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High-efficiency Drinking Water Pump
Calio-Therm NC
Installation/Operating Manual
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Legal information/Copyright
Installation/Operating Manual Calio-Therm NC
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.
© KSB Aktiengesellschaft, Frankenthal 08.11.2016
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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 .....................................................................................................8
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 ..........................................................................................................................................................12
4.2 Description ....................................................................................................................................................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 ................................................................................................................................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 .................................................................................................................................17
5.5 Casing/insulation ..........................................................................................................................................18
5.6 Electrical connection ....................................................................................................................................18
6 Commissioning/Start-up/Shutdown ........................................................................................... 20
Contents
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6.1 Commissioning/start-up ...............................................................................................................................20
6.2 Shutdown ......................................................................................................................................................22
6.3 Operating limits ............................................................................................................................................22
6.4 Shutdown/storage/preservation ..................................................................................................................23
6.5 Returning to service .....................................................................................................................................23
7 Servicing/Maintenance ............................................................................................................... 24
7.1 Servicing/inspection ......................................................................................................................................24
7.2 Drainage/cleaning ........................................................................................................................................24
7.3 Removing the pump set from the piping ...................................................................................................24
8 Trouble-shooting ........................................................................................................................ 26
9 Related Documents .................................................................................................................... 27
9.1 Wiring diagram .............................................................................................................................................27
10 EU Declaration of Conformity ................................................................................................... 28
Index ............................................................................................................................................ 29
Contents
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Glossary
Discharge line
The pipeline which is connected to the
discharge nozzle
Noise characteristics
The noise emission to be expected, indicated as
sound pressure level LpA 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
Glossary
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1 General
1.1 Principles
This operating manual is supplied as an integral part of 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/size and 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 (⇨ Section 4.6 Page 14)
1.2 Target group
This operating manual is aimed at the target group of trained and qualified specialist
technical personnel. (⇨ 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
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product
1 General
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2 Safety
All the information contained in this section refers to hazardous situations.
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 manual contains general installation, operating and maintenance instructions
that must be observed to ensure safe pump operation and prevent personal injury
and damage to property.
The safety information in all sections of this manual must be complied with.
This manual must be read and completely understood by the specialist personnel/
operators responsible prior to installation and commissioning.
The contents of this manual must be available to the specialist personnel at the site
at all times.
Information attached directly to the pump must always be complied with and be
kept in a perfectly legible condition at all times. This applies to, for example:
▪ Arrow indicating the direction of rotation
▪ Markings for connections
▪ Name plate
The operator is responsible for ensuring compliance with all local regulations not
taken into account in this 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 rates indicated in the data sheet or product literature
(to prevent overheating, bearing damage, etc).
!
DANGER
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▪ Observe the maximum flow rates indicated in the data sheet or product
literature (to prevent overheating, mechanical seal damage, cavitation damage,
bearing damage, etc).
▪ 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 machinery 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.
2.5 Consequences and risks caused by non-compliance with this manual
▪ Non-compliance with this operating manual 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 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
▪ The operator shall fit contact guards for hot, cold and moving parts and check
that the guards function properly.
▪ Do not remove any 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.)
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▪ 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.
▪ Any work on the pump set shall only be performed 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. (⇨ Section 6.4 Page 23)
▪ Decontaminate pumps which handle fluids posing a health hazard.
▪ As soon as the work has been completed, re-install and/or re-activate any safety-
relevant and protective devices. Before returning the product to service, observe
all instructions on commissioning. (⇨ Section 6.1 Page 20)
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
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 (as applicable) 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 by 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
(⇨ Section 6.4.1 Page 23)
3.4 Return to supplier
1. Drain the pump as per operating instructions. (⇨ Section 7.2 Page 24)
2. Always flush and clean the pump, particularly if it has been used for handling
noxious, explosive, hot or other hazardous fluids.
3. If the pump set has handled fluids whose residues could lead to corrosion
damage in the presence of atmospheric humidity or could ignite upon contact
with oxygen, the pump set must also be neutralised, and anhydrous inert gas
must be blown through the pump to ensure drying.
4. Always complete and enclose a certificate of decontamination when returning
the pump (set).
Always indicate any safety and decontamination measures taken.
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3.5 Disposal
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. 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)
4.1 General
▪ Non-self-priming in-line pump
Pump for handling clean or aggressive fluids which are neither chemically nor
mechanically aggressive to the pump materials.
