the sealing elements and make sur...

Page 20: ...pump parts to prevent tilting or tipping over Fig 6 Placing the pump set down safely The control panel can be turned The position must be effected with the pump set removed from the system The pump s...

Page 21: ...tion shell indicates the direction of flow 2 Accurately insert the sealing element 3 Bolt the pump flange to the pipe flange 4 Tighten the bolts hand tight with an assembly tool e g wrench 5 Accuratel...

Page 22: ...losure insulation WARNING The pump takes on same temperature as the fluid handled Risk of burns Insulate the volute casing Fit protective equipment 5 6 Electrical connection DANGER Electrical connecti...

Page 23: ...ater dripping onto the cables will run off NOTE The cable must be of type H05VV F 3G1 or similar with an outside diameter 7 2 mm Circuit breaker 10 16 A minimal rated current x 1 4 slow blowing fuse o...

Page 24: ...intentional start up The wiring diagram is on hand Section 10 2 Page 64 1 Unscrew the cable glands IPX4D 2 Undo and store the 2 screws of the cover of the terminal wiring compartment 3 Remove the cove...

Page 25: ...al code Frequency of starts Contact rating Dual pump configuration DUAL 1 5 mm2 H Signal High L Signal Low Power supply 1 230 V AC 10 50 Hz 60 Hz 1 5 mm2 PE N N L L 20 24 hours In operation message 1...

Page 26: ...l The information can be accessed at the status terminal pair with terminals NC COM NO 1 2 COM Fig 9 Wiring diagram for the in operation message 1 Pump not in operation rotor not rotating alarm active...

Page 27: ...ductive connection to C 5 6 1 4 External analog 0 10 V DC signal Fig 11 Terminal pair 0 10 V Vin 0 10 V R Signal 5 V 0 V GND The wiring diagram is on hand Section 10 2 Page 64 1 Connect the external a...

Page 28: ...e the pumps at their Modbus terminals in line topology as illustrated Use a network cable with a defined wave impedance cable type B to TIA 485 A 2 Connect a terminating resistor of 120 to the first a...

Page 29: ...f up to 1 5 mm2 6 Fit the cover of the terminal wiring compartment Fasten it with the 2 screws 7 Tighten the cable glands IPX4D Connection to the Modbus master Connect all pump sets to a Modbus master...

Page 30: ...iceTool a5 Dual pump configuration The terminating resistor is enabled when the corresponding pump integrated DIP switch in the terminal wiring compartment next to the Modbus terminal pair is enabled...

Page 31: ...pump to stand by pump will not have any impact on the duty point and operating mode Connect the control modules of the two pumps with a commercial shielded data cable The terminals of the RUN terminal...

Page 32: ...n compliance with the permissible pressure and temperature limits if the pump is operated with the suction and discharge lines closed Hot fluids escaping Never operate the pump with the shut off eleme...

Page 33: ...out liquid fill Prime the pump as per operating instructions Always operate the pump within the permissible operating range WARNING Hot surfaces Pump and piping take on the temperature of the fluid ha...

Page 34: ...TION Operation outside the permissible ambient temperature Damage to the pump set Observe the specified limits for permissible ambient temperatures Observe the following parameters and values during o...

Page 35: ...e or explosive fluids Never use the pump to handle waste water or abrasive fluids Do not use the pump for foodstuff applications Heating water to VDI 2035 Higher viscosity fluids water glycol mixture...

Page 36: ...lied for the functional check run of the pump 1 For prolonged shutdown periods start up the pump set regularly between once a month and once every three months for approximately five minutes This will...

Page 37: ...gments lit up in blue when pump settings are being made Settings overview Table 14 Overview of settings using the control button Menu Time to open the corresponding menu Details Operating mode Press a...

Page 38: ...lectrical input power Symbol lights up Display shows the electrical power W m Calculated head mWC Constant pressure Control operating mode Symbol lights up when this operating mode is active Proportio...

Page 39: ...set to Proportional pressure Control p v and medium output setpoint 50 7 2 2 Temperature governed differential pressure control The temperature governed differential pressure control increases or decr...

Page 40: ...ch has last been set Step 4 a Confirming the current setpoint Press the control element Step 4 b Changing the setpoint Turn the control element and set the required setpoint in increments of 1 within...

Page 41: ...Within the permissible flow rate range the Proportional pressure Control decreases or increases the differential pressure setpoint between 1 2 HS and HS factory setting Q 1 HS 1 Hmin Hmax 1 2 HS H Fig...

Page 42: ...es the setpoint turning it anti clockwise decreases the setpoint The LED segments will light up in increments of 10 Press the control element to save the setpoint NOTE If 10 seconds pass without any s...

Page 43: ...t the thermostatic valves is reduced Application If the system characteristic curve is known e g hydraulic balancing Set the set value manually Select a control curve that is minimally above the chara...

Page 44: ...ode operating mode is selected the Eco Mode characteristic curve 4 is a parabola instead of a straight line The characteristic curves of both Eco Mode and Proportional pressure Control intersect the m...

Page 45: ...nt which has last been set Step 4 a Confirming the current setpoint Press the control element Step 4 b Changing the setpoint Turn the control element and set the required setpoint in increments of 1 w...

Page 46: ...ate If 5 minutes pass without any settings being made or the control button being pressed the display will revert to idle mode H 1 2 3 10 Q Fig 27 Open loop Control settings Table 19 Selecting Open lo...

Page 47: ...ade or saved the control unit will revert to the previous settings NOTE To start the pump the RUN terminal pair must be bridged factory setting or the terminal pair must receive the START signal Table...

Page 48: ...eration 48 of 68 Calio 1157 821 04 EN Size Speed Minimum speed Setpoint input 0 Maximum speed Setpoint input 100 rpm rpm 50 180 1000 3600 65 60 1000 3100 65 120 1000 3200 80 80 1000 2400 100 60 1000 2...

Page 49: ...ct closed terminals bridged Pump set starts up Contact open terminals not bridged Pump set stops 7 3 2 External analog 0 10 V DC signal CAUTION External voltage applied to the RUN terminal Damage to t...

Page 50: ...e as well as in alternation the electrical input power and the flow rate If 5 minutes pass without any settings being made or the control button being pressed the display will revert to idle mode Tabl...

Page 51: ...uty pump is stopped it signals a start command to the stand by pump The stand by pump will be started up and the first pump will be stopped Redundant operation In the event of a failure of the duty pu...

Page 52: ...pump Operation DUAL operating mode Press the control element The symbol will light up NOTE If 10 seconds pass without any settings being made or saved the control unit will revert to the previous set...

Page 53: ...top 1 Pump in operation R Operating hours pump 07 DA 00 02 UINT16 Operating hours R Pump power 07 DC 00 02 INT16 Watt R Temperature power supply module SPM 07 DF 00 02 INT16 C R Ambient temperature 07...

Page 54: ...one unit Table 28 Error value key Error value Description Bit E01 Temperature limit exceeded 0 E02 Overcurrent 1 E03 Internal error 2 E04 Pump rotor blocked 3 E05 Temperature increase speed decrease 4...

Page 55: ...analog 0 10 V signal is disabled the last valid setpoint is valid regardless of whether the input is made via the control element or Modbus The operating mode can be changed at any time via Modbus or...

Page 56: ...symbols representing the Dual pump Operation DUAL Modbus and 0 10 V sub modes will start flashing Step 2 Selecting the Modbus operating mode Turn the control element and select the required operating...

Page 57: ...mperature rises by 3 C The pump set has been in night mode for more than 7 hours Settings The Setback Operation function and its settings via the KSB ServiceTool are described in the KSB ServiceTool s...

Page 58: ...24 hours Once the pump has started up successfully it will acknowledge the error message error code E04 will disappear from the display Settings None 7 3 8 Temperature monitoring To protect the motor...

Page 59: ...Firmware update required Alarm Pump stops E13 No pump model stored Alarm Pump stops E15 Minimum flow Warning E16 Maximum flow Warning I10 Broken wire at analog input Information The pump behaviour can...

Page 60: ...zard 1 Always flush and clean the pump before transporting it to the workshop Provide a certificate of decontamination for the pump 8 3 Removing the pump set from the piping DANGER Hazardous electrica...

Page 61: ...r housing by authorised specialist personnel Remove any magnetic parts from the vicinity of the rotor Keep the assembly area clean Keep a safety distance of at least 0 3 m from electronic components W...

Page 62: ...for start stop function C Air in the system Shut off valves closed Vent the system and the pump Section 6 1 2 Page 32 Open the shut off elements E01 Excessive temperature Let the pump cool down for s...

Page 63: ...have not been cleared have the motor checked by KSB Service E11 Broken wire of temperature sensor NTC in the motor Have it checked by KSB Service E12 Firmware not compatible Carry out a firmware updat...

Page 64: ...frequency inverter 10 2 Wiring diagram D D STATUS COM RUN NO DUAL 0 10 V C NC PE ALARM POWER NO C NC N L Vin 0 V R 1 2 H 0 V 0 V 0 V L a1 a2 a3 a4 a5 b1 b2 b3 Fig 30 Wiring diagram of a Calio Connect...

Page 65: ...2009 and or 622 2012 Electrical components8 2011 65 EU Restriction of the use of certain hazardous substances in electrical and electronic equipment RoHS 2014 30 EU Electromagnetic Compatibility EMC...

Page 66: ...ndled Density 35 I Intended use 8 K Key to safety symbols markings 7 M Manual functions 16 N Name plate 15 O Operating limits 34 Operating modes 16 Other applicable documents 6 P Piping 22 Preservatio...

Page 67: ......

Page 68: ...KSB SE Co KGaA Johann Klein Stra e 9 67227 Frankenthal Germany Tel 49 6233 86 0 www ksb com 1157 821 04 EN...

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