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5 Installation at Site

19 of 68

Calio

1157.821/04-EN

5 Installation at Site

5.1 Safety regulations

DANGER

Installation in potentially explosive atmospheres

Explosion hazard!

▷

Never install the pump in potentially explosive atmospheres.

▷

Observe the information given in the data sheet and on the name plates of the
pump system.

DANGER

Use for drinking water or foodstuff applications

Danger of poisoning!

▷

Never use the pump for drinking water or foodstuff applications.

5.2 Checks to be carried out prior to installation

Before beginning with the installation check the following:

▪

The pump set can be operated on the power supply network according to the
data on the name plate. (

Section 4.4, Page 15)

▪

The 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 sure they are positioned correctly.

CAUTION

Ingress of fluid into the motor

Damage to the pump set!

▷

Install the pump set with the pump shaft in a horizontal position. Connect the
piping without transmitting any stresses and strains.

▷

Never install the pump set with the motor terminal box pointing downwards.

▷

Undo the hexagon socket head cap screws. Then turn the motor housing.

CAUTION

Air entering the pump

Damage to vertically installed pump sets whose direction of flow is downwards!

▷

Fit a vent valve at the highest point of the suction line.

NOTE

Installing shut-off valves upstream and downstream of the pump set is
recommended. Make sure that no leakage water can drip onto the drive or
terminal box.

Содержание Calio

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 67: ......

Страница 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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