4.2 Description
Example: Calio-Therm NC 25-40-130
Table 3: Designation key
Code Description
Calio Type series
Therm Drinking water pump
NC Fixed speed
25 Nominal diameter of pump nozzle
20 G 1 1/4
25 G 1 1/2
40 Head in m x 10 (example: 40 = 4 m)
130 Length
130 130 mm
4.3 Name plate
1
2
3
1
2
3
4
5
6
Fig. 1: Name plate (example)
1
Type series/ Size 2 Supply voltage and frequency,
current input, electric input power
3 Pressure class, enclosure,
temperature class of fluid handled,
thermal class of motor
4 Material number
5 Serial number (Material number -
Production date - Consecutive
number)
6 Motor direction of rotation
4 Description of the Pump (Set)
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Example: 29134843-201634-12345
Table 4: Designation key
Number Description
2016 Year of production 2016
34 Week of production (calendar week) 34
12345 Consecutive number (will be reset to 0 at the beginning of
each week of production)
4.4 Design details
Design
▪ Maintenance-free high-efficiency wet rotor pump (glandless)
Drive
▪ Electric motor
▪ Integrated motor protection
▪ 1~230 VAC, 50 Hz
▪ IP44 enclosure
▪ 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
Connections
▪ Screw-ended
Operating modes
▪ Fixed speed operation with 3 speed levels
Automatic functions
▪ Soft start
▪ Full motor protection with integrated trip electronics
Manual functions
▪ Vent function
▪ Deblocking function
▪ Setting the speed level
Signalling and display functions
▪ None
Key to the serial number
4 Description of the Pump (Set)
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4.5 Configuration and function
3
2
1
4
Fig. 2: Sectional drawing of the pump
1
Discharge nozzle 2 Impeller
3 Suction nozzle 4 Plain bearing
The pump is designed with a radial fluid inlet and a radial outlet arranged on the
same axis. The impeller is firmly connected to the motor shaft. The fluid handled
lubricates and cools the rotating assembly, which is isolated from the stator winding.
All wetted parts are approved for use with drinking water; the impeller is made of
plastic, the bearings of ceramics, and the motor shaft and pump casing of stainless
steel. The motor housing made of aluminium is fastened to the pump casing with 4
screws. The front cover with integrated cable gland is fastened to the motor housing
with 2 screws and can be removed once the screws have been undone in order to
connect the power cable to the pump’s terminals.
The fluid enters the pump via the suction nozzle (6) and is accelerated outward in a
cylindrical flow by the rotating impeller (7). 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 (1), where it leaves the pump. The shaft runs in plain
bearings (4), which are supported by the motor.
4.6 Noise characteristics
Table 5: Noise characteristics [dB A]
Sound pressure level
All max. 43
4.7 Scope of supply
▪ Pump
▪ Sealing elements for threaded connection
▪ Installation/operating manual
▪ Insulation shells (for 180 mm overall length only)
Design
Function
4 Description of the Pump (Set)
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4.8 Dimensions and weight
For dimensions and weights please refer to the type series booklet of the pump.
4 Description of the Pump (Set)
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5 Installation at Site
5.1 Safety regulations
DANGER
Hazardous fluids/ substances in the piping
Risk of injury!
▷ Flush and thermally disinfect the piping prior to commissioning the pump.
DANGER
Installation in potentially explosive atmospheres
Explosion hazard!
▷ Never install the pump in potentially explosive atmospheres.
▷ Never use the pump to handle explosive fluids.
5.2 Checks to be carried out prior to installation
Before installing the pump make sure that the following requirements are met:
▪ Check the data on the name plate of the pump to make sure it can be operated
on the available mains.
▪ The fluid to be handled matches the description of suitable fluids.
▪ The above safety instructions have been complied with.
5.3 Installing the pump set
Install the pump set in an easily accessible place.
CAUTION
Ingress of fluid into the motor
Damage to the pump set!
▷ Install the pump set with the pump shaft in horizontal position. Connect the
piping without transmitting any stresses and strains.
▷ Never install the pump set with the motor terminal box pointing downwards.
NOTE
Installing shut-off valves upstream and downstream of the pump is recommended.
Make sure that no leaking water can drip onto the pump motor or terminal box.
The terminal box can be positioned correctly by turning the motor head.
Table 6: Permissible installation positions
Sizes
All
To do so, undo the bolts/screws and turn the motor head until it has reached its
correct position.
Tighten the bolts/screws again.
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DANGER
Leakage at the pump
Leakage of hot fluids!
▷ Insert the O-ring in the correct position.
