KSB Calio S BMS Operating Manual

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High-efficiency Circulator Pump

Calio S BMS

Installation/Operating Manual

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Legal information/Copyright

Installation/Operating Manual Calio S BMS

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 modification 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 Symbols .............................................................................................................................................................6

2 Safety...................................................................................................................................................... 7

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

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

2.3 Intended use .....................................................................................................................................................7

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

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

2.6 Safety awareness ..............................................................................................................................................8

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

3.3 Storage/preservation......................................................................................................................................10

3.4 Return to supplier...........................................................................................................................................10

3.5 Disposal ...........................................................................................................................................................11

4 Description of the Pump (Set)............................................................................................................. 12

4.1 General description ........................................................................................................................................12

4.2 Designation.....................................................................................................................................................12

4.3 Name plate......................................................................................................................................................12

4.4 Design details..................................................................................................................................................13

4.5 Configuration and function...........................................................................................................................14

4.6 Noise characteristics .......................................................................................................................................14

4.7 Scope of supply...............................................................................................................................................14

4.8 Dimensions and weight..................................................................................................................................14

4.9 Accessories ......................................................................................................................................................14

4.10 Technical data.................................................................................................................................................15

5 Installation at Site................................................................................................................................ 16

5.1 Safety regulations ..........................................................................................................................................16

5.2 Checks to be carried out prior to installation...............................................................................................16

5.3 Installing the pump set ..................................................................................................................................16

5.4 Connecting the piping ...................................................................................................................................18

5.5 Enclosure/insulation .......................................................................................................................................18

5.6 Electrical connection ......................................................................................................................................19

6 Commissioning/Start-up/Shutdown................................................................................................... 23

6.1 Commissioning/Start-up.................................................................................................................................23

6.1.1 Prerequisites for commissioning/start-up .........................................................................................23

6.1.2 Priming and venting the pump.........................................................................................................23

6.1.3 Start-up............................................................................................................................................... 23

6.1.4 Control panel .....................................................................................................................................24

6.1.5 Mode of operation ............................................................................................................................26

6.2 Shutdown........................................................................................................................................................38

6.3 Operating limits..............................................................................................................................................38

6.3.1 Ambient temperature........................................................................................................................38

6.3.2 Density of the fluid handled .............................................................................................................39

6.4 Shutdown/storage/preservation ....................................................................................................................39

6.4.1 Measures to be taken for shutdown ................................................................................................39

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6.5 Returning to service .......................................................................................................................................39

7 Servicing/Maintenance........................................................................................................................ 40

7.1 Maintenance/inspection.................................................................................................................................40

7.2 Drainage/cleaning ..........................................................................................................................................40

7.3 Removing the pump set from the piping .....................................................................................................40

7.3.1 Dismantling the complete pump set ................................................................................................40

8 Trouble-shooting.................................................................................................................................. 42

9 Related Documents.............................................................................................................................. 44

9.1 Sectional drawing with list of components ..................................................................................................44

9.2 Wiring diagram...............................................................................................................................................44

10 EU Declaration of Conformity............................................................................................................. 46

Index ..................................................................................................................................................... 47

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Glossary

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Glossary

Discharge line

The pipeline which is connected to the discharge nozzle

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 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.

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 Symbols

Table1: 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2: 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.

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

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 in the fields of application and within the

use limits specified 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.

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2 Safety

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▪ 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.

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

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

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2 Safety

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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 (set) are only permitted with the

manufacturer's prior consent.

▪ Use only original spare parts or parts/components authorised by the

manufacturer. The use of other parts/components 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 (set) must have cooled down to ambient temperature.

▪ Pump pressure must have been released and the pump must have been drained.

▪ When taking the pump set out of service always adhere to the procedure

described in the manual. (ðSection6.4,Page39)

▪ 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23)

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

CAUTION

Improper pump transport

Damage to the pump!

▷ Never suspend the pump/pump set from the power cable.

▷ Prevent the pump (set) from getting knocked or dropped.

3.3 Storage/preservation

If commissioning is to take place some time after delivery, we recommend that the following measures be taken for pump (set) storage.

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 where the atmospheric humidity is as constant as possible.

If properly stored indoors, the pump set is protected for a maximum of 12 months.

For storing a pump (set) which has already been operated, observe the instructions in

(ðSection6.4.1,Page39)

3.4 Return to supplier

1. Drain the pump as per operating instructions. (ðSection7.2,Page40)

2. Flush and clean the pump, particularly if it has been used for handling noxious,

explosive, hot or other hazardous fluids.

3. If the pump has handled fluids whose residues could lead to corrosion damage

in the presence of atmospheric humidity or could ignite upon contact with oxygen also neutralise the pump and blow through with anhydrous inert gas to ensure drying.

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

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

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3.5 Disposal

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 S 25-40-130

Table3: Designation key

Code Description

Calio S Type series

25 Nominal diameter of pipe connection

15 Rp1/2

25 Rp1

30 Rp 11/4

40 Head in m x 10 (example: 4m=40)

130 Overall length

130 130mm

See dimensions

BMS Building Management System

BMS With BMS function

Without BMS function

4.3 Name plate

1~230V 50/60 Hz Max 0,48 A EEI≤0.23 - PART2

Class F IP44 TF110PN10

Calio S 25-60 BMS

Prod Nr. 1412 - 000201

Material Nr. 29 134 307

Made in Switzerland

Johann-Klein-Straße 9

Deutschland

67227 Frankenthal

KSB SE & Co. KGaA

Fig.1: Name plate (example)

1 Type series, size 2 Voltage, frequency, max. input

power, energy efficiency index (EEI)

3 Thermal class, enclosure, pressure

class, temperature class

4 Material number

5 Production number

1) Blank

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4 Description of the Pump (Set)

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Key to the production

number

Example: 1412-000201

Table4: Key to the production number

Code Description

14 Year of production 2014

12 Week of production (week 12)

000201 Consecutive number

4.4 Design details

Design

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

▪ Screw-ended

Drive

▪ High-efficiency electric motor with continuously variable differential pressure

control

▪ Electronically commutated synchronous motor with permanent magnet rotor

▪ 1~230VAC, 50Hz/60Hz

▪ Enclosure IP44

▪ Thermal class F

▪ Temperature class TF110

▪ Interference emissions EN61000-6-3

▪ Interference immunity EN61000-6-2

Bearings

▪ Product-lubricated special plain bearing

Operating modes

▪ Constant-pressure control

▪ Proportional-pressure control

▪ Eco Mode with dynamic differential pressure setpoint adjustment

▪ Open-loop control via setpoint setting

Automatic functions

▪ Continuous output adjustment depending on the mode of operation

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

▪ 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

Signalling and display functions

▪ Alternating display of flow rate and electrical input power

▪ Error codes indicated on the display

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4 Description of the Pump (Set)

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4.5 Configuration and function

Fig.2: 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

Table5: Noise characteristics

Size Sound pressure level

All 45 dB (A) max.

4.7 Scope of supply

The following items are included in the scope of supply:

▪ Pump set

▪ Two-piece thermal insulation shell (single pump)

▪ Sealing elements

▪ Installation/operating manual

4.8 Dimensions and weight

For dimensions and weights please refer to the type series booklet of the pump (set).

4.9 Accessories

No accessories available.

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4 Description of the Pump (Set)

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4.10 Technical data

Table6: Technical data

Feature or characteristic Value

Maximum flow rate Depends on the pump type, see type series booklet

Maximum head Depends on the pump type, see type series booklet

Speed Depends on the pump type, see type series booklet

Mains voltage 1~ 230VAC +/- 10%

Frequency 50 Hz / 60 Hz

Rated current See name plate

Thermal class See name plate

Enclosure See name plate

Input power P1 Depends on the pump type, see type series booklet

Nominal diameter See name plate / type code in the type series booklet

Mating flanges See name plate / type code in the type series booklet

Pump weight Depends on the pump type, see type series booklet

Permissible ambient temperature 0°C to +40°C

Maximum relative humidity ≤ 80%

Permissible fluid temperature -10°C to + 110°C

Maximum permissible operating pressure

PN10

Sound pressure level < 45dB(A)

Minimum inlet pressure 80°C: 0.5bar; 95°C: 1.5bar

Permissible fluids Heating water to VDI 2035

Water/glycol mixture, max. mixing ratio 1:12) (only use brand name products with corrosion inhibitors; observe the information provided by the producer as well as the safety data sheets). Fluids other than those above must only be used upon prior approval by the pump manufacturer. For ethylene/propylene glycols with corrosion inhibitors, commercial oxygen binders, anti-corrosives, fluids with several additives, and cooling brines see the following danger note.

EEI See type series booklet.

EMC (electromagnetic compatibility) 2004/108/EC

RFI emission EN 61000-6-3

Interference immunity EN 61000-6-2

DANGER

Non-compliance with manufacturer's instructions

Personal injury and damage to property!

▷ Use permissible fluids only.

▷ Always observe the safety data sheets and manufacturer's instructions!

▷ Observe the manufacturer's instructions on mixing ratios.

▷ If any additives are to be mixed into the fluid, do so on the discharge side of

the pump.

2) If any glycol is added to the fluid handled, the operating data of the pump must be adjusted to a higher viscosity,

depending on the mixing ratio.

3) Reference value for the most efficient of circulators: EEI≤0.20

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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:

▪ The pump set can be operated on the power supply network according to the

data on the name plate.

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

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

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.

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.

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.

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

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.3: Permissible installation positions

DANGER

Leakage at the pump

Leakage of hot fluids!

▷ Insert the O-ring in the correct position.

Screw-ended pumps

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. Connect the pump and piping with a pipe union.

4. Tighten the pipe union hand-tight with an assembly tool (e.g. pipe wrench).

5. Accurately insert the sealing element in the opposite pipe union.

6. Tighten the pipe union hand-tight with an assembly tool (e.g. pipe wrench).

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.

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6. Bolt the pump flange to the pipe flange.

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

5.4 Connecting the piping

DANGER

Excessive loads acting on the pump nozzles

Danger to life from leakage of hot fluids!

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

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

transmitting any stresses or strains.

▷ Take appropriate measures to compensate 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.

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 pipes 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

NOTE

The pump is supplied with a thermal insulation shell.

WARNING

The pump takes on same temperature as the fluid handled

Risk of burns!

▷ Insulate the volute casing.

▷ Fit protective equipment.

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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 regulations IEC 60364 and, for explosion-proof models, EN60079.

DANGER

Work performed on an energised terminal box

Danger of death from electric shock!

▷ Switch off the power supply at least 5 minutes prior to commencing work and

ensure that it cannot be switched on again unintentionally.

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

Connection to the power supply must be effected by means of a fixed power cable with a minimum cross-section of 3x1.5mm2, which is fitted with a plug-type connection or an all-pole isolating switch with a minimum contact opening of 3mm.

NOTE

Connection to the power supply must be effected by a power cable which is fitted with an all-pole isolating switch or a plug-type connection.

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 to prevent any hazards.

The cables for the power supply and for transmitting a general fault message as well as the data cables are wired to plug-in terminals located on both sides of the pump. The terminals are arranged in two terminal wiring compartments with a screwed-on cover each (IP 44). On one side of the housing, the cables for the power supply and general fault message are guided and wired to the pump. The corresponding symbols for the connections are marked on the cover. The terminal wiring compartment for data signals (0-10VDC, external start/stop) are located on the opposite side of the housing and marked by the corresponding symbols on the cover.

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Fig.4: Front left view of a Calio pump

C1 Symbol for connection of external signal C1 start/stop

D1 Symbol for connection of external analog 0-10VDC signal

Fig.5: Terminal wiring compartment for the data cables

D2 Terminal base for the external analog 0-10VDC signal connection

C2 Terminal base for the external start/stop signal connection

Fig.6: Front right view of a Calio pump

E1 Symbol for connection of volt-free general fault message

F1 Symbol for connection of power supply 1~230VAC, 50/60Hz

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

Fig.7: Terminal wiring compartment for power supply and transmitting a general fault message

E2 Terminal base for the general fault message connection (volt-free), terminals

NC / COM / NO

F2 Terminal base for the power supply connection 1~230VAC, 50/60Hz,

terminals PE/N/ L

Table7: Key to the symbols

Function Symbol Terminal

pair

Terminal crosssection

Terminal identification

Frequency of starts

Contact rating

Power supply 1~230VAC, 50/60Hz

1 2 3

1.5mm

3 - PE 2 - N 1 - L

< 20 / 24h

General fault message

1 2 3

1.5mm

3 - NO 2 - COM 1 - NC

Min: 12 VDC at 10mA Max: 250 V at 1A

External analog 0-10VDCsignal

0-10V

1 2

1.5mm

1 - 0 2 - Uin

External signal for start/ stop of pump (terminal pair supplied bridged)

RUN

1 2

1.5mm

1 - 0 2 - R

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Connecting the cables at the pump

1. Verify the supply voltage at the site against the data on the name plate of the

pump.

2. Undo the two screws at the cover of the terminal wiring compartment. Take this

cover off the drive unit.

3. Wire the cables to the terminals as indicated in the wiring diagram.

4. Fit the cover on the terminal wiring compartment. Fasten it to the drive unit with

the two screws.

Uin

0-10V

COM

0-10VRUN

POWER ALARM

External start/stop

External 0-10V

Supply voltage 1~230V

General fault message

Fig.8: Wiring diagram

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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.

▪ The pump has been primed with the fluid to be handled. The pump has been

vented.

6.1.2 Priming and venting the pump

NOTE

The pumps are self-venting.

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.

1. Prime the pump and suction line with the fluid to be handled.

2. Fully open the shut-off element in the suction line.

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 shaft seal

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.

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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 any, have been vented and primed with the

fluid to be pumped.

ü The lines for priming and venting have been closed.

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

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

3. Start up the motor.

6.1.4 Control panel

Operating elements

All settings are made using the dial on the housing front. To turn the dial, press the button in the middle of the dial. 10LED segments are arranged around the dial. These segments represent setpoint values ranging from 10% to 100%. The LED segments light up in blue when pump settings are being made (the figure below shows a setpoint of 40%).

NOTE

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

III

I = dial

II = control button

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

. .

m3/h

Fig.9: Display

Display

The flow rate and the electrical input power are shown as 3-digits numbers on the integrated display. The display alternates in 5-second intervals between the two values in [m3/h] and [W] respectively. The setpoint is indicated in [%].

Symbols

The operating modes, functions and settings are indicated by symbols on the front panel. Lit symbols indicate which operating mode or function is active, whether an external 0-10V signal is being transmitted and whether the pump is emitting a general fault message.

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Table8: Key to the symbols

Symbol Description Unit

m3/h Flow rate (calculated)

This symbol is lit when the flow rate value is shown on the display. (The display alternates in 5-second intervals between the flow rate and the electrical input power).

m3/h

W Electrical input power (measured)

This symbol is lit when the power value is shown on the display. (The display alternates in 5-second intervals between the flow rate and the electrical input power).

Constant-pressure Control operating mode This symbol is lit when this operating mode is active.

Proportional-pressure Control operating mode This symbol is lit when this operating mode is active.

Open-loop Control operating mode This symbol is lit when this operating mode is active.

ECO

ECO energy saving mode Both these symbols are lit when this operating mode is active.

0-10V 0-10V operating mode

This symbol is lit when this operating mode is active.

VDC

SERVICE The pump signals a general fault message

An error code is shown on the display. The display indicates error code E01 - E06.

6.1.4.1 Locking the control panel

Regardless of the operating mode the pump is in, its control panel can be locked with a second DIP switch in the wiring compartment of the pump to prevent unintentional changes of the setpoint, etc. If the Control Panel Lock function is enabled, the factory settings cannot be reset.

Table9: Setting at the pump

Status of the Control Panel Lock function Position of DIP switch 2 at the pump

= enabled

Terminals

Top Bottom

DIP

1 2

Power

= disabled

Terminals

Top Bottom

DIP

1 2

Power

Table10: Function of the DIP switches

Function DIP switch 1 DIP switch 2

Lock of pump control panel - ✘

Setback operation of pump ✘ -

6.1.4.2 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:

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Mode of operation Proportional-pressure control Functions The 0..10V function is disabled.

Setpoints 50%

6.1.5 Mode of operation

6.1.5.1 Information on settings

For common applications such as two-pipe systems Proportional-pressure Control (Δp-v) 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 the Proportional-pressure Control operating mode (Δp-v) can be selected. 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 maximum performance.

6.1.5.2 Constant-pressure control

Function

Irrespective of the flow rate, within the permissible flow rate range limited by the maximum pump characteristic ①, the pump control system maintains a constant pump head based on the set differential pressure setpoint HS.

min

max

HS2

Fig.10: Constant-pressure Control function

Setting

Activating the display from idle mode: Press the control button. 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.

Table11: Setting the operating mode to Constant-pressure Control and selecting the setpoint

Step 1: Activating the setting mode Press the control button for 3 seconds. The mode which has last been selected will start flashing.

Step 2: Selecting the Constant-pressure Control operating mode Turn the dial until the symbol of the required operating mode starts flashing.

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Step 3: Activating the Constant-pressure Control operating mode Press the control button. The setpoint which has last been set will be indicated by means of the flashing blue LED segments.

Confirming the current setpoint ⇨ Step 4a Changing the setpoint ⇨ Step 4b

Step 4a: Confirming the current setpoint Press the control button.

Step 4b: Changing the setpoint Turn the dial and set the required setpoint in increments of 1% within the range from 0% to 100%. (Turning the dial clockwise will increase the setpoint; turning the dial anti-clockwise will decrease it). The LED segments will light up in increments of 10% of the setpoint. Press the control button 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.

max

min

Fig.11: Constant-pressure Control settings

NOTE

To start the pump the terminal pair “RUN” must be bridged (factory-set) or the terminal pair must receive the signal “Start”. (ðSection6.1.5.7.2,Page36)

1 2

Fig.12: Terminal pair RUN

1 = 0

2 = R

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6.1.5.3 Proportional-pressure control

Function

Within the permissible flow rate range the pump control system decreases or increases the differential pressure setpoint of the pump between 1/2 HS and H

(factory-set) in a linear fashion with the flow rate.

HS1

min

max

/2 H

Fig.13: Proportional-pressure Control function

Setting

Table12: Setting the operating mode to Proportional-pressure Control and selecting the setpoint

Step 1: Activating the setting mode Press the control button for 3 seconds. The mode which has last been selected will start flashing.

Step 2: Selecting the Proportional-pressure Control operating mode Turn the dial until the symbol of the required operating mode starts flashing.

Step 3: Activating the Proportional-pressure Control operating mode Press the control button. The setpoint which has last been set will be indicated by means of the flashing blue LED segments.

Confirming the current setpoint ⇨ Step 4a Changing the setpoint ⇨ Step 4b

Step 4a: Confirming the current setpoint Press the control button.

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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.14: Proportional-pressure Control settings

NOTE

To start the pump the terminal pair “RUN” must be bridged (factory-set) or the terminal pair must receive the signal “Start”. (ðSection6.1.5.7.2,Page36)

1 2

Fig.15: Terminal pair RUN

1 = 0

2 = R

6.1.5.4 Open-loop control

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 10 speed levels.

2 3

Fig.16: Open-loop control function, running at speed level 2

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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Table13: 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.

2 3

Fig.17: Open-loop Control settings

NOTE

To start the pump the terminal pair “RUN” must be bridged (factory-set) or the terminal pair must receive the signal “Start”. (ðSection6.1.5.7.2,Page36)

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Table14: Speeds

Size n

Min. Max.

[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

6.1.5.5 Eco Mode

Function

In Eco Mode the pump characteristic curve (4) is quadratic, starting at the discharge head setpoint H

Eco Start

= 1/4 x HS with HS = selected setpoint (see Setting the operating

mode to Proportional-pressure Control). By changing the differential pressure setpoint the pump characteristic curve can be adjusted to higher or lower differential pressures or discharge heads. Compared with the Proportional-pressure Control operating mode the EcoMode can save more than 40% in electrical input power. The various pump characteristic curves and control ranges are illustrated in Fig. EcoMode – Characteristic curve, example of a size 25-10.0pump.

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0,00

1,00

2,00

3,00

4,00

5,00

6,00

7,00

8,00

9,00

10,00

11,00

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

Fig.18: EcoMode – Characteristic curve, example of a size 25-10.0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

Setting

Table15: Setting the operating mode to Eco Mode and selecting the setpoint

Step 1: Activating the setting mode Press the control button for 3seconds. The mode which has last been selected will start flashing.

Step 2: Selecting the Eco Mode operating mode Turn the dial until the symbol of the required operating mode starts flashing.

ECO

Step 3: Activating the Eco Mode operating mode Press the control button. The setpoint which has last been set will be indicated by means of the flashing blue LED segments.

Confirming the current setpoint ⇨ Step 4a Changing the setpoint ⇨ Step 4b

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Step 4a: Confirming the current setpoint Press the control button.

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 terminal pair “RUN” must be bridged (factory-set) or the terminal pair must receive the signal “Start”. (ðSection6.1.5.7.2,Page36)

1 2

Fig.19: RUN terminal pair

1 = 0

2 = R

6.1.5.6 0-10V

Function

An external analog 0-10VDC signal serves as external setpoint input for the pump. The pump processes the current external analog signal as a differential pressure setpoint if the Constant-pressure Control or Proportional-pressure Control operating modes are active, or as speed setpoint if the Open-loop Control operating mode is active. If the signal level is below <2VDC the pump will switch off and the last LED segment will extinguish.

Table16: 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

< 2 VDC Pump will switch off

≥ 2 VDC Pump will start up

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V [ V DC]

100% of the setpoint

2 V

Setpoint

0 % of the setpoint

10 V

Fig.20: Analog 0-10V signal as setpoint for the pump

Setting

The external analog signal is wired to the terminal pair "0-10V" integrated in the pump.

Table17: Activating/de-activating the 0-10V operating mode and setting the setpoint

Step 1: Enabling the sub-mode (0-10V) Press the control button for 6seconds. The sub-mode symbol 0-10V will start flashing.

Step 2: Selecting the 0-10V operating mode Turn the dial until the symbol of the required operating mode starts flashing.

0-10V

Step 3: Activating or de-activating the 0-10V operating mode Press the control button. 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18: LED segments per signal level [V]

Lit LED segment Voltage

0 2,4

1 3,2

2 4,0

3 4,8

4 5,6

5 6,4

6 7,2

7 8,0

8 8,8

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Lit LED segment Voltage

9 9,6

10 10,0

The external analog signal is wired to the terminal pair "0-10V" integrated in the pump.

NOTE

To start the pump the terminal pair “RUN” must be bridged (factory-set) or the terminal pair must receive the signal “Start”. (ðSection6.1.5.7.2,Page36)

1 2

Fig.21: Terminal pair RUN

1 = 0

2 = R

6.1.5.7 Functions

6.1.5.7.1 Setback operation

DANGER

Work at the DIP switch by unqualified personnel

Danger of death from electric shock!

▷ The pump must be de-energised before the Setback Operation function can be

enabled/disabled at DIP switch1.

Function

When the fluid temperature has been sinking continuously the pump recognises minimum heating requirements. If the Setback Operation function is enabled, the pump automatically switches to operation at minimum speed and also reduces the speed of the circular running light. When the setpoint is changed, the pump changes from Setback Operation to its previous operating mode. When the demand on heating performance rises again, the pump automatically returns to its previous operating mode. Unless the 0-10V function is active, the Setback Operation function can be enabled in all operating modes via DIP switch 1 (the function is enabled with DIP switch 1 in top position).

NOTE

This function is disabled in the factory setting.

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Power

Terminals

Top Bottom

DIP

1 2

Terminal DIP

1 2

Power

Fig.22: Position of DIP switch 1

Position of DIP switch 1 Setback Operation function

Top Enabled

Bottom Disabled

Prerequisites:

1. The pump is installed in the supply line.

2. The Setback Operation function must be enabled in the higher-level control

system (this will reduce the supply temperature).

Supply 1

≤60 min

Supply 2

Supply

Fig.23: Setback operation

6.1.5.7.2 External start/stop

Function

The pump is started up/stopped as a function of an external signal. To determine the status of the transferred signal, one of the two terminals is internally supplied with a low voltage. The voltage at both terminals of the pair is measured to the same chassis ground. The measurement at the second terminal of the pair will indicate the voltage drop.

Table19: Pump start and stop

Measured voltage drop Response

0 Pump starts up (contact closed / terminals bridged)

> 0 Pump stops (contact open / terminals not bridged)

Setting

The external signal is wired to the terminal pair RUN integrated in the pump.

1 2

Fig.24: Terminal pair RUN

1 = 0

2 = R

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6.1.5.7.3 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. Once the pump is switched on again it will be operated with the data and duty point that were active before the pump was last stopped.

Settings

None

6.1.5.7.4 Deblocking the impeller

Function

The pump is started up at maximum torque to remove any hydraulic blocking which may occur (at the impeller or motor shaft). The pump input power is limited in this case (protective function). If the blocking cannot be removed, the pump will stop the start-up attempt and display error code E04. After a short break the pump will try to start up again. The number of start-up attempts is unlimited. Once the pump has started up successfully, it will acknowledge the error message; error code E04 will disappear from the display.

Settings

None

6.1.5.7.5 Protective functions

Function

The electronic motor protection automatically reduces the pump power in the event of overloading. Warning E05 is shown on the display.

Settings

None

6.1.5.7.6 Alerts

Function

To protect the pump from destruction it is stopped in the event of severe errors (E01

- E04, E06). The integrated relay with a volt-free NC and a volt-free NO contact can be used as a general fault message.

Table20: Error codes, causes and response

Error code on the pump display

Cause Response

E01 Overheating The pump is stopped

E02 Overcurrent The pump is stopped

E03 Internal fault The pump is stopped

E04 Rotor blocked The pump is stopped

E05 Rise in temperature Speed is reduced

E06 Voltage error The pump is stopped

E08 Motor fault The pump is stopped

Setting

The signal is wired to the terminal pair Alarm with terminals NO/COM/NC.

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Calio S BMS

COM

Pump failure-free

1 = NC

COM

2 = COM 3 = NO

Pump failure (E01 - E04, E06)

1 2 3

Fig.25: Wiring diagram for the alarm message

6.2 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 check valve, the shut-off element in the discharge line may remain open, provided the site's requirements and regulations are taken into account 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.

6.3 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.

6.3.1 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:

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Table21: Fluid temperature specified for the ambient temperature [°C]

Fluid temperature Ambient temperature

All 110 30

90 40

6.3.2 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.

6.4 Shutdown/storage/preservation

6.4.1 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. Start up the pump (set) regularly between once a month and once every three

months for approximately five minutes during prolonged shutdown periods. This will prevent the formation of deposits within the pump and the pump intake area.

The pump is removed from the pipe and stored

The pump has been properly drained (ðSection7.2,Page40) and the safety instructions for dismantling the pump have been observed.

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

6.5 Returning to service

For returning the pump to service observe the sections on commissioning/start-up 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 injuries by escaping fluid!

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

relevant and protective devices.

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7 Servicing/Maintenance

7.1 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. In the event of a failure, please contact your heating system engineer.

7.2 Drainage/cleaning

WARNING

Fluids, 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 residues of the fluid

handled.

▷ 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 the pump if it has been used for handling noxious, hot or other

hazardous fluids. Always flush and clean the pump before transporting it to the workshop. Provide a cleaning record for the pump.

7.3 Removing the pump set from the piping

7.3.1 Dismantling the complete pump set

DANGER

Work performed on an energised terminal box

Danger of death from electric shock!

▷ Switch off the power supply at least 5 minutes prior to commencing work and

ensure that it cannot be switched on again unintentionally.

DANGER

Strong magnetic field in the rotor area

Danger of death for persons with pacemaker!

▷ Keep a safety distance of at least 0.3 m.

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.

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WARNING

Danger by strong magnetic field

Danger of crushing injuries when pulling out the rotor! Due to the strong magnetic field the rotor can be suddenly pulled back into its original position! Danger of magnetic parts near the rotor being attracted!

▷ The rotor must generally 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.

CAUTION

Strong magnetic field in the rotor area

Interference with magnetic data carriers, electronic devices, components and instruments!

Uncontrolled magnetic attraction forces between magnetic components, tools or similar!

▷ Remove any magnetic parts from the vicinity of the rotor.

▷ Keep the assembly area clean.

CAUTION

Danger by strong magnetic field

Negative impact on or damage to electrical devices!

▷ The rotor must generally only be removed from the motor housing by

authorised specialist personnel.

ü The relevant notes and steps stated have been observed/carried out.

ü The pump has cooled down to ambient temperature.

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

set.

1. De-energise the pump set (disconnect the motor) and ensure that it cannot be

re-energised unintentionally.

2. Close the shut-off elements.

3. Disconnect the discharge and suction nozzles from the piping.

4. Depending on the pump/motor size, remove the supports from the pump set.

5. Remove the complete pump set from the piping.

Page 42

8 Trouble-shooting

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Calio S BMS

8 Trouble-shooting

WARNING

Improper work to remedy faults

Risk of injury!

▷ For any work to remedy faults observe the relevant information in this manual

or in the relevant accessory manufacturer's product literature.

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

Error code on the display

E02

Error code on the display

E03

Error code on the display

E04

Error code on the display

E05

Error code on the display

E06

Error code on the display

E08

Error code on the display

Table22: Trouble-shooting

A B E01 E02 E03 E04 E05 E06 E08 Possible cause Remedy

✘ - - - - - - - - Master switch OFF, defective

fuse, earth conductor not or incorrectly connected

Check master switch. Check fuse. Check pump connection.

- ✘ - - - - - - - Remote start/stop contact has

been removed. Overcurrent at the pump motor

Fit connecting bridge for start/ stop function.

- - ✘ - - - - - - Overheating Let the pump cool down for

some minutes. Then try to restart it. Verify that the water and ambient temperature are within the indicated temperature ranges.

- - - ✘ - - - - - Overcurrent Disconnect the pump from the

power supply (for 1minute). Then re-connect it to the power supply.

- - - - ✘ - - - - Internal fault Disconnect the pump from the

power supply (for 1minute). Then re-connect it to the power supply.

- - - - - ✘ - - - Rotor blocked Start up and stop the pump

several times. If the pump is still blocked, properly dismantle and deblock it.

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

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8 Trouble-shooting

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Calio S BMS

A B E01 E02 E03 E04 E05 E06 E08 Possible cause Remedy

- - - - - - ✘ - - Rise in temperature 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.

- - - - - - - ✘ - Voltage error Verify that the voltage matches

the data on the name plate.

- - - - - - - - ✘ Motor fault

Incorrect rotor angle due to external flow or other causes, e.g. blocked rotor.

Disconnect the pump from the power supply. After 1minute, re-connect it to the power supply. If the fault has not been cleared, have the motor checked by

KSBService.

5) Only for pump sizes with a power rating of 800Watt (40-120/-180, 50-100/-120/-150/-180, 65-120, 80-80, 100-60)

Page 44

9 Related Documents

44 of 48

Calio S BMS

9 Related Documents

9.1 Sectional drawing with list of components

101

81-59

01-44

Part No. Description Part No. Description

01-44 Rotor 101 Volute casing

81-59 Stator

9.2 Wiring diagram

Uin

0-10V

COM

0-10VRUN

POWER ALARM

External start/stop

External 0-10V

Supply voltage 1~230V

General fault message

Fig.26: Wiring diagram

Page 45

9 Related Documents

45 of 48

Calio S BMS

Page 46

10 EU Declaration of Conformity

46 of 48

Calio S BMS

10 EU Declaration of Conformity

Manufacturer: KSB SE & Co. KGaA

Johann-Klein-Straße 9

67227 Frankenthal (Germany)

The manufacturer herewith declares that the product:

Calio S BMS

Series code range: 2018w01 to 2019w52

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

time to time:

– 2006/42/EC: Machinery Directive

– 2009/125/EC: Creation of a framework for the stipulation of requirements for

the environmentally compatible design of energy-related products (Ecodesign Directive), Regulation No. 641/2009 and/or 622/2012

– 2014/35/EU: Electrical Equipment Designed for Use within Specific Voltage

Limits (Low Voltage)

– 2014/30/EU: Electromagnetic Compatibility (EMC)

The manufacturer also declares that

▪ the following harmonised international standards have been applied:

– EN 809

– EN 60335-1, EN 60335-2-51

– EN 61000-6-2, EN 61000-6-3

– EN 16297-1, EN 16297-2

Person authorised to compile the technical file:

Christopher Hamkins Head of Productionalisation KSB SE & Co. KGaA Johann-Klein-Straße 9 67227 Frankenthal (Germany)

The EU Declaration of Conformity was issued in/on:

Frankenthal, 1 February 2018

Joachim Schullerer

Head of Product Development Pump Systems and Drives

KSB SE & Co. KGaA

Johann-Klein-Straße 9

67227 Frankenthal

Page 47

Index

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Calio S BMS

Index

Automatic functions13

Bearings13

Commissioning23

Design13 Designation12 Disposal11 Drive13

Event of damage6

Faults

Causes and remedies42

Fields of application7 Fluid handled

Density39

Intended use7

Key to safety symbols/markings7

Manual functions13

Name plate12

Operating limits38 Operating modes13

Piping18 Preservation10, 39 Product description12

Return to supplier10 Returning to service39

Safety7 Safety awareness8 Scope of supply14 Shutdown39 Signalling and display functions13 Start-up24 Storage10, 39

Warnings7 Warranty claims6

Page 48

KSB SE & Co. KGaA

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

Tel. +49 6233 86-0

www.ksb.com

1157.83/03-EN

KSB Calio S BMS Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual