Related Manuals for KSB Calio SI Series
Summary of Contents for KSB Calio SI Series
- Page 1 Circulator for OEMs Calio SI HMI/Dual/EcoMatch Stand-alone Circulator for OEMs Installation/Operating Manual...
- Page 2 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 29/11/2016...
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Page 3: Table Of Contents
Contents Contents Glossary .............................. 5 General.............................. 6 Principles ................................ 6 Target group.............................. 6 Symbols ................................ 6 Safety .............................. 7 Key to safety symbols/markings........................ 7 General................................ 7 Intended use .............................. 8 Personnel qualification and training....................... 8 Consequences and risks caused by non-compliance with this manual ............ 8 Safety awareness .............................. 9 Safety information for the user/operator ....................... 9 Safety information for maintenance, inspection and installation .............. 9 Unauthorised modes of operation ........................ 9... - Page 4 Contents 6.4.1 Measures to be taken for shutdown .................... 40 Returning to service ............................ 40 Servicing/Maintenance ........................ 41 Maintenance/inspection.......................... 41 Drainage/cleaning ............................ 41 Removing the pump set from the piping ..................... 41 7.3.1 Dismantling the complete pump set .................... 41 Trouble-shooting.......................... 43 Related Documents .......................... 44 Overview of LED colour coding and operating mode / characteristic curve.......... 44 Electrical connection ............................ 46 EU Declaration of Conformity ......................
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Page 5: Glossary
Glossary 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... -
Page 6: General
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. -
Page 7: Safety
2 Safety 2 Safety All the information contained in this section refers to hazardous situations. DANGER 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. -
Page 8: Intended Use
2 Safety 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. ▪... -
Page 9: Safety Awareness
2 Safety 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 ▪... -
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 (as applicable) and the insurer about the damage in writing immediately. -
Page 11: Disposal
3 Transport/Temporary Storage/Disposal 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. ▷... -
Page 12: Description Of The Pump (Set)
4 Description of the Pump (Set) 4 Description of the Pump (Set) 4.1 General description Glandless, non-self-priming in-line pumps for handling clean fluids or fluids which are neither chemically nor mechanically aggressive to the pump materials. The combination of a high-efficiency hydraulic system with high-efficiency motor technology, integrated differential pressure control and operating software enables an optimum adjustment of the pumps to changing operating conditions and minimises operating costs. -
Page 13: Name Plate
4 Description of the Pump (Set) Code Description DUAL Manual settings and/or external input via PWM signal EcoMatch Manual settings or external input via PWM signal with automatic adjustment of the operating point 4.3 Name plate Fig. 2: Name plate (example) Type series Supply voltage and frequency, input power, pressure class,... -
Page 14: Configuration And Function
4 Description of the Pump (Set) Operating modes ▪ Fixed speed operation with differential pressure input via external PWM signal ▪ Constant-pressure control, based on four selectable, pre-defined curves ▪ Proportional-pressure control, based on four selectable, pre-defined curves ▪ EcoMatch with automatic adjustment of the operating point 4.5 Configuration and function Fig. 3: Sectional drawing of the pump Discharge nozzle... -
Page 15: Scope Of Supply
4 Description of the Pump (Set) 4.7 Scope of supply ▪ Pump ▪ Installation/operating manual ▪ Sealing elements ▪ Connection cable 230 V 4.8 Dimensions and weight For dimensions and weights please refer to the type series booklet of the pump. 4.9 Accessories No accessories available. -
Page 16: Standards And Technical Codes / Directives
4 Description of the Pump (Set) Characteristic Value Maximum permissible operating PN 10 pressure Minimum inlet pressure (p) T < 75 °C: 0.05 bar T > 90 °C: 0.28 bar Permissible fluids Heating water to VDI 2035 Water/glycol mixture, max. mixing ratio 1:1 . If the glycol content equals or exceeds 20 %, check and verify the operating data (only use brand name products with corrosion inhibitors, observe the information provided by the producer as well as the safety data sheets). -
Page 17: Installation At Site
5 Installation at Site 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. -
Page 18: Connecting The Piping
5 Installation at Site NOTE Do not install the pump at the lowest point of the system to prevent any impurities from collecting in the pump. Table 8: Permissible installation positions Sizes Screw-ended pumps 1. Place the pump in the specified installation position. Accurately insert the sealing element. -
Page 19: Enclosure/Insulation
5 Installation at Site CAUTION Welding beads, scale and other impurities in the piping Damage to the pump! ▷ Free the piping from any impurities. 5.5 Enclosure/insulation WARNING The pump takes on same temperature as the fluid handled Risk of burns! ▷... - Page 20 5 Installation at Site Socket for power cable Power cable plug L (230 VAC) Brow n Green/Yellow Ground N (230 VAC) Blue PWM data cable (Controller to pump)/ Brow n plug External 0 - 10 VDC signal Ground PWM/ Blue External signal 0 VDC Black PWM (Pump to controller)
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Page 21: Commissioning/Start-Up/Shutdown
6 Commissioning/Start-up/Shutdown 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. ▪... -
Page 22: Operation
6 Commissioning/Start-up/Shutdown 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. - Page 23 6 Commissioning/Start-up/Shutdown Fig. 5: Front view of the pump Control elements LEDs L1 - L6 Setting When the pump is started up for the first time, it is factory-set to the Constant Power (CC) operating mode with characteristic curve CC5 for maximum power and speed. Table 10: Colour coding LED1 and LED6 for Constant Power operating mode Position Operating mode / operating status...
- Page 24 6 Commissioning/Start-up/Shutdown Position Operating mode / operating status Characteristic curve Gree Gree CS5 (max) Gree Proportional-pressure Control (PP) PP with EcoMatch PP-EcoMatch Constant-pressure Control (CP) Yello Yello Yello Yello CP with EcoMatch CP-EcoMatch Yello PWM with heating applications Yello profile A Yello Yello Yello PWM with solar applications profile C C1...
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Page 25: Operating Modes
6 Commissioning/Start-up/Shutdown 6.1.5 Operating modes The pump offers six different operating modes. ▪ Operation with constant power (CC) (factory setting) ▪ Operation at fixed speed (CS) ▪ Operation with constant-pressure control (CP) or in combination with the EcoMatch function ▪ Operation with proportional-pressure control (PP) or in combination with the EcoMatch function ▪... - Page 26 6 Commissioning/Start-up/Shutdown After the required operating curve has been selected and no further adjustments are made for approximately 5 seconds, the pump automatically saves the operating curve and starts operating. Within the 5-second delay, a different operating mode / characteristic curve can be selected. After approximately 30 seconds the pump indicates the current input power (see operating status display).
- Page 27 6 Commissioning/Start-up/Shutdown Table 17: Colour coding LED L1 indicating readiness for operation Description Ready for operation Gree The operating curve can be set by using the ▼ and ▲ control elements. To select the next larger operating curve, press control element ▼. To select the next smaller operating curve, press control element ▲.
- Page 28 6 Commissioning/Start-up/Shutdown Pump type Sizes Calio SI HMI / Dual / EcoMatch 15-50 130 Calio SI HMI / Dual / EcoMatch 25-50 130 Calio SI HMI / Dual / EcoMatch 25-50 6 m Calio SI 15-60 130 Calio SI 25-60 130 Calio SI 25-60 7 m Calio SI 15-70 130...
- Page 29 6 Commissioning/Start-up/Shutdown Table 22: Colour coding LED L1 to LED L6 for the constant differential pressure (CS) operating curves Description Constant-pressure curve CP1 Yello Constant-pressure curve CP2 Yello Constant-pressure curve CP3 Yello Constant-pressure curve CP4 Yello Constant-pressure control with EcoMatch (CP-EcoMatch) Yello After the required operating curve has been selected and no further adjustments are made for approximately 5 seconds, the pump automatically saves the operating curve...
- Page 30 6 Commissioning/Start-up/Shutdown The operating curve can be set by using the ▼ and ▲ control elements. To select the next larger operating curve, press control element ▼. To select the next smaller operating curve, press control element ▲. The following table shows the colour coding of LEDs L1 to L6 for the five operating curves PP1 to PP5 for the Proportional-pressure Control (CP) operating mode.
- Page 31 6 Commissioning/Start-up/Shutdown 90 100 PWM [%] Fig. 8: PWM signal, external control system ➔ pump Point Parameter / function PWM input [%] PWM signal level Pump ID Maximum speed Minimum speed Stand-by Maximum speed b) PWM signals from the pump to the external control system The pump can send the following parameters/statuses to an external control system.
- Page 32 6 Commissioning/Start-up/Shutdown Point Parameter / function PWM return signal PWM return signal level [%] Pump ID 0 - 100 Blocked rotor 0 - 100 Minimum flow rate Maximum flow rate Dry running 0 - 100 Operating curves PWM-A1 to PWM-A4 In PWM profile A the pump can be operated with four different operating curves of the type CC (operation at maximum power and speed).
- Page 33 6 Commissioning/Start-up/Shutdown After the required operating curve has been selected and no further adjustments are made for approximately 5 seconds, the pump automatically saves the operating curve and starts operating. Within the 5-second delay, a different operating mode / characteristic curve can be selected. After approximately 30 seconds the pump indicates the current input power (see operating status display).
- Page 34 6 Commissioning/Start-up/Shutdown Point Parameter / function PWM input [%] PWM signal level Stand-by Stand-by b) PWM signals from the pump to the external control system The pump can send the following parameters/statuses to an external control system. ▪ Pump ID ▪...
- Page 35 6 Commissioning/Start-up/Shutdown Table 28: Maximum speed and maximum power input for the PWM profile C Pump type PWM profile C Characteristic curve / P [W] / n [rpm] PWM-C1 PWM-C2 PWM-C3 PWM-C4 4 m CC1 / 9 / 1400 CC2 / 11 / 1950 CC3 / 18 / 2375 CC5 / 25 / 2750 5 m...
- Page 36 6 Commissioning/Start-up/Shutdown Table 31: Colour coding LED L1 to L6 for PWM profile C operating curves (solar applications) Description PWM-C1 Gree PWM-C2 Gree PWM-C3 Gree PWM-C4 Gree After the required operating curve has been selected and no further adjustments are made for approximately 5 seconds, the pump automatically saves the operating curve and starts operating.
- Page 37 6 Commissioning/Start-up/Shutdown Table 33: Minimum and maximum speed [rpm] for each size Pump type Pump speed Min. Max. 4 m 1400 2750 5 m 1400 3080 6 m 1400 3350 7 m 1400 3650 7.5 m 1400 3750 Table 34: Pump sizes by pump type Pump type Sizes 4 m Calio SI 15-40 130...
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Page 38: Shutdown
6 Commissioning/Start-up/Shutdown After approximately 30 seconds the pump indicates the current input power (see operating status display). When one of the two control buttons is pressed, the pump displays the current operating mode and a new operating mode can be selected. 6.1.5.8 Operation with the EcoMatch function In EcoMatch mode combined with Constant-pressure Control (CP) or Proportional- pressure Control (PP) LED6 flashes when the pump automatically adjusts the... -
Page 39: Operating Limits
6 Commissioning/Start-up/Shutdown 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! -
Page 40: Shutdown/Storage/Preservation
6 Commissioning/Start-up/Shutdown 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. -
Page 41: Servicing/Maintenance
7 Servicing/Maintenance 7 Servicing/Maintenance 7.1 Maintenance/inspection The circulators are 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. - Page 42 7 Servicing/Maintenance 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! ▷...
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Page 43: Trouble-Shooting
If problems occur that are not described in the following table, consultation with the KSB customer service is required. A Pump is running but does not deliver B Pump does not start up or pump running irregularly... -
Page 44: Related Documents
9 Related Documents 9 Related Documents 9.1 Overview of LED colour coding and operating mode / characteristic curve Table 39: Colour coding Position Operating mode / operating status Characteristic curve Ready for operation Gree Constant Power (CC) CC1 (min) Yello Yello Yello Yello CC5 (max) Yello Fixed Speed (CS) - Page 45 9 Related Documents Position Operating mode / operating status Characteristic curve Gree Gree Gree Calio SI HMI/Dual/EcoMatch 45 of 52...
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Page 46: Electrical Connection
9 Related Documents 9.2 Electrical connection The pre-configured cables included in the scope of supply of the pump serve to connect the pump to the power supply and to establish the connection to the interface of an external controller/ control system. Wiring diagram The pump can be connected to the PWM interface of an external controller/ control system. -
Page 47: Eu Declaration Of Conformity
10 EU Declaration of Conformity 10 EU Declaration of Conformity KSB Pompa Armatür San. ve Tic. A.Ş. Manufacturer: Seker Mah. Fatih Sultan Mehmet Bulv. 451/A TR-06930 Ankara Factory The manufacturer herewith declares that the product: Calio SI HMI/Dual/EcoMatch Series code range: 2016w38 to 2017w52 ▪... -
Page 48: Index
Index Index Applications 8 Bearings 13 Commissioning 21 Design 13 Designation 12 Disposal 11 Drive 13 Faults Causes and remedies 43 Fluid handled Density 39 Intended use 8 Misuse 8 Name plate 13 Operating limits 39 Operating modes 14 Piping 18 Preservation 10, 40 Return to supplier 10 Returning to service 40 Safety 7 Safety awareness 9 Shutdown 40 Start-up 22 Storage 10, 40 Calio SI HMI/Dual/EcoMatch 48 of 52... - Page 52 KSB Aktiengesellschaft Johann-Klein-Straße 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 www.ksb.com...