An arrow on the pump casing indicates the direction of flow.
NOTE
The direction of flow of a vertically installed pump should be upwards.
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
To prevent any impurities from collecting in the pump do not install the pump at
the lowest point of the system.
1. Place the pump in the specified installation position.
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).
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.
✓ Suction lift lines have been laid with a rising slope, suction head lines with a
downward slope towards the pump.
✓ The nominal diameters of the pipes are equal to or greater than the nominal
diameters of the pump nozzles.
Screw-ended pumps
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✓ 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 Casing/insulation
WARNING
The pump takes on same temperature as the fluid handled
Risk of burns!
▷ Insulate the volute casing.
▷ Fit protective equipment.
CAUTION
Heat building up at motor housing and pump casing
Pump overheating!
▷ Never insulate the motor and electronic system housings.
5.6 Electrical connection
DANGER
Electrical connection work by unqualified personnel
Danger of death from 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.
1. Check the available mains voltage against the data on the name plate.
The pumps must be connected in accordance with the applicable regulations. The
electrical data is printed on the name plate of the pump.
The pumps do not require any external motor protection.
NOTE
If a conventional motor protection switch is used, the overload setting must be
adjusted to the current indicated on the name plate of the pump. When changing
the speed level, this setting must be adjusted accordingly.
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If the piping is not filled with water, the pump should only be operated for a short
period of time to prevent any damage to the pump bearings (lubricated by the fluid
handled).
1. Check the available mains voltage against the data on the name plate.
2. Undo the two screws at the front cover using a suitable screwdriver.
3. Remove the front cover.
4. Lead a suitable three-phase power cable (e g. 3 x 0.75 mm2) through the pump’s
cable gland.
5. Strip the cable sheath and cores in accordance with applicable regulations.
6. Connect the cores to the pump’s terminals L, N and PE.
7. Firmly tighten the cable gland and provide strain relief.
8. Place the front cover in position and close tightly using the two screws.
9. The power cable should be led downwards in a suitable fashion in order to
prevent damage.
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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.
▪ After prolonged standstill of the pump (set) the pump rotor has been rotated by
means of a screwdriver to make sure the motor is not locked.
6.1.2 Safety regulations
DANGER
Hazardous fluids/ substances in the piping
Risk of injury!
▷ Flush and thermally disinfect the piping prior to commissioning the pump.
DANGER
Pump operation without front cover
Risk of fatal injury due to electric shock!
Risk of injury!
▷ Only operate the pump with the front cover fitted and with the PE connection
(earthing) established.
WARNING
Hot surface
Risk of injury!
▷ Allow the pump set to cool down to ambient temperature.
WARNING
Risk of hot fluid escaping as a result of incorrect assembly/ dismantling
Risk of burns!
▷ Do not damage the seal elements and sealing surfaces.
6.1.3 Priming and venting the pump
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. Vent the pump and suction line and prime both with the fluid to be handled.
2. Fully open the shut-off element in the suction line.
3. During operation (at top speed) loosen the screw plug until some air escapes.
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DANGER
Hot fluid handled spurting out in the vent plug area
Risk of burns!
▷ Wear protective clothing.
4. Close the screw plug again.
5. Repeat this procedure several times until all air has escaped.
6.1.4 Start-up
DANGER
Non-compliance with the permissible pressure and temperature limits if the pump is
operated with the suction and discharge lines closed.
Leakage of hot fluids!
▷ 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.
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.
✓ The system piping has been cleaned.
✓ Pump, suction line and inlet tank, if any, have been vented and primed with the
fluid to be pumped.
✓ 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.
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6.1.5 Mode of operation
6.1.5.1 Open-loop control mode with manual setpoint input
The pump is operated at the set speed level (characteristic curve). The required speed
level is selected by turning the control knob at the control module. In this example
(see illustration) the pump is operated at medium speed.
The speed level should be set for trouble-free operation of the system, minimising
running noises and energy consumption.
H
Q
1
2
3
1
2 3
Fig. 3: Open-loop Control settings
6.2 Shutdown
✓ 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 fluid may escape!
▷ 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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6.3.1 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:
Table 7: Fluid temperature specified for the ambient temperature [°C]
Fluid temperature Ambient temperature
All 90 30
70 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
✓ 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 (⇨ Section 7.2 Page 24) and the safety
instructions for dismantling the pump have been observed.
Observe any additional instructions and information provided. (⇨ 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.
6 Commissioning/Start-up/Shutdown
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7 Servicing/Maintenance
7.1 Servicing/inspection
The circulator pumps 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.
The rotor can be deblocked by undoing the screwed plug, inserting a screw driver
into the shaft end, and rotating the rotor.
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 Safety regulations
DANGER
Hazardous fluids/ substances in the piping
Risk of injury!
▷ Flush and thermally disinfect the piping prior to commissioning the pump.
DANGER
Installation in potentially explosive atmospheres
Explosion hazard!
▷ Never install the pump in potentially explosive atmospheres.
▷ Never use the pump to handle explosive fluids.
DANGER
Pump operation without front cover
Risk of fatal injury due to electric shock!
Risk of injury!
▷ Only operate the pump with the front cover fitted and with the PE connection
(earthing) established.
7 Servicing/Maintenance
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WARNING
Hot surface
Risk of injury!
▷ Allow the pump set to cool down to ambient temperature.
WARNING
Risk of hot fluid escaping as a result of incorrect assembly/ dismantling
Risk of burns!
▷ Do not damage the seal elements and sealing surfaces.
7.3.2 Removing the complete pump set from the piping
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
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.
✓ The relevant notes and steps have been observed/carried out.
✓ The pump has cooled down to ambient temperature.
✓ 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.
7 Servicing/Maintenance
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8 Trouble-shooting
WARNING
Improper work to remedy faults
Risk of injury!
▷ For any work to remedy faults observe the relevant information in this
operating manual and/or in the relevant accessory manufacturer's
documentation.
If problems occur that are not described in the following table, consultation with the
KSB customer service is required.
Pump is running but does not deliver
Pump does not start up or pump running irregularly
Pump running but not delivering water
Noises during pump operation
Table 8: Trouble-shooting
A B C D Possible cause
Remedy
1)
✘ - - - Pump not connected to power supply Check the fuses and correct connection to power
supply. If required, disconnect the pump from the
power supply and re-connect it to the power
supply (voltage reset).
- ✘ - - Impurities in the pump See section on maintenance. (⇨ Section 7.1 Page
24)
- - ✘ - Air in the system Vent the system and the pump.
- - ✘ - Shut-off valves closed Open the gate valve.
- - - ✘ Pump power output too high Select a lower speed level.
- - - ✘ System pressure too low Increase the system pressure by filling more water
into the boiler.
- - - ✘ Air in the system Vent the pump (vent plug) and piping.
A
B
C
D
1)
Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.
8 Trouble-shooting
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9 Related Documents
9.1 Wiring diagram
1-phase
PE L N
Fig. 4: Wiring diagram for single-phase a.c. current
9 Related Documents
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10 EU Declaration of Conformity
Manufacturer: KSB Aktiengesellschaft
Johann-Klein-Straße 9
67227 Frankenthal (Germany)
The manufacturer herewith declares that the product:
Calio-Therm NC
Series code range: 1640 to 1752
▪ is in conformity with the provisions of the following Directives as amended from time to time:
– Electromagnetic Compatibility Directive 2014/30/EU
– Low-voltage Directive 2014/35/EU
The manufacturer also declares that
▪ the following harmonised international standards have been applied:
– DIN EN 55014-1, EN 55014-2
– DIN EN 60335-1, EN 60335-2-51
– DIN EN 61000-3-2, EN 61000-3-3
The EU Declaration of Conformity was issued in/on:
Frankenthal, 1 Oct. 2016
Joachim Schullerer
Head of Product Development Pump Systems and Drives
KSB Aktiengesellschaft
Johann-Klein-Straße 9
67227 Frankenthal
10 EU Declaration of Conformity
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Index
A
Applications 7
Automatic functions 13
B
Bearings 13
C
Commissioning 20
Connections 13
D
Design 13
Designation 12
Disposal 11
Drive 13
F
Faults
Causes and remedies 26
Fluid handled
Density 23
I
Intended use 7
M
Manual functions 13
Misuse 8
N
Name plate 12
O
Operating limits 22
Operating modes 13
P
Piping 17
Preservation 10, 23
Product description 12
R
Return to supplier 10
Returning to service 23
S
Safety 7
Safety awareness 8
Shutdown 23
Signalling and display functions 13
Start-up 21
Storage 10, 23
Index
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1157.881/01-EN
KSB Aktiengesellschaft
67225 Frankenthal • Johann-Klein-Str. 9 • 67227 Frankenthal (Germany)
Tel. +49 6233 86-0 • Fax +49 6233 86-3401
www.ksb.com
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