KSB Calio S Installation & Operating Manual
High-efficiency circulator / drinking water pump
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Summary of Contents for KSB Calio S
- Page 1 High-efficiency Circulator / Drinking Water Pump Calio S / Calio-Therm S Installation/Operating Manual...
- Page 2 Legal information/Copyright Installation/Operating Manual Calio S / Calio-Therm S 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.
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Page 3: Table Of Contents
Start-up............................... 24 6.1.4 Operation ............................ 25 6.1.5 Mode of operation .......................... 26 Shutdown................................ 32 Operating limits.............................. 33 6.3.1 Ambient temperature........................ 33 6.3.2 Density of the fluid handled ...................... 33 Shutdown/storage/preservation ........................ 33 6.4.1 Measures to be taken for shutdown .................... 33 Calio S / Calio-Therm S 3 of 44... - Page 4 Drainage/cleaning ............................ 35 Removing the pump set from the piping ..................... 35 Trouble-shooting.......................... 37 Related Documents .......................... 38 Sectional drawing with list of components .................... 38 EU Declaration of Conformity ...................... 40 Index .............................. 41 Calio S / Calio-Therm S 4 of 44...
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Page 5: Glossary
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 Calio S / Calio-Therm S 5 of 44... -
Page 6: General
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. -
Page 7: Safety
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. Calio S / Calio-Therm S 7 of 44... -
Page 8: Intended Use
▪ Accident prevention, health regulations and safety regulations ▪ Explosion protection regulations ▪ Safety regulations for handling hazardous substances ▪ Applicable standards, directives and laws Calio S / Calio-Therm S 8 of 44... -
Page 9: Safety Information For The User/Operator
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. Calio S / Calio-Therm S 9 of 44... -
Page 10: Transport/Temporary Storage/Disposal
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. -
Page 11: Disposal
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. Calio S / Calio-Therm S 11 of 44... -
Page 12: Description Of The Pump (Set)
4.2 Designation Example: Calio S 25-40-130 BMS Table 3: Designation key Code Description... -
Page 13: Name Plate
▪ Screw-ended Drive ▪ High-efficiency electric motor with continuously variable differential pressure control ▪ Electronically commutated synchronous motor with permanent magnet rotor ▪ 230 V, 50 Hz/60 Hz ▪ IP42 enclosure ▪ Thermal class F Blank Calio S / Calio-Therm S 13 of 44... - Page 14 ▪ 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 Calio S / Calio-Therm S 14 of 44...
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Page 15: Configuration And Function
The fluid is pumped to the discharge nozzle (1), where it leaves the pump. The shaft runs in radial plain bearings (2), which are supported by the motor (4). 4.6 Noise characteristics Table 5: Noise characteristics Size Sound pressure level 45 dB (A) max. Calio S / Calio-Therm S 15 of 44... -
Page 16: Scope Of Supply
As above, plus drinking water. Standard design If any glycol is contained in the fluid, the operating data of the pump must be adjusted to a higher viscosity, depending on the mixing ratio. Calio S / Calio-Therm S 16 of 44... - Page 17 ▷ 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. Reference value for the most efficient of circulators: EEI ≤ 0.20 Calio S / Calio-Therm S 17 of 44...
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Page 18: Installation At Site
▷ Observe the information given in the data sheet and on the name plates of the pump system. DANGER Calio S pumps used for drinking water or foodstuff applications Danger of poisoning! ▷ The pump materials are not suitable for drinking water and foodstuff applications. -
Page 19: Connecting The Piping
6. Tighten the pipe union hand-tight with an assembly tool (e.g. pipe wrench). 5.4 Connecting the piping WARNING Hot surface Risk of burns ▷ Never touch a pump set when it is in operation. Calio S / Calio-Therm S 19 of 44... -
Page 20: Enclosure/Insulation
The pump takes on same temperature as the fluid handled Risk of burns! ▷ Insulate the volute casing. ▷ Fit protective equipment. NOTE The pump set is supplied with a thermal insulation shell. (Calio S only) Calio S / Calio-Therm S 20 of 44... -
Page 21: Electrical Connection
Table 8: Power cable Cable Cable type Outside diameter of the cable 5.5 - 10.0 mm Outside diameter of the core (including 2.95 mm max. insulation) Cable cross-sections 0.75 mm - 1.5 mm massive or fine core cable Calio S / Calio-Therm S 21 of 44... - Page 22 A marking underneath the PE terminal helps identify the correct connection. After the cable has been wired to the plug, screw the cable entry onto the plug and tighten it. Fig. 7: Plug-type connection with marking PE marking Calio S / Calio-Therm S 22 of 44...
