KSB Calio Operating Manual

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High-efficiency Circulator Pump

Calio

Rating 800Watt

Installation/Operating Manual

Page 2

Legal information/Copyright

Installation/Operating Manual Calio

Original operating manual

All rights reserved. The 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 manufacturer's express written consent.

Subject to technical modication without prior notice.

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Contents

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Contents

Glossary .................................................................................................................................................. 5

1 General.................................................................................................................................................... 6

1.1 Principles ...........................................................................................................................................................6

1.2 Target group.....................................................................................................................................................6

1.3 Other applicable documents............................................................................................................................6

1.4 Symbols .............................................................................................................................................................6

2 Safety...................................................................................................................................................... 7

2.1 Key to safety symbols/markings.......................................................................................................................7

2.2 General..............................................................................................................................................................7

2.3 Intended use .....................................................................................................................................................8

2.4 Personnel qualification and training...............................................................................................................8

2.5 Consequences and risks caused by non-compliance with this manual .........................................................8

2.6 Safety awareness ..............................................................................................................................................9

2.7 Safety information for the operator/user.......................................................................................................9

2.8 Safety information for maintenance, inspection and installation ................................................................9

2.9 Unauthorised modes of operation..................................................................................................................9

3 Transport/Temporary Storage/Disposal............................................................................................. 10

3.1 Checking the condition upon delivery..........................................................................................................10

3.2 Transport.........................................................................................................................................................10

3.2.1 Placing the pump set down...............................................................................................................10

3.3 Storage/preservation......................................................................................................................................11

3.4 Return to supplier...........................................................................................................................................12

3.5 Disposal ...........................................................................................................................................................12

4 Description of the Pump (Set)............................................................................................................. 13

4.1 General description ........................................................................................................................................13

4.2 Designation.....................................................................................................................................................13

4.3 Name plate......................................................................................................................................................13

4.4 Design details..................................................................................................................................................14

4.5 Configuration and function...........................................................................................................................15

4.6 Noise characteristics .......................................................................................................................................15

4.7 Scope of supply...............................................................................................................................................16

4.8 Dimensions and weights ................................................................................................................................16

4.9 Accessories ......................................................................................................................................................16

5 Installation at Site................................................................................................................................ 17

5.1 Safety regulations ..........................................................................................................................................17

5.2 Checks to be carried out prior to installation...............................................................................................17

5.3 Installing the pump set ..................................................................................................................................17

5.4 Piping ..............................................................................................................................................................19

5.4.1 Connecting the piping.......................................................................................................................19

5.5 Enclosure/insulation .......................................................................................................................................20

5.6 Electrical connection ......................................................................................................................................20

5.6.1 Connecting the electric cables ..........................................................................................................22

5.6.1.1 Power supply..................................................................................................................................23

5.6.1.2 “In operation” message................................................................................................................23

5.6.1.3 General fault message...................................................................................................................24

5.6.1.4 External analog 0-10VDC signal................................................................................................24

5.6.1.5 External start/stop .........................................................................................................................25

5.6.1.6 Connecting the Modbus system ...................................................................................................25

5.6.1.7 Connecting dual-pump configurations........................................................................................29

6 Commissioning/Start-up/Shutdown................................................................................................... 30

6.1 Commissioning/Start-up.................................................................................................................................30

6.1.1 Prerequisites for commissioning/start-up ......................................................................................... 30

6.1.2 Priming and venting the pump.........................................................................................................30

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6.1.3 Start-up............................................................................................................................................... 31

6.2 Operating limits..............................................................................................................................................31

6.2.1 Ambient temperature........................................................................................................................32

6.2.2 Minimum inlet pressure.....................................................................................................................32

6.2.3 Maximum operating pressure ........................................................................................................... 32

6.2.4 Fluid handled .....................................................................................................................................32

6.2.4.1 Permissible fluids ...........................................................................................................................32

6.2.4.2 Density of the fluid handled.........................................................................................................33

6.2.4.3 Fluid temperature..........................................................................................................................33

6.3 Shutdown/storage/preservation ....................................................................................................................33

6.3.1 Measures to be taken for shutdown ................................................................................................33

6.3.2 Shutdown ...........................................................................................................................................34

6.4 Returning to service .......................................................................................................................................34

7 Operation.............................................................................................................................................. 35

7.1 Structure of the pump control system ..........................................................................................................35

7.2 Control panel..................................................................................................................................................35

7.3 Display.............................................................................................................................................................36

7.4 Mode of operation.........................................................................................................................................37

7.4.1 Information about settings ...............................................................................................................37

7.4.2 Constant-pressure control .................................................................................................................37

7.4.3 Proportional-pressure control ........................................................................................................... 39

7.4.4 Eco Mode............................................................................................................................................ 40

7.4.5 Open-loop control .............................................................................................................................41

7.5 Functions.........................................................................................................................................................43

7.5.1 External start/stop.............................................................................................................................. 43

7.5.2 External analog 0-10VDC signal ....................................................................................................43

7.5.3 Dual-pump operation (DUAL) ........................................................................................................... 45

7.5.4 Modbus............................................................................................................................................... 46

7.5.5 Setback operation.............................................................................................................................. 50

7.5.6 Ramps .................................................................................................................................................51

7.5.7 Deblocking the impeller .................................................................................................................... 51

7.5.8 Protection against excessive temperature........................................................................................51

7.5.9 Saving data......................................................................................................................................... 52

7.5.10 General fault messages......................................................................................................................52

7.6 Resetting the factory setting .........................................................................................................................53

8 Information about settings ................................................................................................................. 54

9 Servicing/Maintenance........................................................................................................................ 55

9.1 Maintenance/inspection.................................................................................................................................55

9.2 Drainage/cleaning ..........................................................................................................................................55

9.3 Removing the pump set from the piping .....................................................................................................55

10 Trouble-shooting.................................................................................................................................. 57

11 Related Documents.............................................................................................................................. 59

11.1 Exploded view with list of components........................................................................................................59

11.2 Wiring diagram...............................................................................................................................................59

12 EU Declaration of Conformity............................................................................................................. 60

Index ..................................................................................................................................................... 61

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Glossary

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Glossary

Discharge line

The pipeline which is connected to the discharge nozzle

Noise characteristics

The noise characteristics are indicated as surface sound pressure level in dB(A).

Pump

Machine without drive, additional components or accessories

Pump set

Complete pump set consisting of pump, drive, additional components and accessories

Suction lift line/suction head line

The pipeline which is connected to the suction nozzle

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1 General

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1 General

1.1 Principles

This operating manual is valid for the type series and variants indicated on the front cover. The operating manual describes the proper and safe use of this equipment in all phases of operation.

The name plate indicates the type series and size as well as the main operating data. They uniquely identify the pump (set) and serve as identification for all further business processes.

In the event of damage, immediately contact your nearest KSB Service centre to maintain the right to claim under warranty.

Noise characteristics see (ðSection4.6,Page15)

1.2 Target group

This operating manual is aimed at the target group of trained and qualified specialist technical personnel. (ðSection2.4,Page8)

1.3 Other applicable documents

Table1: Overview of other applicable documents

Document Contents

Data sheet Description of the technical data of the pump (set)

For accessories and/or integrated machinery components observe the relevant manufacturer's product literature.

1.4 Symbols

Table2: Symbols used in this manual

Symbol Description

✓ Conditions which need to be fulfilled before proceeding with the

step-by-step instructions

⊳ Safety instructions

⇨ Result of an action

⇨ Cross-references

Step-by-step instructions

Note Recommendations and important information on how to handle the product

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2 Safety

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2 Safety

DANGER

All the information contained in this section refers to hazardous situations.

In addition to the present general safety information the action-related safety information given in the other sections must be observed.

2.1 Key to safety symbols/markings

Table3: Definition of safety symbols/markings

Symbol Description

DANGER

DANGER This signal word indicates a high-risk hazard which, if not avoided, will result in death or serious injury.

WARNING

WARNING This signal word indicates a medium-risk hazard which, if not avoided, could result in death or serious injury.

CAUTION

CAUTION This signal word indicates a hazard which, if not avoided, could result in damage to the machine and its functions.

General hazard In conjunction with one of the signal words this symbol indicates a hazard which will or could result in death or 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 voltage.

Machine damage In conjunction with the signal word CAUTION this symbol indicates a hazard for the machine and its functions.

Warning: Strong magnetic field In conjunction with one of the signal words this symbol indicates a hazard involving magnetic fields and identifies information about protection against magnetic fields.

Warning for persons with pacemaker In conjunction with one of the signal words this symbol indicates a hazard involving magnetic fields and identifies special information for persons with a pacemaker.

Warning about hot surfaces In conjunction with one of the signal words this symbol indicates a hazard involving hot surfaces.

2.2 General

This operating manual contains general installation, operating and maintenance instructions that must be observed to ensure safe operation of the system and prevent personal injury and damage to property.

The safety information in all sections of this manual must be complied with.

The operating manual must be read and understood by the responsible specialist personnel/operators prior to installation and commissioning.

The contents of this operating manual must be available to the specialist personnel at the site at all times.

Information attached directly to the product must always be complied with and kept in a perfectly legible condition at all times. This applies to, for example:

▪ Flow direction arrow

▪ Markings for connections

▪ Name plate

▪ Warnings

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The operator is responsible for ensuring compliance with all local regulations not taken into account in this operating manual.

