KSB Calio S Installation & Operating Manual
High-efficiency circulator pump
Hide thumbs
Also See for Calio S:
- Installation & operating manual (44 pages) ,
- Installation & operating manual (44 pages)
Table of Contents
Advertisement
Quick Links
Advertisement
Table of Contents
Subscribe to Our Youtube Channel
Related Manuals for KSB Calio S
Summary of Contents for KSB Calio S
- Page 1 High-efficiency Circulator Pump Calio S 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 SE & Co. KGaA, Frankenthal 12/07/2022...
-
Page 3: Table Of Contents
Connecting the power cable ...................... 23 Commissioning/Start-up/Shutdown.................... 25 Commissioning/Start-up .......................... 25 6.1.1 Prerequisites for commissioning/start-up .................. 25 6.1.2 Priming and venting the pump...................... 25 6.1.3 Start-up............................... 26 Operating limits.............................. 27 6.2.1 Frequency of starts.......................... 27 6.2.2 Ambient temperature........................ 27 6.2.3 Minimum inlet pressure........................ 27 Calio S 3 of 52... - Page 4 Removing the pump set from the piping ..................... 43 8.3.1 Removing the power cable ....................... 45 Trouble-shooting.......................... 46 Related Documents .......................... 47 10.1 Sectional drawing with list of components .................... 47 UK Declaration of Conformity...................... 48 Index .............................. 49 Calio S 4 of 52...
-
Page 5: Glossary
Setback Operation avoids running the pump set at an unchanged control curve during the night. It lowers the mass flow rate, noise level and power consumption. Suction lift line/suction head line The pipeline which is connected to the suction nozzle Calio S 5 of 52... -
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 facility 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: Key To Safety Symbols/Markings
In conjunction with one of the signal words this symbol indicates a hazard involving magnetic fields and identifies special information for persons with a pacemaker. Warning about hot surfaces In conjunction with one of the signal words this symbol indicates a hazard involving hot surfaces. Calio S 7 of 52... -
Page 8: Safety
2.2.1 Prevention of foreseeable misuse ▪ Observe all safety information and instructions in this manual. ▪ Never exceed the permissible application and operating limits specified in the data sheet or product literature regarding pressure, temperature, etc. Calio S 8 of 52... -
Page 9: Personnel Qualification And Training
▪ If stopping 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. Calio S 9 of 52... -
Page 10: Safety Information For Maintenance, Inspection And Installation
Never operate the pump (set) outside the limits stated in the data sheet and in this operating manual. The warranty relating to the operating reliability and safety of the pump (set) supplied is only valid if the equipment is used in accordance with its intended use. Calio S 10 of 52... -
Page 11: Transport/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 12: Return To Supplier
Contact your local waste disposal partner for returns. If the used electrical or electronic equipment contains personal data, the operator is responsible for deleting it before the equipment is returned. Calio S 12 of 52... -
Page 13: Description
4.2 Product information as per Regulation No. 1907/2006 (REACH) For information as per chemicals Regulation (EC) No. 1907/2006 (REACH), see https:// www.ksb.com/ksb-en/About-KSB/Corporate-responsibility/reach/ 4.3 Designation Example: Calio S 25-40-130 Table 5: Designation key Code Description Calio S Type series Connection Rp 1/2... -
Page 14: Name Plate
Class F IPX4D 6 - 25 W P/N: 291349XX S/N: 291349XX-A201920-XXXX1 Made in Turkey | KSB SE & Co. KGaA Johann-Klein-Str. 9 67227 Frankenthal (Germany) Fig. 1: Name plate (example) 1 Type series, size 7 Production number 2 Mains voltage, frequency... -
Page 15: Design Details
▪ Setting the speed level ▪ Vent function ▪ Deblocking the rotor Signalling functions and display functions ▪ Alternating display of flow rate, head and electrical input power ▪ Error codes indicated on the display Calio S 15 of 52... -
Page 16: Configuration And Function
The fluid is pumped to the discharge nozzle (8), where it leaves the pump. The shaft runs in radial plain bearings (9), which are supported by the motor (11). Calio S 16 of 52... -
Page 17: Noise Characteristics
▪ Two-piece thermal insulation shell (only for overall length ≥ 180 mm) ▪ Installation/operating manual 4.9 Dimensions and weight For dimensions and weights please refer to the type series booklet of the pump (set). 4.10 Accessories No accessories available. Calio S 17 of 52... -
Page 18: Installation At Site
▪ The data on the name plate of the pump set has been checked. The pump set must be suitable for operation on the available power supply network. (ð Section 4.4, Page 14) ▪ The fluid to be handled matches the description of suitable fluids. (ð Section 6.2.5.1, Page 28) Calio S 18 of 52... -
Page 19: Installing The Pump Set
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. Calio S 19 of 52... -
Page 20: Connecting The Piping
▷ Take appropriate measures to compensate for thermal expansion of the piping. CAUTION Contamination/dirt in the piping Damage to the pump! ▷ Flush the piping prior to commissioning or replacing the pump. Remove any foreign matter. Calio S 20 of 52... -
Page 21: Fitting The Enclosure/Insulation
Two-piece thermal insulation shell supplied for overall length ≥ 180 mm. ü The supplied thermal insulation shell is fitted for overall length ≥ 180 mm. 1. Insulate the enclosure using suitable materials or, if available, fit the supplied thermal insulation shell to the pump casing. Calio S 21 of 52... -
Page 22: Electrical Connection
3 mm. If the power cable of the device is damaged, have it replaced by the manufacturer, a customer service technician or a similarly qualified person. See EN 60335-1. Calio S 22 of 52... -
Page 23: Connecting The Power Cable
7. Select straight or angled plug housing (scope of supply) according to the installation position. If the electronic system housing (control panel) is turned by 90 degrees, only use the straight plug housing (see illustration). Fit wire end sleeves on stranded/flexible electric cables. Calio S 23 of 52... - Page 24 Fig. 7: Fastening the contact insert to the plug housing 1 Projection 9. Screw the union nut and joint ring onto the thread at the plug housing. Tightening torque = 1 Nm 10. Connect the plug-type connector at the pump set. Calio S 24 of 52...
-
Page 25: Commissioning/Start-Up/Shutdown
2. During operation at maximum speed loosen the vent plug with a suitable tool until some of the fluid handled escapes. 3. Tighten the vent plug to a maximum tightening torque of 0.5 Nm. 4. Repeat the procedure until all air has escaped. Calio S 25 of 52... -
Page 26: Start-Up
ü The priming lines and venting lines have been closed. 1. Fully open the shut-off element in the suction line. 2. Close or slightly open the shut-off element in the discharge line. 3. Start up the pump set. Calio S 26 of 52... -
Page 27: Operating Limits
> 300 m, an allowance of 0.01 bar / 100 m must be added. Table 9: Minimum inlet pressure p specified for the fluid temperature T max. Fluid temperature Minimum inlet pressure [°C] [bar] 5 to 75 0,05 76 to 95 Calio S 27 of 52... -
Page 28: Maximum Operating Pressure
Impermissibly high density of the fluid handled Motor overload! ▷ Observe the information on fluid density in the data sheet. The power input of the pump set will change in proportion to the density of the fluid handled. Calio S 28 of 52... -
Page 29: Shutdown
The pump (set) is removed from the pipe and stored ü The pump has been drained properly (ð Section 8.2, Page 43) and the safety instructions for dismantling the pump have been observed. 1. Observe any additional instructions and information provided. (ð Section 3, Page 11) Calio S 29 of 52... -
Page 30: Returning To Service
For returning the equipment to service, observe the sections on commissioning/start- up (ð Section 6.1, Page 25) and the operating limits (ð Section 6.2, Page 27) . In addition, carry out all servicing/maintenance operations before returning the pump (set) to service. (ð Section 8, Page 42) Calio S 30 of 52... -
Page 31: Operation
▪ Symbol lights up when this operating mode is active. Proportional-pressure Control operating mode ▪ Symbol lights up when this operating mode is active. Dynamic Control operating mode ▪ Symbol lights up when this operating mode is active. Calio S 31 of 52... -
Page 32: Operating Modes
▪ The bar diagram shows the active speed level. Setback Operation function ▪ Symbol lights up when this operating mode is active. Service mode (only for KSB Service) ▪ Symbol lights up when this function is active. ▪ Control panel remains operational when drive is stopped. -
Page 33: Constant-Pressure Control
(+) or (-) respectively. Step 4: Confirming the current setpoint ▪ Press and hold the control button (●) for a minimum of 3 seconds. – The set setpoint flashes and is saved. Fig. 10: Constant-pressure Control settings Calio S 33 of 52... -
Page 34: Proportional-Pressure Control
▪ Increase or decrease the setpoint by pressing the control buttons (+) or (-) respectively. Step 4: Confirming the current setpoint ▪ Press and hold the control button (●) for a minimum of 3 seconds. – The set setpoint flashes and is saved. Calio S 34 of 52... - Page 35 7 Operation Fig. 12: Proportional-pressure Control settings Calio S 35 of 52...
-
Page 36: Open-Loop Control
2150 3000 3400 25-40-130 1400 2150 2750 25-60-130 2150 3000 3400 25-40 1400 2150 2750 25-60 2150 3000 3400 25-80 2000 3000 3950 30-40 1400 2150 2750 30-60 2150 3000 3400 30-80 2000 3000 3950 Calio S 36 of 52... -
Page 37: Functions
> 15 K > 3 K < 2 h Fig. 14: Switchover between day mode and night mode A Boiler mode B Fluid temperature C Pump mode Calio S 37 of 52... - Page 38 ▪ Press and hold the control button (●) for a minimum of 3 seconds. – The set status flashes and is saved. – When the status has been saved successfully, the symbol "nd" (night derating) is shown on the display. Calio S 38 of 52...
-
Page 39: Dynamic Control
– The flashing symbol indicates the active operating mode. Step 2: Selecting Dynamic Control ▪ Press the control button (●) for a minimum of 0.5 seconds until the symbol for Dynamic Control flashes. Characteristic curve at fully open thermostatic valves Calio S 39 of 52... - Page 40 – 1 = Dynamic Control enabled Step 4: Saving the Dynamic Control status ▪ Press and hold the control button (●) for a minimum of 3 seconds. – The set status flashes and is saved. Calio S 40 of 52...
-
Page 41: Protective Functions
Error code on the Cause Status Response display Excessive temperature Alarm Pump stops. Overcurrent Alarm Pump stops. Internal fault Alarm Pump stops. Blocked rotor Alarm Pump stops. Voltage error Alarm Pump stops. Motor fault Alarm Pump stops. Calio S 41 of 52... -
Page 42: Servicing/Maintenance
For contact details please refer to the enclosed "Addresses" booklet or visit "www.ksb.com/contact" on the Internet. The pump set is almost maintenance-free. If the pump set has not been in operation for a prolonged period of time or if the system severely is contaminated, the pump rotor can become blocked. -
Page 43: Drainage/Cleaning
Danger of death for persons with pacemaker! Interference with magnetic data carriers, electronic devices, components and instruments! Uncontrolled magnetic attraction forces between magnet-equipped components, tools or similar! ▷ Keep a safety distance of at least 0.3 m. Calio S 43 of 52... - Page 44 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 44 of 52...
-
Page 45: Removing The Power Cable
2. Disconnect the plug-type connector from the pump set. 3. Lever out the contact insert with a suitable tool as shown in the illustration. Fig. 17: Removing the contact insert 4. Pull the contact insert out of the plug housing. Calio S 45 of 52... -
Page 46: Trouble-Shooting
If problems occur that are not described in the following table, consultation with the KSB service is required. A Pump is running, but does not deliver B Pump does not start up or pump running irregularly C Pump running but not delivering water. -
Page 47: Related Documents
10 Related Documents 10 Related Documents 10.1 Sectional drawing with list of components 81-59 Fig. 18: Sectional drawing Table 22: List of components Part No. Description Part No. Description Volute casing Impeller Copper winding Plain bearing Rotor 81-59 Stator Calio S 47 of 52... -
Page 48: Declaration Of Conformity
11 UK Declaration of Conformity 11 UK Declaration of Conformity Manufacturer: KSB SE & Co. KGaA Johann-Klein-Straße 9 67227 Frankenthal (Germany) This UK Declaration of Conformity is issued under the sole responsibility of the manufacturer. The manufacturer herewith declares that the product:... -
Page 49: Index
Event of damage 6 Faults Causes and remedies 46 Fluid handled Density 28 Installation at site 18 Intended use 8 Key to safety symbols/markings 7 Manual functions 15 Name plate 14 Operating limits 27 Operating modes 15 Other applicable documents 6 Piping 21 Preservation 11, 29 Product description 13 Calio S 49 of 52... - Page 52 KSB SE & Co. KGaA Johann-Klein-Straße 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 www.ksb.com...
Need help?
Do you have a question about the Calio S and is the answer not in the manual?
Questions and answers