- Page 23 (PE) After the cable/plug assembly has been completed, connect the plug to the jack at the pump. The cores/strands can be removed from the plug by pressing down the blue ring. Calio S / Calio-Therm S 23 of 44...
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Page 24: Commissioning/Start-Up/Shutdown
Damage to the pump set! ▷ Never operate the pump set without a liquid fill. ▷ Prime the pump as per operating instructions. ▷ Always operate the pump within the permissible operating range. Calio S / Calio-Therm S 24 of 44... -
Page 25: Operation
For the input of the discharge head setpoint, the setpoint is displayed in the unit [m]. Fig. 9: Display panel of the pump Example: Display of the (measured) electrical input power in Proportional-pressure control operating mode. The input power will be displayed for 5 seconds. Calio S / Calio-Therm S 25 of 44... -
Page 26: Mode Of Operation
In Constant-pressure Control the set head ② is maintained irrespective of the flow rate. The set differential pressure setpoint H is constant, situated between the maximum curve ① and the permissible flow rate range. Calio S / Calio-Therm S 26 of 44... - Page 27 – The value to be saved flashes several times and will then be stored in permanent memory. NOTE If 10 seconds pass without any settings being made or saved, the control unit will revert to the previous settings. Fig. 12: Constant-pressure Control settings Calio S / Calio-Therm S 27 of 44...
- Page 28 – The value to be saved flashes several times and will then be stored in permanent memory. NOTE If 10 seconds pass without any settings being made or saved, the control unit will revert to the previous settings. Calio S / Calio-Therm S 28 of 44...
- Page 29 – The value to be saved flashes several times and will then be stored in permanent memory. NOTE If 10 seconds pass without any settings being made or saved, the control unit will revert to the previous settings. Calio S / Calio-Therm S 29 of 44...
- Page 30 Step/option Press and hold the control element (●) for 3 seconds. This will activate the display backlighting. The flashing operating mode symbol indicates the active operating mode (Constant-pressure Control, Proportional-pressure Control, Open-loop Control). Calio S / Calio-Therm S 30 of 44...
- Page 31 Fig. 17: Display of error code E8 (motor fault) If an error has occurred, the pump settings cannot be modified. Once the error has been cleared, the display will revert to the set operating mode. Calio S / Calio-Therm S 31 of 44...
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Page 32: Shutdown
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. Calio S / Calio-Therm S 32 of 44... -
Page 33: Operating Limits
The pump (set) is removed from the pipe and stored ü The pump has been drained properly (ð Section 7.2, Page 35) and the safety instructions for dismantling the pump have been observed. (ð Section 7.3, Page 35) 1. Observe any additional instructions and information provided. (ð Section 3, Page 10) Calio S / Calio-Therm S 33 of 44... -
Page 34: Returning To Service
1. For returning the equipment to service, observe the sections on commissioning/ start-up (ð Section 6.1, Page 24) and the operating limits . 2. In addition, carry out all servicing/maintenance operations before returning the pump (set) to service (ð Section 7, Page 35) . Calio S / Calio-Therm S 34 of 44... -
Page 35: Servicing/Maintenance
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. Calio S / Calio-Therm S 35 of 44... - Page 36 2. Disconnect the discharge nozzle and suction nozzle from the piping. 3. Depending on the pump size / motor size, remove the supports from the pump set. 4. Remove the complete pump set from the piping. Calio S / Calio-Therm S 36 of 44...
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Page 37: Trouble-Shooting
▪ Air in the system ▪ Vent the system and the pump. Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure. Calio S / Calio-Therm S 37 of 44... -
Page 38: Related Documents
9 Related Documents 9 Related Documents 9.1 Sectional drawing with list of components 81-59 Part No. Description Part No. Description Volute casing Impeller Plain bearing 81-59 Stator Copper winding Rotor Calio S / Calio-Therm S 38 of 44... - Page 39 9 Related Documents Calio S / Calio-Therm S 39 of 44...
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Page 40: Eu Declaration Of Conformity
– EN 16297-1, EN 16297-2 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 Calio S / Calio-Therm S 40 of 44... -
Page 41: Index
Disposal 11 Drive 13 Warranty claims 6 Event of damage 6 Fields of application 8 Fluid handled Density 33 Intended use 8 Manual functions 14 Name plate 13 Operating limits 33 Operating modes 14 Piping 20 Preservation 10, 33 Return to supplier 10 Returning to service 34 Calio S / Calio-Therm S 41 of 44... - Page 44 KSB SE & Co. KGaA Johann-Klein-Straße 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 www.ksb.com...
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