2.3 Intended use

▪ The pump (set) must only be operated within the operating limits described in

the other applicable documents.

▪ Only operate pumps/pump sets which are in perfect technical condition.

▪ Do not operate the pump (set) in partially assembled condition.

▪ Only use the pump to handle the fluids described in the data sheet or product

literature of the pump model or variant.

▪ Never operate the pump without the fluid to be handled.

▪ Observe the minimum flow rate and maximum flow rate indicated in the data

sheet or product literature (e.g. to prevent overheating, cavitation damage, bearing damage).

▪ Do not throttle the flow rate on the suction side of the pump (to prevent

cavitation damage).

▪ Consult the manufacturer about any use or mode of operation not described in

the data sheet or product literature.

Prevention of foreseeable misuse

▪ Never exceed the permissible operating limits specified in the data sheet or

product literature regarding pressure, temperature, etc.

▪ Observe all safety information and instructions in this manual.

2.4 Personnel qualification and training

All personnel involved must be fully qualified to transport, install, operate, maintain and inspect the equipment this manual refers to.

The responsibilities, competence and supervision of all personnel involved in transport, installation, operation, maintenance and inspection must be clearly defined by the operator.

Deficits in knowledge must be rectified by means of training and instruction provided by sufficiently trained specialist personnel. If required, the operator can commission the manufacturer/supplier to train the personnel.

Training on the pump (set) must always be supervised by technical specialist personnel.

This device may be operated by children from the age of 8 as well as by persons of limited physical, sensory or mental abilities or lacking experience and knowledge, provided that they are supervised, they have been instructed on how to use this device safely and they understand the hazards it presents. It is impermissible for

children to play with this device. Children must not clean the device or perform any service work to be carried out by the operator at the device without supervision.

2.5 Consequences and risks caused by non-compliance with this manual

▪ Non-compliance with these operating instructions will lead to forfeiture 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 chemical

effects and explosions

– Failure of important product functions

– Failure of prescribed maintenance and servicing practices

– Hazard to the environment due to leakage of hazardous substances

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2.6 Safety awareness

In addition to the safety information contained in this manual and the intended use, the following safety regulations shall be complied with:

▪ Accident prevention, health regulations and safety regulations

▪ Explosion protection regulations

▪ Safety regulations for handling hazardous substances

▪ Applicable standards, directives and laws

2.7 Safety information for the operator/user

▪ Fit protective equipment (e.g. contact guards) supplied by the operator for hot,

cold or moving parts, and check that the equipment functions properly.

▪ Do not remove any protective equipment (e.g. contact guards) during operation.

▪ Contain leakages (e.g. at the shaft seal) of hazardous fluids handled (e.g.

explosive, toxic, hot) so as to avoid any danger to persons and the environment. Adhere to all relevant laws.

▪ Eliminate all electrical hazards. (In this respect refer to the applicable national

safety regulations and/or regulations issued by the local energy supply companies.)

▪ If shutting down the pump does not increase potential risk, fit an emergency-

stop control device in the immediate vicinity of the pump (set) during pump set installation.

2.8 Safety information for maintenance, inspection and installation

▪ Modifications or alterations of the pump are only permitted with the

manufacturer's prior consent.

▪ Use only original spare parts or parts authorised by the manufacturer. The use of

other parts can invalidate any liability of the manufacturer for resulting damage.

▪ The operator ensures that maintenance, inspection and installation is performed

by authorised, qualified specialist personnel who are thoroughly familiar with the manual.

▪ Only carry out work on the pump (set) during standstill of the pump.

▪ Only perform work on the pump set when it has been disconnected from the

power supply (de-energised).

▪ The pump casing 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 out of service always adhere to the procedure

described in the manual. (ðSection6.3,Page33)

▪ Decontaminate pumps which handle fluids posing a health hazard.

▪ As soon as the work has been completed, re-install and re-activate any safety-

relevant devices and protective devices. Before returning the product to service, observe all instructions on commissioning. (ðSection6.1,Page30)

2.9 Unauthorised modes of operation

Never operate the pump (set) outside the limits stated in the data sheet and in this manual.

The warranty relating to the operating reliability and safety of the supplied pump (set) is only valid if the equipment is used in accordance with its intended use.

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3 Transport/Temporary Storage/Disposal

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3 Transport/Temporary Storage/Disposal

3.1 Checking the condition upon delivery

1. On transfer of goods, check each packaging unit for damage.

2. In the event of in-transit damage, assess the exact damage, document it and

notify KSB or the supplying dealer and the insurer about the 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.

▷ Observe the information on weights, centre of gravity and fastening points.

▷ Observe the applicable local accident prevention regulations.

▷ Use suitable, permitted lifting accessories, e.g. self-tightening lifting tongs.

To transport the pump/pump set suspend it from the lifting tackle as shown.

Fig.1: Proper pump transport

Fig.2: Incorrect pump transport

3.2.1 Placing the pump set down

WARNING

Insufficient stability

Risk of crushing hands and feet!

▷ During assembly/dismantling, secure the pump (set)/pump parts to prevent

tilting or tipping over.

Place the pump set down as illustrated.

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✔

Fig.3: Placing the pump set down safely

3.3 Storage/preservation

If commissioning is to take place some time after delivery, we recommend that the following measures be taken:

CAUTION

Damage during storage due to humidity, dirt, or vermin

Corrosion/contamination of the pump (set)!

▷ For outdoor storage cover the packed or unpacked pump (set) and accessories

with waterproof material.

CAUTION

Wet, contaminated 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.

Store the pump (set) in a dry, protected room at constant atmospheric humidity.

If properly stored indoors, the equipment is protected for a maximum of 12months. New pumps/pump sets are supplied by our factory duly prepared for storage.

For storing a pump (set) which has been operated, observe the instructions in (ðSection6.3.1,Page33) .

Table4: Ambient conditions for storage

Ambient condition Value

Relative humidity 80% maximum

Ambient temperature 0°C to +40°C

▪ Well ventilated

▪ Dry

▪ Dust-free

▪ Shock-free

▪ Vibration-free

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3.4 Return to supplier

1. Prior to returning the product to the supplier, flush and clean it, particularly if it

has been used in noxious, explosive, hot or other hazardous fluids.

2. If the product has been used in fluids whose residues could lead to corrosion

damage in the presence of atmospheric humidity or could ignite upon contact with oxygen, the product must also be neutralised and treated with anhydrous inert gas to ensure drying.

3. Always complete and enclose a certificate of decontamination when returning

the product. Indicate any safety measures and decontamination measures taken.

NOTE

If required, a blank certificate of decontamination can be downloaded from the following web site: www.ksb.com/certificate_of_decontamination

3.5 Disposal

DANGER

Strong magnetic field in the rotor area

Danger of death for persons with pacemaker! Interference with magnetic data carriers, 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 handled, consumables and supplies which are hot and/or pose a health hazard

Hazard to persons and the environment!

▷ Collect and properly dispose of flushing fluid and any fluid residues.

▷ Wear safety clothing and a protective mask if required.

▷ Observe all legal regulations on the disposal of fluids posing a health hazard.

1. Dismantle the pump (set).

Collect greases and other lubricants during dismantling.

2. Separate and sort the pump materials, e.g. by:

- Metals

- Plastics

- Electronic waste

- Greases and other lubricants

3. Dispose of materials in accordance with local regulations or in another

controlled manner.

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4 Description of the Pump (Set)

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4 Description of the Pump (Set)

4.1 General description

▪ High-efficiency circulator pumps with continuously variable speed control

▪ Non-self-priming in-line pump with integrated permanent magnet motor and

electronic variable speed system

Pump for handling clean, non-aggressive fluids which are not chemically and mechanically aggressive to the pump materials.

4.2 Designation

Example:

Calio

40-180

Table5: Designation key

Code Description

Calio Type series

40 40 DN40

50 DN50

65 DN 65

80 DN80

100 DN100

180 Head

180 Head1) × 10

Example: 18m × 10 = 180

4.3 Name plate

1~230V 50/60 Hz

1~230V 50/60Hz

PN 6/10

0,20 - 2,70A TF110

Class F IP44 46 - 611W EEI ≤0.20

4 5 6

7 8

9 10 11

Fig.4: Name plate (example)

1 Type series, size 7 Current input

2 Mains voltage, frequency 8 Pressure class

3 Thermal class 9 Temperature class

4 Enclosure 10 Energy efficiency index EEI

5 Material number 11 Input power

6 Production number 12 QR code

Key to the production

number

Example: 29134313-201630-12345

Table6: Key to the production number

Number Description

29134313 Material number

2016 Year of production

1) At Q = 0 m³/h

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4 Description of the Pump (Set)

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Number Description

30 Week of production

12345 Consecutive number

4.4 Design details

Design

▪ Maintenance-free high-efficiency wet rotor pump (glandless)

Drive

▪ High-efficiency electric motor with continuously variable differential pressure

control

▪ Electronically commutated synchronous motor with permanent magnet rotor

▪ Integrated motor protection

▪ 1~230VAC +/- 10%

▪ Frequency 50 Hz

▪ Enclosure IPX4D

▪ Thermal class F

▪ Temperature class TF110

▪ Energy efficiency index EEI ≤0.23

▪ Interference emissions EN61000-6-3

▪ Interference immunity EN61000-6-1

Bearings

▪ Product-lubricated special plain bearing

Connections

▪ Flanged connection

Operating modes

▪ Constant-pressure control

▪ Proportional-pressure control

▪ Open-loop control via setpoint setting

▪ Eco Mode with dynamic differential pressure setpoint adjustment

Automatic functions

▪ Continuous output adjustment depending on the mode of operation

▪ 0-10V with external differential pressure/speed setpoint

▪ Dual-pump operation

▪ Setback operation

▪ External start/stop

▪ Deblocking function

▪ Self-venting function

▪ Soft start

▪ Full motor protection with integrated trip electronics

Manual functions

▪ Setting the operating mode

▪ Setting the differential pressure setpoint

▪ Setting the speed level

▪ Locking the control panel (with the KSB Service Tool only)

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4 Description of the Pump (Set)

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Signalling and display functions

▪ Periodically alternating display of flow rate and electrical input power

▪ Error codes indicated on the display

▪ General fault message

▪ Head displayed in addition

▪ “In operation” message

▪ Modbus

4.5 Configuration and function

Fig.5: Description and sectional drawing of the pump set

1 Thermal insulation shell 7 Discharge nozzle

2 Control panel 8 Radial plain bearing

3 Connections for control cables 9 Impeller

4 Display 10 Motor shaft

5 Control element (dial and control

button)

11 Motor

6 Connections for power supply, "in

operation" message and general fault message

12 Suction nozzle

Design

The pump is designed with a radial fluid inlet (suction nozzle) and a radial outlet (discharge nozzle) arranged on the same axis. The impeller is rigidly connected to the motor shaft. Mechanical sealing is not required as the rotating assembly is completely isolated from the stator winding. The rotating 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 integrated continuously variable differential pressure control and operating software enable an optimum adjustment of the pump to changing operating conditions and minimise operating costs. The combination of an efficient hydraulic system with a high-efficiency electric motor makes sure that the input power is converted into hydraulic energy as efficiently as possible.

Function

The fluid enters the pump via the suction nozzle (12) and is accelerated outward in a cylindrical flow by the rotating impeller (9). In the flow passage of the pump casing the kinetic energy of the fluid is converted into pressure energy. The fluid is pumped to the discharge nozzle (7), where it leaves the pump. The shaft runs in radial plain bearings (8), which are supported by the motor (11).

4.6 Noise characteristics

Average sound pressure level <45dB(A)

2) Calio 100-60 < 49 dB (A)

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4.7 Scope of supply

Depending on the 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

4.8 Dimensions and weights

For dimensions and weights please refer to the data sheet of the pump (set).

4.9 Accessories

▪ BACnet MS/TP communication module

▪ Spacer

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5 Installation at Site

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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!

▷ The pump materials are not suitable for drinking water and foodstuff

applications. 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:

▪ Check the data on the name plate of the pump to make sure it can be operated

on the power supply network available. (ðSection4.3,Page13)

▪ The fluid to be handled matches the description of suitable fluids.

(ðSection6.2.4.1,Page32)

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

We recommend installing shut-off valves upstream and downstream of the pump. Make sure that no leaking water can drip into the pump motor or terminal box.

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NOTE

The direction of flow of a vertically installed pump should be upwards.

NOTE

Do not install the pump at the lowest point of the system to prevent any impurities from collecting in the pump.

Positioning the control unit

WARNING

Insufficient stability

Risk of crushing hands and feet!

▷ During assembly/dismantling, secure the pump (set)/pump parts to prevent

tilting or tipping over.

✔

Fig.6: Placing the pump set down safely

The control unit can be turned through 360°. The position must be effected with the pump set removed from the system.

ü The pump set is secured against tipping over.

1. Undo and store the 4 hexagon socket head cap screws.

2. Rotate the drive unit until it has reached the required position. Compare it

against the permissible installation positions. Adjust the position if required.

3. Fit and tighten the 4 hexagon socket head cap screws again.

Permissible installation positions

✔

Fig.7: Permissible installation positions

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DANGER

Leakage at the pump

Leakage of hot fluids!

▷ Insert the O-ring in the correct position.

Flanged pump

1. Position the pump set as indicated in an easily accessible place.

ð An arrow on the pump casing and thermal insulation 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. Accurately insert the sealing element on the opposite side.

6. Bolt the pump flange to the pipe flange.

7. Tighten the bolts hand-tight with an assembly tool (e.g. wrench).

5.4 Piping

5.4.1 Connecting the piping

WARNING

Hot surface

Risk of burns

▷ Never touch a pump set when it is in operation.

WARNING

Impermissible loads acting on the pump nozzles

Risk of burns by hot fluids escaping!

▷ Do not use the pump as an anchorage point for the piping.

▷ Anchor the pipes in close proximity to the pump and connect them without

transmitting any stresses or strains.

▷ Take appropriate measures to compensate for thermal expansion of the piping.

CAUTION

Contamination/dirt in the piping

Damage to the pump!

▷ Flush the piping prior to commissioning or replacing the pump. Remove any

foreign matter.

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NOTE

Installing check and shut-off elements in the system is recommended, depending on the type of plant and pump. However, such elements must not obstruct proper drainage or hinder disassembly of the pump.

ü Suction lift lines have been laid with a rising slope, suction head lines with a

downward slope towards the pump.

ü The nominal diameters of the pipelines are equal to or greater than the nominal

diameters of the pump nozzles.

ü The pipelines have been anchored in close proximity to the pump and connected

without transmitting any stresses or strains.

1. Thoroughly clean, flush and blow through all vessels, pipelines and connections

(especially of new installations).

CAUTION

Welding beads, scale and other impurities in the piping

Damage to the pump!

▷ Free the piping from any impurities.

5.5 Enclosure/insulation

WARNING

The pump takes on same temperature as the fluid handled

Risk of burns!

▷ Insulate the volute casing.

▷ Fit protective equipment.

NOTE

The pump is supplied with a thermal insulation shell.

5.6 Electrical connection

DANGER

Electrical connection work by unqualified personnel

Risk of fatal injury due to electric shock!

▷ Always have the electrical connections installed by a trained and qualified

electrician.

▷ Observe the IEC60364 regulations as well as any regional regulations.

DANGER

Electrostatic charging

Danger of death from electric shock!

▷ Provide potential equalisation between the pump set and the foundation.

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DANGER

Pump acting as a generator when running in reverse

Danger to life from hazardous induction voltage 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 contact with hot casings/housings or

pipelines.

DANGER

Hazardous electrical voltage when the covers of the terminal wiring compartments are removed

Danger of death from electric shock!

▷ For working on the terminals, switch off the power supply at least 5minutes

prior to commencing work and ensure that it cannot be switched on again unintentionally.

▷ If applicable, switch off the external power supply to message relays and

control cables and make sure it cannot be switched on again unintentionally.

▷ Keep the covers of the terminal wiring compartments closed during operation

as well as during maintenance work.

WARNING

Incorrect connection to the mains

Damage to the mains network, short circuit!

▷ Observe the technical specifications of the local energy supply companies.

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 or automatic circuit breaker type C.

NOTE

Using a plug-type connection for the power cable is impermissible. Connection to power supply must be effected by means of a fixed power cable with

a minimum cross-section of 3x1.5mm2 and a minimum contact opening of 3mm. Connection to the power supply must be effected by a power cable which is fitted

with an all-pole isolating switch. Should the power cable of this device become damaged, a replacement cable must be fitted by the manufacturer, the manufacturer' customer service technicians or a similarly qualified person.

Residual current device

If residual current devices (RCDs) are used, frequency inverters must in accordance with DINVDE0160 be connected via universal AC/DC sensitive residual current devices (RCDs). Standard AC sensitive RCDs might either fail to respond or respond erroneously to any direct-current components which may be present. Discharge current per pump <3.5mA.

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5.6.1 Connecting the electric cables

1 Connection of external analog signal, 0-10VDC 5 Connection of power supply 1~230VAC +/-10%,

50Hz 2 Connection of External Start/Stop signal 6 Connection for "in operation" message 3 Connection to Modbus network 7 Connection for general fault message 4 Connection for dual-pump operation (DUAL)

The left side has 4 connection options and 3 cable glands. If all 4 connections are to be used, run the control cables of connections 2 and 3 through the cable gland in the middle.

ü The mains voltage at the site has been verified against the data on the name

plate.

ü The pump set has been de-energised and secured against unintentional start-up.

ü The wiring diagram is on hand. (ðSection11.2,Page59)

1. Unscrew the cable glands (IPX4D).

2. Undo and store the 2 screws of the cover of the terminal wiring compartment.

3. Remove the cover of the terminal wiring compartment.

4. Break and remove the closing disc of the required cable gland with a suitable

tool (e.g. screwdriver).

5. Guide the required electric cable through the corresponding cable gland and

connect it to the terminal provided.

6. Fit the cover of the terminal wiring compartment. Fasten it with the 2 screws.

7. Tighten the cable glands.

Table7: Key to the symbols

Function Symbol

Terminal pair

Terminal

cross-section

Terminal

identification

Frequency of

starts

Contact

rating

External analog signal 010VDC

0-10V 1,5mm2- - -

External start/stop signal (terminal pair supplied bridged)

RUN 1,5mm2- - -

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Function Symbol

Terminal pair

Terminal

cross-section

Terminal

identification

Frequency of

starts

Contact

rating

Modbus network Modbus 1,5mm2- - -

Dual-pump configuration DUAL 1,5mm2- - -

Power supply 1~230VAC +/- 10%, 50Hz

1,5mm2Y = PE

N = N L = L

<20/24hours -

“In operation” message 1,5mm2- - Min: 12VDC at 10mA

Max: 250V at 1A

General fault message 1,5mm2- - -

5.6.1.1 Power supply

Fig.8: Power supply 1~230VAC +/- 10%, 50Hz

ü The wiring diagram is on hand. (ðSection11.2,Page59)

1. Connect the power supply to the terminal pair L, N, PE integrated in the pump.

5.6.1.2 “In operation” message

The pump signals its operating status by means of the integrated, volt-free relay contact. Pump not in operation = rotor not rotating, no flow. Pump in operation = rotor rotating.

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This information can be accessed at the "status" terminal pair with terminals NO/ COM/NC.

Pump not in operation (rotor not rotating)

Pump in operation (rotor rotating)

Fig.9: Wiring diagram for the "in operation" message

5.6.1.3 General fault message

The pump signals a general fault message by means of the integrated, volt-free relay contact. General fault message ... = rotor not rotating, no flow.

This information can be accessed at the "alarm" terminal pair with terminals NO/ COM/NC. The changeover contact function can be set with the KSB Service Tool.

General fault message (Rotor not rotating)

No general fault message or no power supply

Fig.10: Wiring diagram for the general fault message

5.6.1.4 External analog 0-10VDC signal

Fig.11: Terminal pair 0-10V

ü The wiring diagram is on hand. (ðSection11.2,Page59)

1. Wire the external analog signal to the 0-10V terminal pair integrated in the

pump.

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5.6.1.5 External start/stop

Fig.12: RUN terminal pair

ü The wiring diagram is on hand. (ðSection11.2,Page59)

1. Wire the external signal (volt-free switching contact) to the RUN terminal pair

integrated in the pump. Unscrew the cable glands (IPX4D). The terminal pair is supplied bridged.

5.6.1.6 Connecting the Modbus system

Connection to higher-level automation systems per Modbus at the example of four pumps

Communication between the connected pumps and the Modbus master is effected via Modbus. Cable reflections occur at the open cable ends (first and last connection of a bus system). The higher the selected baud rate, the larger the cable reflections. The use of terminating resistors will establish a defined rest potential and keep reflections to a minimum.

ü The control unit has been de-energised.

1. Wire the pumps at their Modbus terminals in line topology as illustrated.

ð Use a network cable with a defined wave impedance (cable typeB to

TIA-485-A).

2. Connect a terminating resistor of 120Ω to the first and last Modbus device of a

bus line.

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Adress 1

Adress n

Modbus

Modbus-Master

Connection to a building management system (BMS)

Wire the bus terminating

resistor to the master /

enable it

Modbus network cable with defined wave impedance (e.g. Ethernet cable)

COMRUN

DUAL0-10 V

Vin

0 V

1 2

D-

D+

0 V

Adress n-1

Fig.13: Modbus wiring for Calio 800W pumps

Connection to bus systems with Modbus

Table8: Technical data of the Modbus interface

Parameter Description/value

Terminal cross-section 1,5mm

Interface RS485 (TIA-485-A) optically isolated

Bus connection Shielded bus cable, twisted in pairs, 1x 2x 0.5mm

Cable length 1000m maximum, stub lines impermissible, for cable

lengths >30m take suitable measures to prevent overvoltages.

Wave impedance 120Ω (cable type B to TIA-485-A)

Data rate [baud] 4,800, 9,600, 38,400, 57,600, 115,200, 19,200 = factory

setting

Protocol Modbus RTU standard

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Parameter Description/value

Data format 8 data bits, parity EVEN/ ODD/ None, 1stopbit

Modbus address ID #1 to #247 selectable; ID #17 = factory setting

ü The mains voltage at the site has been verified against the data on the name

plate.

ü The pump set has been de-energised and secured against unintentional start-up.

ü The wiring diagram is on hand.

1. Unscrew the cable glands (IPX4D).

2. Undo and store the 2 screws of the cover of the terminal wiring compartment.

3. Remove the cover of the terminal wiring compartment.

4. Break and remove the closing disc of the required cable gland with a suitable

tool (e.g. screwdriver).

5. Wire a suitable bus cable to the terminal pair of the three-piece Modbus

terminal and connect it to earth.

ð The terminals are suitable for a core cross-section of 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.

Connection to the Modbus master

All pumps are connected to a Modbus master. The Modbus master controls the bus communication and sends telegrams to the connected pumps. All pumps are slaves; they only respond when they are addressed. They are unable to send telegrams by themselves. Each pump is assigned its own unique address at the time of commissioning.

Use a cable with a defined wave impedance (e.g. Ethernet cable) as Modbus network cable to prevent signal losses in the cable. Signal losses could lead to system-specific problems, e.g. failure of communication between Modbus master and pump.

1. Remove the cover of the terminal wiring compartment.

2. Connect a suitable Modbus network cable to terminals D+ and D- of the three-

piece Modbus terminal.

3. Terminal G is connected to ground at the pump. The shield of the bus cable can

be connected to this terminal, for example. The terminals are suitable for a core cross-section of up to 1.5mm2.

Terminating the Modbus data line (hardware)

Terminate either end of the Modbus network cable with a 120Ω resistor. Enable both DIP switches for this purpose.

The wave impedance of the cable used corresponds to the terminating resistor.

Example:

Terminating resistor = 120Ω Wave impedance of network cable = 120Ω

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COMRUN

DUAL0-10 V

Vin

0 V

1 2

D-

D+

0 V

Fig.14: Terminal wiring diagram for the Modbus data line

a Data line connections

a1 External 0-10V

a2 External start/stop

a3 Terminating resistor for Modbus cable (DIP switches)

a4 Modbus

a5 Dual-pump configuration

Depending on the size of the last pump in the Modbus network, either wire the terminating resistor as an external resistor of 120Ω to terminals D+ and D- of the Modbus terminal pair (175/350W pumps) or enable the corresponding pumpintegrated DIP switch in the terminal wiring compartment next to the Modbus terminal pair (800W pumps). See illustrations.

Table9: Key to the terminal codes

Terminal code Description

RS485 Modbus

D- A- D0

D+ B+ D1

0 V COM COM

Table10: Settings of Modbus terminating resistors for Calio 800W

Position of DIP switches 1 and 2 Status

ON Modbus terminating resistor enabled

OFF Modbus terminating resistor disabled

NOTE

The two DIP switches 1 and 2 must both be set to the same status.

Fig.15: Terminals of a Calio 800W pump

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5.6.1.7 Connecting dual-pump configurations

Wire the two pumps to each other with a suitable network cable with a defined wave impedance of 120Ω, via the terminal pairs DUAL (a5).

Setting

Make sure the settings and wiring of both pumps are identical to ensure that the changeover from duty 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 pair must be bridged at both pumps.

COMRUN

DUAL0-10 V

Vin

0 V

1 2

D-

D+

0 V

Fig.16: Terminal wiring diagram for dual-pump configuration

a Data line connections

a1 External 0-10V

a2 External start/stop

a3 Terminating resistor for Modbus cable (DIP switches)

a4 Modbus

a5 Dual-pump configuration

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6 Commissioning/Start-up/Shutdown

6.1 Commissioning/Start-up

6.1.1 Prerequisites for commissioning/start-up

Before commissioning/starting up the pump set, make sure that the following conditions are met:

▪ The pump set has been properly connected to the power supply and is equipped

with all protection devices. (ðSection5.6,Page20)

▪ The system piping has been cleaned.

▪ The suction line and inlet tank, if any, have been primed with the fluid to be

handled.

▪ The covers of the terminal wiring compartments have been closed and fastened

with screws.

6.1.2 Priming and venting the pump

DANGER

Non-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 elements in the suction line and/or

discharge line closed.

▷ Only start up the pump set against a slightly or completely open discharge-side

shut-off element.

DANGER

Excessive temperatures due to insufficient lubrication of the plain bearings

Damage to the pump set!

▷ Never operate the pump set without liquid fill.

▷ Observe the specified minimum pressure for operating the pump.

▷ Always operate the pump within the permissible operating range.

CAUTION

Increased wear due to dry running

Damage to the pump set!

▷ Never operate the pump set without liquid fill.

▷ Never close the shut-off element in the suction line and/or supply line during

pump operation.

NOTE

The pumps are self-venting.

1. Fully open the shut-off elements in the suction line.

2. Slightly or fully open the shut-off element in the discharge line.

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6.1.3 Start-up

DANGER

Non-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 elements in the suction line and/or

discharge line closed.

▷ Only start up the pump set against a slightly or completely open discharge-side

shut-off element.

DANGER

Excessive temperatures due to insufficient lubrication of the plain bearings

Damage to the pump set!

▷ Never operate the pump set without 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 handled.

Risk of burns!

▷ Do not touch hot surfaces.

CAUTION

Abnormal noises, vibrations, temperatures or leakage

Damage to the pump!

▷ Switch off the pump (set) immediately.

▷ Eliminate the causes before returning the pump set to service.

ü The system piping has been cleaned.

ü Pump, suction line and inlet tank (if fitted) have been vented and primed with

the fluid to be handled.

ü The priming lines and venting lines have been closed.

1. Fully open the shut-off element in the suction head line/suction lift line.

2. Close or slightly open the shut-off element in the discharge line.

3. Start up the motor.

6.2 Operating limits

DANGER

Non-compliance with operating limits for pressure, temperature, fluid handled and speed

Hot fluids escaping!

▷ Comply with the operating data indicated in the data sheet.

▷ Avoid prolonged operation against a closed shut-off element.

▷ Never operate the pump at product temperatures exceeding those specified in

the data sheet or on the name plate.

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6.2.1 Ambient temperature

CAUTION

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 operation:

Table11: Permissible ambient temperatures specified for the fluid temperature

Fluid temperature Permissible ambient temperature

≤ + 90°C + 40°C

> + 90°C + 30°C

6.2.2 Minimum inlet pressure

The minimum inlet pressure p

min

at the pump suction nozzle serves to avoid cavitation

noises at an ambient temperature of +40°C and the indicated fluid temperature T

max

The indicated values are applicable up to 300m above sea level. For installation at altitudes >300m, an allowance of 0.01bar/100m must be added.

Table12: Minimum inlet pressure p

min

specified for the fluid temperature

Fluid temperature Minimum inlet pressure

[°C] [bar]

≤ 80 0,5

81 to 95 1,5

96 to 110 2,5

6.2.3 Maximum operating pressure

CAUTION

Permissible operating pressure exceeded

Damage to connections and seals!

▷ Never exceed the operating pressure specified in the data sheet.

The maximum operating pressure equals 6, 10 or 16bar, depending on the design variant. See name plate.

6.2.4 Fluid handled

6.2.4.1 Permissible fluids

DANGER

Use for drinking water or foodstuff applications

Danger of poisoning!

▷ The pump materials are not suitable for drinking water and foodstuff

applications. Never use the pump for drinking water or foodstuff applications.

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CAUTION

Unsuitable fluids

Damage to the pump!

▷ Never use the pump to handle corrosive, combustible 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

Suitable for pumping higher-viscosity fluids (water/glycol mixture with a mixing ratio of up to 1:1)

6.2.4.2 Density of the fluid handled

The pump input power changes in proportion to the density of the fluid handled.

CAUTION

Impermissibly high density of the fluid handled

Motor overload!

▷ Observe the information on fluid density in the data sheet.

6.2.4.3 Fluid temperature

CAUTION

Incorrect temperature of the fluid handled

Damage to the pump (set)!

▷ Do not operate the pump (set) outside the specified temperature limits.

Table13: Temperature limits of the fluid handled

Permissible fluid temperature Value

Maximum 110°C

Minimum -10°C

The fluid temperature has an impact on the minimum inlet pressure.

(ðSection6.2.2,Page32)

6.3 Shutdown/storage/preservation

6.3.1 Measures to be taken for shutdown

The pump (set) remains installed

ü Sufficient fluid is supplied for the operation 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.

ð This will prevent the formation of deposits within the pump and the pump

intake area.

The pump (set) is removed from the pipe and stored

ü The pump has been drained properly (ðSection9.2,Page55) and the safety

instructions for dismantling the pump have been observed.

1. Observe any additional instructions and information provided. (ðSection3,Page10)

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6.3.2 Shutdown

ü The shut-off element in the suction line is and remains open.

1. Close the shut-off element in the discharge line.

2. Switch off the motor and make sure the pump set runs down smoothly to a

standstill.

NOTE

If the discharge line is equipped with a non-return or check valve, the shut-off element may remain open provided that the system conditions and system regulations are considered and observed.

For prolonged shutdown periods:

1. Close the shut-off element in the suction line.

CAUTION

Risk of freezing during prolonged pump shutdown periods

Damage to the pump!

▷ Drain the pump and the cooling/heating chambers (if any) or otherwise protect

them against freezing.

6.4 Returning to service

For returning the equipment to service observe the sections on commissioning/startup and the operating limits .

In addition, carry out all servicing/maintenance operations before returning the pump (set) to service.

WARNING

Failure to re-install or re-activate protective devices

Risk of injury from moving parts or escaping fluid!

▷ As soon as the work is completed, re-install and re-activate any safety-relevant

devices and protective devices.

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7 Operation

7.1 Structure of the pump control system

The pump continuously adjusts its speed to run at its best efficiency point.

H1, n

①

②

③

Fig.17: Structure of the pump control system

The operating point estimation integrated in the pump ③ continuously determines the current flow rate and/or head. Based on the selected type of control ① and setpoint - the pump's internal pressure controller ② determines the required differential pressure H2. The internal pressure controller derives the required speed setpoint n2 using a non-linear procedure. This is based on the hydraulic principle that the ratio between two heads equals the ratio of the corresponding speeds squared (see Fig. Relationship between head and speed).

Fig.18: Relationship between head and speed

The current operating point in this example is based on a known current speed (n1) and a known current head (H1). Knowing that all H/n pairs of values are situated on a parabola, for any head setpoint H2 the corresponding speed setpoint n2 can be calculated using the formula n2 = n1 × (H2/H1)

0,5

. Setting the speed setpoint n2 results in the required head. Compared to a PI controller, for example, this procedure has the benefits of doing away with the time-consuming setting of controller parameters and, by making use of hydraulic principles, always achieving a maximum dynamic response without overshoots.

7.2 Control panel

All settings are made using the control element on the housing front. The control element consist 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%. They are shown as numeric values 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%.

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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.

III

I = dial

II = control button

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

7.3 Display

The flow rate, the electrical input power and the head are shown as 3-digit numbers on the integrated display. The display alternates in 5-second intervals between these values with the corresponding units. The flow rate and the head are displayed as numbers with one decimal place; the power input is displayed as a number without any decimal places. The setpoint is indicated in [%] without any decimal places.

(

)

m3/h

ECO

SERVICE

Fig.19: Calio display

Symbols

The symbols on the front panel indicate operating modes and settings. A lit symbol signifies:

▪ The active operating mode

▪ An external 0-10V signal

▪ A general fault message

Table14: Symbols key

Symbol Description Unit

m3/h Calculated flow rate

▪ Symbol lights up.

▪ Display shows the flow rate.

m3/h

W Measured electrical input power

▪ Symbol lights up.

▪ Display shows the electrical power.

m Calculated head metres

of water

Constant-pressure Control operating mode

▪ Symbol lights up when this operating mode is active.

Proportional-pressure Control operating mode

▪ Symbol lights up when this operating mode is active.

Open-loop Control operating mode

▪ Symbol lights up when this operating mode is active.

ECO

ECO operating mode (energy-saving mode)

▪ Symbols light up when this operating mode is active.

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Symbol Description Unit

0-10V 0-10V operating mode

▪ Symbol lights up when this operating mode is active.

▪ Symbol flashes when this operating mode sends a stop

command. E.g. voltage signal<1.5V.

VDC

MODBUS Modbus operating mode

▪ Symbol lights up when this operating mode is active.

▪ Symbol flashes when this operating mode sends a stop

command.

DUAL Dual-pump Operation operating mode

▪ Symbol lights up when this operating mode is active.

▪ Symbol flashes when this operating mode sends a stop

command.

SERVICE General fault message

▪ Error message codes (E01-E08) are shown on the display.

7.4 Mode of operation

7.4.1 Information about settings

For common applications such as two-pipe systems Proportional-pressure Control (Δpv) is the recommended operating mode. This operating mode offers an extended control range with additional potential savings compared to Constant-pressure Control (Δp-c). Depending on the balancing of branch circuits, undersupply may occur at a consumer installation. The Constant-pressure Control operating mode (Δp-c) can be selected as an option (e.g. for underfloor heating systems). If noises are audible at low flow rates, select the Proportional-pressure Control operating mode (Δp-v). The setting of the discharge head setpoint depends on the piping curve of the system and on the heat requirements. As standard the pumps are set to Proportionalpressure Control (Δp-v) and medium output (setpoint 50%).

7.4.2 Constant-pressure control

Function

In constant-pressure control the set head ② is maintained irrespective of the flow rate. The set differential pressure setpoint HS is constant, situated between the maximum curve ① and the permissible flow rate range.

min

max

HS2

Fig.20: Constant-pressure Control function

Setting

Press the control element to activate the display from idle mode. The display will show the current operating mode 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.

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NOTE

If 10seconds pass without any settings being made or saved, the control unit will revert to the previous settings.

Table15: Selecting Constant-pressure Control and the setpoint

Step 1: Activating the setting mode

▪ Press the control element for 3seconds.

– The operating mode which has last been selected will start

flashing.

Step 2: Selecting the Constant-pressure Control operating mode

▪ Turn the control element and select the required operating

mode.

Step 3: Activating the Constant-pressure Control operating mode

▪ Press the control element.

– The number of flashing LED segments shows the setpoint

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% within the range from 0% to 100%.

– Turning it clockwise increases 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.

max

min

Fig.21: Constant-pressure Control settings

NOTE

To start the pump the “RUN” terminal pair must be bridged (factory setting) or the terminal pair must receive the START signal.

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7.4.3 Proportional-pressure control

Function

Within the permissible flow rate range the Proportional-pressure Control decreases or increases the differential pressure setpoint between 1/2 HS and HS (factory-set) in a linear fashion with the flow rate.

HS1

min

max

/2 H

Fig.22: Proportional-pressure Control function

Setting

Table16: Selecting Proportional-pressure Control and the setpoint

Step 1: Activating the setting mode

▪ Press the control element for 3seconds.

– The operating mode which has last been selected will start

flashing.

Step 2: Selecting the Proportional-pressure Control operating mode

▪ Turn the control element and select the required operating

mode.

Step 3: Activating the Proportional-pressure Control operating mode

▪ Press the control element.

– The number of flashing LED segments shows the setpoint

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% within the range from 0% to 100%.

– Turning it clockwise increases 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.

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NOTE

If 10seconds pass without any settings being made or saved, the control unit will revert to the previous settings.

max

min

Fig.23: Proportional-pressure Control settings

NOTE

To start the pump the “RUN” terminal pair must be bridged (factory setting) or the terminal pair must receive the START signal.

7.4.4 Eco Mode

Function

Compared with the Proportional-pressure Control operating mode the Eco Mode can save more than 40% in electrical input power. By changing the differential pressure setpoint the pump characteristic curve can be adjusted to higher or lower differential pressures and/or discharge heads. Starting at the discharge head setpoint H

EcoStart

the

characteristic curve(4) is quadratic. H

Eco Start

= 1/4 x H

0,00

1,00

2,00

3,00

4,00

5,00

6,00

7,00

8,00

[m]

10,00

11,00

0 1 2 3 4 5 6 7 8 9 10 11 12

[m3/h]

Fig.24: EcoMode – Characteristic curve, example of a size 25-100pump

1a Upper limit of constant-pressure control

1b Lower limit of constant-pressure control

2a Upper limit of proportional-pressure control

2b Lower limit of proportional-pressure control

3 Maximum characteristic curve

4 Eco Mode characteristic curve

3) Selected setpoint (see Proportional-pressure Control function)

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Setting

Table17: Selecting Eco Mode and the setpoint

Step 1: Activating the setting mode

▪ Press the control element for 3seconds.

– The operating mode which has last been selected will start

flashing.

Step 2: Selecting the Eco Mode operating mode

▪ Turn the control element and select the required operating

mode.

ECO

Step 3: Activating the Eco Mode operating mode

▪ Press the control element.

– The number of flashing LED segments shows the setpoint

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% within the range from 0% to 100%.

– Turning it clockwise increases 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 settings being made 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.

7.4.5 Open-loop control

Function

In Open-loop Control operating mode the pump runs at a set speed. The speed can be set to one of 100 speed levels.

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2 3

Fig.25: Open-loop control function, running at speed level 2

Setting

Table18: Selecting Open-loop Control and the setpoint

Step 1: Activating the setting mode

▪ Press the control element for 3seconds.

– The operating mode which has last been selected will start

flashing.

Step 2: Selecting the Open-loop Control operating mode

▪ Turn the control element and select the required operating

mode.

Step 3: Activating the Open-loop Control operating mode

▪ Press the control element.

– The number of flashing LED segments shows the setpoint

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% within the range from 0% to 100%.

– Turning it clockwise increases 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 settings being made or saved, the control unit will revert to the previous settings.

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2 3

Fig.26: Open-loop Control 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19: Speeds

Size n

Minimum speed

Setpoint input 0%

Maximum speed

Setpoint input 100%

[rpm] [rpm]

40-120 1000 2900

40-180 1000 3500

50-100 1000 2750

50-120 1000 2930

50-150 1000 3260

50-180 1000 3600

65-120 1000 3200

80-80 1000 2400

100-60 1000 2100

7.5 Functions

7.5.1 External start/stop

The pump is started up or stopped as a function of an external signal.

Table20: Pump start and stop

Contact Effect

Contact closed/ terminals bridged

Pump starts up

Contact open/ terminals not bridged

Pump stops

7.5.2 External analog 0-10VDC signal

Function

An external analog 0-10VDC signal serves as external setpoint input for the pump. If the Constant-pressure Control, Proportional-pressure Control or EcoMode operating modes are active, the pump processes the current external analog signal as a differential pressure setpoint. If the Open-loop control operating mode is active, the pump processes the external analog signal as a speed setpoint. If the signal level <1.5VDC, the pump will stop and the last LED segment will extinguish.

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Table21: Setpoint settings at the pump for signal level 0-10V

Signal level of 0-10V signal

Setpoint setting at the pump

10VDC 100% of the setpoint

2VDC 0% of the setpoint

< 1.5VDC Pump stops

≥ 2VDC Pump starts up

max

2 V

min

10 V1,5 V

U [VDC]

Fig.27: Analog 0-10V signal as setpoint signal for the pump

Setting

Table22: Activating and de-activating the 0-10V operating mode

Step 1: Enabling the sub-mode (DUAL, Modbus, 0-10V)

▪ Press the control element for 6seconds.

– One of the symbols representing the Dual-pump Operation

(DUAL), Modbus and 0-10V sub-modes will start flashing.

Step 2: Selecting the 0-10V operating mode

▪ Turn the control element and select the required operating

mode.

0-10V

Step 3: Activating or de-activating the 0-10V operating mode

▪ Press the control element.

– The symbol will light up. When the signal is activated, the

circular segments will indicate the value of the input signal.

NOTE

If 10seconds pass without any settings being made or saved, the control unit will revert to the previous settings.

Table23: Number of LED segments assigned to electrical voltage

Lit LED segments Electrical voltage [V]

0 2,4

1 3,2

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Lit LED segments Electrical voltage [V]

2 4,0

3 4,8

4 5,6

5 6,4

6 7,2

7 8,0

8 8,8

9 9,6

10 10,0

NOTE

To start the pump the “RUN” terminal pair must be bridged (factory setting) or the terminal pair must receive the START signal.

7.5.3 Dual-pump operation (DUAL)

Function

Activating the DUAL function starts dual-pump operation. After a few seconds, the duty/stand-by operating mode becomes active and will stop one of the pumps. The pump which remains active (on duty) is operated at 0-100%; the other pump is on stand-by. The External Start/Stop function is de-activated for the stand-by pump, irrespective of whether the RUN terminal pair is connected. The duty pump can be controlled by means of the 0-10V operating mode or the integrated External Start/Stop function.

Automatic pump

changeover

The pumps come with an integrated timer that stops the duty pump after 24hours of operation and starts up the stand-by pump. To this effect, before the duty 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 pump the stand-by pump will be started up automatically and will take over the functions of the failed pump. Both functions (pump changeover and redundant operation) are performed automatically.

Electrical connection

Setting

NOTE

Connected pumps will use the settings of the other pump. This does not apply to the Modbus address.

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Table24: Activating and de-activating the Dual-pump Operation (DUAL) operating mode

Step 1: Enabling the sub-mode (DUAL, Modbus, 0-10V)

▪ Press the control element for 6seconds.

– One of the symbols representing the Dual-pump Operation

(DUAL), Modbus and 0-10V sub-modes will start flashing.

Step 2: Selecting the Dual-pump Operation (DUAL) operating mode

▪ Turn the control element and select the required operating

mode.

DUAL

Step 3: Activating or de-activating the Dual-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 settings.

7.5.4 Modbus

Function

The pumps are Modbus slaves and only respond to the Modbus master (external hardware and software). The pump can neither be set nor operated as a Modbus master. The send commands and receive commands comply with the requirements of the Modbus RTU standard protocol.

NOTE

All Modbus data points can only be read (monitored) and input transmitted via Modbus can only be received and processed when the Modbus function is enabled. See Overview of Modbus operating parameters.

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Table25: Overview of Modbus operating parameters

Parameter description Register Length

[byte]

Type/format Unit Access

Error value, bit code 07 D0 00 02 INT16 Bit 0 = error code E01

Bit 1 = error code E02 Bit 2 = error code E03 Bit 3 = error code E04 Bit 4 = error code E05 Bit 5 = error code E06 Bit 6 = error code E07Unassigned Bit 7 = error code E08 Bit 8 = error code E09 Bit 9 = error code I10 Bit 10 = error code E11 Bit 11 = error code E12 Bit 12 = error code E13 Bit 13 = error code I14 (Error codes see the "Error value key" table.)

Calculated head 07 D2 00 02 INT16 Head in m × 10 R

Calculated flow rate 07 D4 00 02 INT16 Flow rate in m3/h x 10 R

Current speed 07 D8 00 02 UINT16 Speed in rpm R

Pump status 07 D9 00 02 UINT16 0 = Pump stop

1 = Pump in operation

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 E0 00 02 INT16 °C R

Motor temperature 07 E1 00 02 INT16 °C R

Temperature reactive power compensation module (PFC)

07 E2 00 02 INT16 °C R

Operating mode selection 08 34 00 02 ENUM 1 = Constant-pressure Control

4 = Proportional-pressure Control (factory setting) 8 = Eco Mode 16 = Open-loop Control

R/W

Setpoint input 08 35 00 02 UINT16 0 - 9999 equals

0 - 100% of the setpoint

R/W

Pump start/stop 08 36 00 02 ENUM 0x05 = Pump stop

0xA0 = Pump start (cannot overwrite the external RUN contact)

R/W

Modbus baud rate 0B B8 00 02 ENUM 0 = 19,200 (factory setting)

2 = 4,800 3 = 9,600 4 = 19,200 5 = 38,400 6 = 57,600 7 = 115,200

R/W

Modbus address 0B B9 00 02 UINT16 0 - 247,

default address 17

R/W

Modbus parity 0B BA 00 02 UINT16 2 = PE: Parity Even (factory

setting) 1 = PO: Parity Odd 0 = P-: No Parity

R/W

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Data points

Data points of type R are read-only; data points of type R/W are read & write enabled.

Function Function code

Read Function code 03

(0x03 Read holding registers)

Write Function code 16

(0x10 Write multiple registers)

All registers (07 D0 … 07 DE) can be read out via function code 0x03 (Read holding registers) as one unit.

Table26: Error value key

Error value Description Bit

E01 Temperature limit exceeded 0

E02 Overcurrent 1

E03 Internal fault 2

E04 Rotor blocked 3

E05 Temperature increase, speed decrease 4

E06 Mains voltage too high/ too low 5

E07 - 6

E08 Motor fault 7

E09 - 8

E11 Broken wire NTC/ speed decrease 10

E12 Firmware update required 11

E13 No pump model stored 12

I10 Broken wire at analog input 9

I14 Both pumps programmed as "left pump" 13

NOTE

Error values I10, E11 and I14 are warnings. The pump does not stop in this case. The error value is displayed until the corresponding error has been resolved. Error value E05 reduces the speed until no overload is detected any more.

Examples of Modbus communication

1. Monitoring the speed:

To be able to read the current speed of the pump, the following request has to be sent by the master: Modbus Request 11 03 07 D8 00 01 07 D5

2. Setpoint input:

The setpoint can be set to any value from 0-9999, with 9999 equalling 100% of the setpoint. Example: Write setpoint 50% Modbus Request 11 10 08 35 00 01 02 13 88 EA A3

3. Input control mode:

The operating mode of the pump can also be changed via Modbus (see table). Example: Write control mode Open-loop Control Modbus Request 11 10 08 34 00 01 02 00 10 E7 E8

Control options of pumps and priorities

The pump can be controlled via the control element (dial), Modbus or the analog input. The control options available are indicated in the table.

The pump will only start up if no alarm is active, the RUN contact is bridged and the pump is connected to 230V. If the 0-10V operating mode is active, the setpoint of the analog input will be valid; all other setpoint inputs will be ignored. If the 0-10V operating mode is disabled, the last valid setpoint is valid, regardless of whether the

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input is made via the control element (dial) or Modbus. The operating mode can be changed at any time via Modbus or the control element (dial); both are of the same priority.

Table27: Control options for the pump ✘ = control option available

Operating mode Setpoint Start/stop

0-10V - ✘ ✘

Modbus ✘ ✘ ✘

Control element (dial)

✘ ✘ -

If the Modbus function and the DUAL (dual-pump operation) functions are both active, either one or both of the pumps can be connected to Modbus. Changes of global input for the duty pump will also be transmitted to the stand-by pump via the terminal pair DUAL. In Dual-pump Operation operating mode the following priorities apply to the setpoint input:

Table28: Priority list

Priority Setpoint input

1 0-10V of master pump

2 0-10V of slave pump

3 The last valid value input via Modbus or

control element (dial) of the master pump or slave pump

NOTE

The pump is delivered with the terminal pair RUN bridged.

DUAL mode

If the DUAL function is active, the pumps are automatically changed over in accordance with the pump changeover time (1...24hours) of uninterrupted operating time; in the event of a failure of the duty pump, the stand-by pump will take over the function of the duty pump.

If the Modbus function has been de-activated, active Modbus input will no longer be processed by the control module. Instead, the previously active local input functions will be re-activated. When returning to the Modbus operating mode, the Modbus input must be re-written and re-sent by the control station.

Setting

For activating/de-activating the Modbus operating mode and adjusting the Modbus communication settings, connect the pump to a Modbus network with a suitable, commercial, shielded data cable. The procedure below describes how to activate/deactivate the Modbus operating mode and adjust the settings for Modbus communication.

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Table29: Activating and de-activating the Modbus operating mode

Step 1: Enabling the sub-mode (DUAL, Modbus, 0-10V)

▪ Press the control element for 6seconds.

– One of the 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

mode.

Modbus

Step 3: Activating or de-activating the Modbus operating mode

▪ Press the control element.

– The symbol will light up.

Step 4: Setting the Modbus address (flashing display)

▪ Turn the control element and set the required address.

▪ Press the control element.

– Factory setting: 17

Step 5: Setting the Modbus baud rate (flashing display)

▪ Turn the control element and set the required baud rate.

▪ Press the control element.

– Factory setting: 19.2

Step 6: Setting the Modbus parity (flashing display)

▪ Turn the control element and set the parity.

▪ Press the control element.

– Factory setting : PE (Parity Even)

– PO (Parity ODD)

– P- (No Parity)

NOTE

If 10seconds pass without any settings being made, the entries made so far made will be saved.

7.5.5 Setback operation

Function

If Setback Operation is enabled, the pump identifies minimum heating requirements when the fluid temperature sinks continuously. The pump automatically switches to operation with minimum speed and reduces the speed of the LED circular running light. When the setpoint is changed or heat demand rises again, the pump automatically reverts from Setback Operation to its previous operating mode.

NOTE

This function is disabled in the factory setting. It can be enabled with the KSB ServiceTool.

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7.5.6 Ramps

During normal operation the motor responds to a setpoint change of the pump controller with maximum dynamic. In order to prevent pressure surges this dynamic is limited while the pump is started up or stopped or when the pump controller changes the setpoint in large increments. In such cases a ramp is applied to attenuate the speed adjustment. The ramps act like first-order low-pass filters with an adjustable time constantτ. The default setting is τ = 1second. The behaviour of such a low pass is illustrated in the Fig. Behaviour of a low pass.

0 1 2 3 4 5 6 7

-0.2

0.2

0.4

0.6

0.8

1.2

τ = 1s

6 · τ

Fig.28: Behaviour of a low pass

The figure shows a setpoint jump ① and the jump response ③. The intersection of the jump response tangent② and the setpoint jump marks the time constant(τ). As a rule of thumb the jump response reaches its final value after a duration of 6×τ.

7.5.7 Deblocking the impeller

Function

The pump is started up at maximum torque to remove any mechanical blocking which may occur (at the impeller or motor shaft). The pump's current input is limited in this case (protective function). If the blocking cannot be removed, the pump will stop the start-up attempt, and error code E04 will be displayed. After a short interval the pump will try to start up again. The start-up attempts are limited to 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

7.5.8 Protection against excessive temperature

To protect the motor against overheating a sensor monitors the winding temperature. If the temperature enters a critical range, the motor outputs warningE05 and the maximum permissible speed is limited. The new maximum speed limit equals 70% of the speed at the time the warning was output. If the temperature is still in the critical range after four minutes have passed, the maximum speed is reduced by another 30%. If the temperature exceeds the alarm limit, the pump is stopped and alarmE01 is displayed.

This procedure is explained in an example.

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100

120

140

160

1000

2000

3000

0 2 4 6 8 10 12 14 16 18 20

1000

2000

3000

4000

-30 %

①

②

T [°C]n [min

-1

]n max [min

-1

]

t [min]

Fig.29: Example: Diagram of protection against excessive temperature

The temperature limit from which the speed is reduced equals 125°C ①. From 148°C ② the pump is stopped. The diagram at the top shows an example of motor temperature over time. The diagram in the middle shows an example of the speed, and the diagram at the bottom shows the maximum permissible speed over time. In the time from 0 to 8 minutes the temperature is below the warning limit; the pump is in normal operation. The maximum permissible speed for this example is 3600rpm. After 8minutes the motor temperature exceeds the warning limit of 125°C. At this point of time the motor speed is 2500rpm. This value is reduced by 30%, equalling 1750rpm, which is the new maximum speed. After 12 minutes the motor temperature is still in the critical range. The maximum speed is reduced by another 30% to 1225rpm. After 16minutes the motor temperature exceeds the alarm limit of 148°C ②; the motor stops.

7.5.9 Saving data

Function

The operating data of the pump are saved. Data storage will be maintained also when the pump is stopped or de-energised. When the pump is started up again, it will be operated with the data and duty point that were active before the pump was last stopped.

Settings

None

7.5.10 General fault messages

Table30: Error codes, causes and response

Error code on the pump display

Cause Status Response

E01 Excessive

temperature

Alarm The pump is stopped

E02 Overcurrent Alarm The pump is stopped

E03 Internal fault Alarm The pump is stopped

E04 Rotor blocked Alarm The pump is stopped

E05 Temperature limit

reached

Warning Speed is reduced

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Error code on the pump display

Cause Status Response

E06 Voltage error Alarm The pump is stopped

E07 - - -

E08 Motor fault Alarm The pump is stopped

E09 - - -

E10 Broken wire of 0-

10V signal

Alarm The pump is stopped

E11 Broken wire of

temperature sensor (NTC) in the motor

Warning Speed is reduced

E12 Firmware update

required

Alarm The pump is stopped

E13 No pump model

stored

Alarm The pump is stopped

I10 Broken wire at

analog input

Information Pump keeps running

I14 Pumps have the

same firmware version

Information Pump keeps running

7.6 Resetting the factory setting

To reset the factory setting of the pump press the control button for more than 30seconds. This comprises the following settings:

Operating mode Proportional-pressure control Functions The Dual, Modbus, 0-10V functions are disabled.

Setpoints 50%

Modbus parameter baud rate 19,200 baud

Modbus parameter slave ID 17

Modbus parameter parity Even

4) For dual pumps only

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8 Information about settings

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9 Servicing/Maintenance

9.1 Maintenance/inspection

The circulators are almost maintenance-free. If the pump has not been in operation for a prolonged period of time or if the system is severely contaminated, the rotor can become blocked.

NOTE

Any repairs on the pump must only be performed by one of our authorised service partners. For contact details please refer to the enclosed "Addresses" booklet or visit "www.ksb.com/contact" on the Internet.

9.2 Drainage/cleaning

WARNING

Fluids handled, consumables and supplies which are hot and/or pose a health hazard

Hazard to persons and the environment!

▷ Collect and properly dispose of flushing fluid and any fluid residues.

▷ Wear safety clothing and a protective mask if required.

▷ Observe all legal regulations on the disposal of fluids posing a health hazard.

1. Always flush and clean the pump before transporting it to the workshop.

Provide a certificate of decontamination for the pump.

9.3 Removing the pump set from the piping

DANGER

Hazardous electrical voltage when the covers of the terminal wiring compartments are removed

Danger of death from electric shock!

▷ For working on the terminals, switch off the power supply at least 5minutes

prior to commencing work and ensure that it cannot be switched on again unintentionally.

▷ If applicable, switch off the external power supply to message relays and

control cables and make sure it cannot be switched on again unintentionally.

▷ Keep the covers of the terminal wiring compartments closed during operation

as well as during maintenance work.

DANGER

Strong magnetic field in the rotor area

Danger of death for persons with pacemaker! Interference with magnetic data carriers, 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.

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DANGER

Pump acting as a generator when running in reverse

Danger to life from hazardous induction voltage at the motor terminals!

▷ Prevent the fluid from flowing back by closing the shut-off elements.

WARNING

Strong magnetic field

Danger of crushing injuries when pulling out the rotor! Strong magnetic field can suddenly pull the rotor back into its original position! Danger of magnetic parts near the rotor being attracted!

▷ The rotor must only be removed from the motor 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.

WARNING

Hot surface

Risk of injury!

▷ Allow the pump set to cool down to ambient temperature.

ü The pump set has been de-energised and secured against unintentional start-up.

ü The pump has cooled down to ambient temperature.

ü A container for collecting the fluid has been positioned underneath the pump

set.

1. Close the shut-off elements.

2. Disconnect the discharge nozzle and suction nozzle from the piping.

3. Depending on the pump size/ motor size, remove the supports from the pump

set.

4. Remove the complete pump set from the piping.

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10 Trouble-shooting

WARNING

Improper work to remedy faults

Risk of injury!

▷ For any work performed to remedy faults, observe the relevant information

given in this operating manual and/or in the product literature provided by the accessories manufacturer.

If problems occur that are not described in the following table, consultation with the customer service is required.

Pump is running, but does not deliver

Pump starts up but stops again immediately

E01 to E13

Error code on the display

I10, I14

Error code on the display

Table31: Trouble-shooting

Error value

Possible cause Remedy

A ▪ Master switch switched off

▪ Defective fuse

▪ Electrical connection incorrect or not

connected (alarm displayed)

▪ Check master switch.

▪ Check fuse.

▪ Check electrical connection of the pump.

B ▪ Remote start/stop contact has been

removed.

▪ Overcurrent at the motor (alarm

displayed)

▪ Fit connecting bridge for start/stop function.

E01 ▪ Excessive temperature ▪ Let the pump cool down for some minutes. Then try to re-

start it.

▪ Verify that the fluid temperature and ambient temperature

are within the permissible temperature ranges.

E02 ▪ Overcurrent ▪ De-energise the pump for 1minute; then re-energise it.

E03 ▪ Internal fault ▪ De-energise the pump for 1minute; then re-energise it.

▪ Carry out a firmware update.

E04 ▪ Rotor blocked ▪ De-energise the pump for 1minute; then re-energise it.

▪ If the pump is still blocked, properly dismantle and deblock

it.

E05 ▪ Temperature limit reached ▪ To prevent a temperature increase inside the pump the

speed has been reduced.

▪ Once the pump has cooled down, it will revert to its normal

operating data. If the temperature continues to rise, E01 will be indicated on the display.

▪ Verify that the fluid temperature and ambient temperature

are within the permissible temperature ranges.

E06 ▪ Voltage error ▪ Verify that the supply voltage matches the data on the name

plate.

▪ Measure the mains voltage.

5) Release pump pressure before attempting to remedy faults on parts which are subjected to pressure.

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10 Trouble-shooting

58 of 64

Calio

Error value

Possible cause Remedy

E08 ▪ Motor fault

▪ Incorrect rotor angle due to external

flow or other causes, e.g. blocked rotor.

▪ De-energise the pump for 1minute; then re-energise it.

▪ If the fault/alarm has not been cleared, have the motor

checked by KSBService.

E10 ▪ Broken wire of 0-10V control signal ▪ Check the analog 0-10V control signal.

E11 ▪ Broken wire of temperature sensor

(NTC) in the motor

▪ Have it checked by KSB Service.

E12 ▪ Firmware not compatible ▪ Carry out a firmware update.

E13 ▪ No pump model stored. (The pump is

stopped.)

▪ Carry out a firmware update.

▪ Enter pump size as indicated on the name plate.

I10 ▪ Broken wire of 0-10V control signal

(pump is not stopped.)

▪ Check the analog 0-10V control signal.

I14 ▪ For dual pumps both pumps are

programmed as "left" pump". (Pumps are not stopped.)

▪ Carry out firmware update for "right pump".

6) Only for pump sizes with a rating of 800W (40-120/-180, 50-100/-120/-150/-180, 65-120, 80-80, 100-60)

7) I10 or E10 can be set with the KSB Service Tool.

Page 59

11 Related Documents

59 of 64

Calio

11 Related Documents

11.1 Exploded view with list of components

101 411 01-44 81-59 a

Fig.30: Exploded view

Part No. Description Part No. Description

01-44 Rotor 101 Pump casing

81-59 Stator 411 Joint ring

a Heat sink including frequency inverter

11.2 Wiring diagram

D+

D-

STATUS

COMRUN

DUAL0-10 V

ALARM POWER

Vin

0 V

1 2

0 V

Fig.31: Wiring diagram of a Calio

Connections for control cables

a1 External 0-10V

a2 External start/stop

a3 Terminating resistor for Modbus cable (DIP switches)

a4 Modbus

a5 Dual-pump configuration

Connections for power supply and general fault message

b1 Power supply 1~230VAC +/- 10%, 50Hz

b2 “In operation” message

b3 General fault message

Page 60

12 EU Declaration of Conformity

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Calio

12 EU Declaration of Conformity

Manufacturer: KSB Aktiengesellschaft

Johann-Klein-Straße 9

67227 Frankenthal (Germany)

The manufacturer herewith declares that the product:

Calio

Series code range: 2017w37 to 2018w52

▪ is in conformity with the provisions of the following Directives as amended from time to time:

– Pump set: EC Machinery Directive 2006/42/EC

– Pump set: Low-voltage Directive 2014/35/EU

– Pump set: Electromagnetic Compatibility Directive 2014/30/EU

– Pump set: Ecodesign Directive 2009/125/EC, Regulations No. 641/2009 and 622/2012

The manufacturer also declares that

▪ the following harmonised international standards have been applied:

– EN 809

– EN 60335-1, EN 60335-2-51

– EN 61000-6-1, EN 61000-6-3

– EN 16297-1, EN 16297-2

Person authorised to compile the technical file:

Christopher Hamkins Head of Productionalisation KSB Aktiengesellschaft Johann-Klein-Straße 9 67227 Frankenthal (Germany)

The EU Declaration of Conformity was issued in/on:

Frankenthal, 13 September 2017

Joachim Schullerer

Head of Product Development Pump Systems and Drives

KSB Aktiengesellschaft

Johann-Klein-Straße 9

67227 Frankenthal

Page 61

Index

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Calio

Index

Applications8 Automatic functions14

Bearings14

Commissioning30 Connections14

Design14 Designation13 Disposal12 Drive14

Event of damage6

Fault/malfunction

Causes and remedies57

Fluid handled

Density33

Intended use8

Key to safety symbols/markings7

Manual functions14 Misuse8

Operating limits31 Operating modes14 Other applicable documents6

Piping20 Preservation11, 33 Product description13

Return to supplier12 Returning to service34

Safety7 Safety awareness9 Scope of supply16 Shutdown33 Signalling and display functions15 Start-up31 Storage11, 33

Transport10

Warnings7 Warranty claims6

Page 62

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Page 64

KSB Aktiengesellschaft

Johann-Klein-Straße 9 • 67227 Frankenthal (Germany)

Tel. +49 6233 86-0

www.ksb.com

1157.821/01-EN

KSB Calio Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual