Kolmeks FC Series User manual

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OPERATING INSTRUCTIONS
CENTRIFUGAL PUMPS WITH INTEGRATED FREQUENCY CONVERTER
FC_ -SERIES
AE_-,
L_-,
AL_-,
T- and
AT-
SARJAT

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Content
1. General............................................................................................ 3
1.1 Symbols................................................................................................................................................ 3
1.2 Applications ........................................................................................................................................ 3
1.3 Manufacturer ...................................................................................................................................... 3
1.4 Version................................................................................................................................................. 3
2.1 Handling, transport and storage of the pump .................................................................................. 4
2. Handling, transport and storage of the pump ............................4
3. Design and function......................................................................4
3.1 Construction ........................................................................................................................................ 4
3.2 Technical data..................................................................................................................................... 4
3.3 Rating plate ....................................................................................................................................... 5
3.4 Pump identification ........................................................................................................................... 5
4. Safety ............................................................................................6
4.1 Safety instructions ............................................................................................................................. 6
4.3 Elements of danger if safety regulations are not obeyed............................................................... 6
4.4 Safety instructions for inspection and assembly............................................................................. 6
4.2 Training ............................................................................................................................................... 6
4.5 Operating the pump........................................................................................................................... 6
5. Installation, introduction and start-up ........................................6
5.1 General................................................................................................................................................. 6
5.2 Positions for installation ....................................................................................................................7
5.3 Electrical connections .........................................................................................................................7
5.4 Control methods and connections .................................................................................................... 8
5.4.1 I/O’s of the FC-pump (inputs and outputs).................................................................................... 8
5.4.2 Factory settings .............................................................................................................................. 8
5.4.3 FCA -pump - speed reference from potentiometer ...................................................................... 9
5.4.4 FCB -pump - constant pressure between the pump flanges ......................................................10
5.4.5 FCC -pump - constant pressure between inlet- and outlet-line...................................................11
5.4.6 FCCVAK -pump - constant pressure between supply- and return-line with
external controller in use (SETUP 1) ....................................................................................................... 12
5.4.7 FCCVAK -pump - constant pressure between supply- and return-line with
controller of the frequency converter in use (SETUP 2)........................................................................ 13
5.4.8 FCD -pump - constant pressure in discharge flange....................................................................14
5.4.9 FCE -pump - sensorless, pre-programmed pump curves ............................................................ 15
5.4.10 FCF -pump - constant temperature ............................................................................................ 16
5.4.11 FCF -pump - the speed according to temperature ...................................................................... 17
5.4.12 FCG -pump - controlled by external system ................................................................................18
5.4.13 Connections to the alarm receiving station.................................................................................19
5.4.14 Local control panel (optional)...................................................................................................... 20
6. Service, spare parts and troubleshooting.................................. 22
6.1 Shaft seals......................................................................................................................................... 22
6.2 Other parts ....................................................................................................................................... 22
6.3 Troubleshooting ............................................................................................................................... 23
7. Declaration of Conformity ........................................................... 27

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1. General
Suitability of materials and seals for pumped liquid shall be always checked between pur-
chaser and supplier.
The nominal pressure and the max. temperature of pumped liquid are stamped on the pump
rating plate. Never use the pump in any other application or conditions without manufacturer’s
acceptance. In the case of damage there may be danger to persons by having poisoning, burns,
wounds etc. depending on the pumped liquid and it’s temperature and pressure. The pump
surface temperature may cause danger depending on the working conditions.
Clean, thin, non-aggressive liquids.
- circulating water in for heating and cooling systems
- water-glycol mixtures. Recommendation: propylene glycol
- nominal pressure 10 bar.
- like in L- and AL -series, but nominal pressure 16 bar.
Clean, thin, slightly aggressive liquids.
- domestic water, oxygen rich waters
- nominal pressure 10 bar.
Agressive, thin, not bigger solid particles containing liquids
- in addition to above mentioned liquids various acids, salts, oxidizing and chemically
active organic fluids
- nominal pressure 16 bar.
Temperature range: -10 ... + 95 °C (continuous + 80°C)
Max. temperature of environment +40°C (diurnal average max. +35°C)
AE-, L-, AL-,
T-, AT-
1.2 Applications
L-, ALH-
LS-, ALS-
AEP-, LP-,
ALP-
Pump series Applications
The most common applications are heating, air condition, cooling systems. Also heat exchangers, pressure boos-
ting systems, district heating systems, ice halls, public baths and industrial processies.
1.1 Symbols
Warns that failure to observe the precaution
may cause personal injury or damage to pro-
perty.
Warns that failure to observe the precau-
tion may cause electric shock
1.3 Manufacturer
Indicates something to be noted by the
reader.
This product is manufactured by OY KOLMEKS AB, P.O.BOX 27, FIN-14201 TURENKI, FINLAND.
1.4 Version
Release date of this manual is 04.01.2005. This is version no. 5.
All types of
FC-pumps

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The pump and motor constitute a unit, where the rotating parts of both the pump and the motor are on the same
shaft (mono-block design). The motor is of a dry type and the frequency converter is integrated to the electric motor.
Electric motor: Totally enclosed, fan cooled A.C. motor, with frequency converter.
Protection form: IP54
Insulating class: F
3.1 Construction
3. Design and function
3.2 Technical data
Pump type Flanges Weight kg(* Max. input Nominal current Twin pump
power kW A (400 V)
AE_-25/4,-26/4FC_ G 1 15 0,27 0,53 -
AE_-25/2,-26/2FC_ G 1 20 0,85 1,5 -
AE-32/4, -33/4FC_ G 1 1/4 20 0,5 0,9 -
AE-32/2, -33/2FC_ G 1 1/4 20 1,5 2,6 -
L_-32A/4FC_ DN32 19 0,27 0,53 T-32A/4FC_
L_-32A/2FC_ DN32 25 0,85 1,5 T-32A/2FC_
L_-40A/4FC_ DN40 25 0,5 0,9 T-40A/4FC_
L_-40A/2FC_ DN40 29 1,5 2,6 T-40A/2FC_
L_-50A/4FC_ DN50 33 0,7 1,4 T-50A/4FC_
L_-50C/2FC_ DN50 49 2,5 4,5 T-50C/2FC_
L_-65A/4FC_ DN65 47 0,7 1,4 T-65A/4FC_
L_-65A/4FC_ DN65 56 1,6 2,6 T-65A/4FC_
L_-65A/4FC_ DN65 67 2,8 4,7 T-65A/4FC_
L_-65B/2FC_ DN65 69 4,3 6,9 T-65B/2FC_
L_-65B/2FC_ DN65 100 8,0 12,4 T-65B/2FC_
L_-80A/4FC_ DN80 48 0,7 1,4 T-80A/4FC_
L_-80A/4FC_ DN80 62 1,6 2,6 T-80A/4FC_
L_-80A/4FC_ DN80 76 3 4,9 T-80A/4FC_
L_-80A/2FC_ DN80 74 4,3 6,9 T-80A/2FC_
L_-80A/2FC_ DN80 105 8,0 12,4 T-80A/2FC_
AL_-1032/4FC_ DN32 25 0,5 0,9 T-40A/4FC_ (DN40)
AL_-1032/2FC_ DN32 29 1,5 2,6 T-40A/2FC_ (DN40)
AL_-1066/4FC_ DN65 47 0,7 1,4 T-65A/4FC_
AL_-1066/4FC_ DN65 56 1,6 2,6 T-65A/4FC_
AL_-1066/4FC_ DN65 67 2,8 4,7 T-65A/4FC_
AL_-1065/2FC_ DN65 69 4,3 6,9 T-65B/2FC_
AL_-1065/2FC_ DN65 100 8,0 12,4 T-65B/2FC_
AL_-1081/4FC_ DN80 62 1,6 2,6 T-80A/4FC_
AL_-1081/4FC_ DN80 76 3 4,9 T-80A/4FC_
AL_-1081/2FC_ DN80 74 4,3 6,9 T-80A/2FC_
AL_-1081/2FC_ DN80 105 8,0 12,4 T-80A/2FC_
AL_-1102/4FC_ DN100 70 1,6 2,6 AT-1102/4FC_
AL_-1102/4FC_ DN100 86 3,7 5,8 AT-1102/4FC_
AL_-1106/4FC_ DN100 170 4,4 7,2 AT-1129/4FC_
AL_-1106/4FC_ DN100 200 8,3 13,0 AT-1129/4FC_
AL_-1129/4FC_ DN125 175 4,4 7,2 AT-1129/4FC_
AL_-1129/4FC_ DN125 205 8,3 13,0 AT-1129/4FC_
Noise level of all pump types is under 70 dB (A, 1 m).
(* Single pump weight (AL). The weight of the twin pump (T/AT) is depending on the size of the motor and equipment
each unit. The weight of the twin pump is about two times the single pump weight.
Normally the pumps are stable when they are transported and don’t go down even they are bent 10°. Pumps
shall be stored in a dry and cool place protected from dust. Temperature of environment must be in -10 °C ...
+50°C. It is not allowed to lift the pump from frequency converter. In the case of longer storage time or the
pump serves as a stand-by, it is recommended to rotate the pump manually f.ex. from the motor fan at least
once a month.
2. Handling, transport and storage of the pump
2.1 Handling, transport and storage of the pump

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3.4 Pump identification
L P - 50 A / 4 FC C 10 45
L_= single in-line pump, with flanges
AL_= single in-line pump, with flanges
AT,T = twin in-line pump, with flanges
AE = single in-line pump, with pipe connection
no letter = grey cast iron EN-GJL-200 / 10 bar
H = nodular cast iron EN-GJS-400 / 16 bar
P = bronze CuPb5Sn5Zn5 / 10 bar
S = stainless steel AISI 316 / 16 bar
Material of pump housing, sealing flange
and impeller / nominal pressure of the
pump:
Pump series:
Flange sizes:
AE_:
25/26 = G 1
32 = G1 1/4
Version number (AL/AT) or letter (L_ /T)
Poles of the electric motor:
2 = rotation speed 50 r/s (50 Hz)
4 = rotation speed 25 r/s (50 Hz)
rotation speed 30 r/s (60 Hz)
FC = the frequency converter is integrated to
the motor
Control method:
A, B, C, D, E, F, G (please check 5.4 Control methods and connections)
The range of the pressure (dierence) transmit-
ter:
Examble:
10 = 0 - 1 bar
60 = 0 - 6 bar
Control range (depending on pump type):
Examble:
45 = 0,5 - 4,5 m
80 = 0,5 - 8 m
20 = 2 - 20 m
60 = 1 - 6 bar
5 - 30
LP-50A/4FCC1045 S6 K2 V1-C320001
10 135
540,45
OKFC-100 B2 F15
400 0,70
PM
123456/04
1,4
3.3 Rating plate
Shows the information about the electric motor and also design data of the pump.
L_/T:
40 = DN 40
50 = DN 50
65 = DN 65
80 = DN 80
100 = DN 100
125 = DN 125
AL_/AT:
x03 = DN 32
x05 = DN 50
x06 = DN 65
x08 = DN 80
x10 = DN 100
x12 = DN 125

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4.2 Training
The persons who have responsibility for installing or/and operating the pump, should be trained.
4.3 Elements of danger if safety regulations are not obeyed
If the safety regulations are not obeyed, personal injuries or damage to the pump or related devices may occur. Vali-
dity safety instructions must be obeyed.
4.4 Safety instructions for inspection and assembly
it is user’s responsibility to ensure that persons who carry out inpections and installations are qualified experts and
familiarized themselves with these instructions carefully.
4.5 Operating the pump
Working safety of the delivered pump and related devices can be ensured only if these devices are operated according
to the section 1.2 Applications of this manual.
1. FC-pump must be disconnected from the mains if repair work is to be carried out. Check that the mains supply has
been disconnected and necessary time has passed (at least 4 minutes).
2. The device must be connected correctly to the earth. User must be protected from supply voltage and the pump
must be protected from short circuit according to the national and local requirements and standards. The overload
protection is included in FC -pump.
3. Earth leakage is more than 3,5 mA. It means, that installation of supply cable must be fixed.
4.1 Safety instructions
The position of the motor unit with the frequency converter can be changed by removing the motor unit from the
pump housing and setting it to the desired position (not in LH- and ALH-serie and in FCB, FCC ja -FCD-types with
certain limitations).
5. Installation, introduction and start-up
This manual includes important information concerning installation and operating the pump. Persons
who are involved in installation or/and operation of the pump, should read and understand these
instruction before installation or starting the pump.
4. Safety
There are live parts inside the frequency converter, when the supply voltage is connected. Incorrect
installation may cause damage to the pump or bodily injuries, even death. Touching the live parts may
be mortal even the supply voltage is disconnected. Wait at least 4 minutes! Obey instructions of this
manual and national and local requirements and standards.
- installation must be protected by fuses and insulated correctly.
- covers and cable inlet must be installed.
Attention:
It is user’s or certfied electrician’s responsibility to ensure the correct earthing and protection in accor-
dance with applicable national and local requirements and standards.
When installating the pump pay attention to the following:
- space enough for service and inspection of the pump
- free visibility to the scale of the potentiometer and curve plate of the pump.
- possibility to use lifting mechanism if needed
- shut-o valves on the both sides of the pump
- the frequency converter is not too close hot pipes.
5.1 General

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5.2 Positions for installation
Allowed positions
Allowed positions, if the pipes of the pressure dierence transmitter are not installed to the flanges of the
pump
Not allowed positions
5.3 Electrical connections
All electrical work shall be carried out by qualified electrician approved by the local authorities.
Supply voltage may be connected with standard cable, screened cable is not required. Ensure,
that the nominal voltage of the electric motor corresponds the local supply voltage.
ATTN Use always screened control cables.
Before starting the pump fill and vent the system. Make
sure that the pump rotates freely by rotating it manually
f.ex. from the motor fan. Never start or let the pump run
dry.
Before starting the pump fill and vent the system. After
starting make sure that there is no extra noise coming
from the pump and that no leakages appear.

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5.4 Control methods and connections
5.4.1 I/O’s of the FC-pump (inputs and outputs)
5.4.2 Factory settings
Terminal 1 / X101. No operation (setup1) or Feedback 4-20 mA (setup2) depending on selected control method.
Terminal 2 / X101. Speed reference 0-10V (setup1) or Reference of controller 0-10V (setup2) depending on selected
control method.
Terminal 3 / X101. Setup selection. Terminals 6-3 open/closed means setup1/setup2 selected. If setup1 is selected,
speed reference 0-10V is connected to the terminals 2-8 with potentiometer or external signal. The speed of the pump
is controlled according to the voltage signal. If the voltage is selected with potentiometer, the speed is constant.
When Setup2 is selected the controller of frequency converter is in use. The reference of controller 0-10V is connected
to the terminals 2-8 with potentiometer or external signal. Feedback signal 4-20 mA is connected to the terminal 1.
The speed of the pump changes according to the need of regulation.
Terminal 4 / X101. Stop / Start. Terminals 6-4 open means pump is not running, closed means pump is running.
Terminal 5 / X101. Reference freeze (both setup’s). When terminals 5 and 6 are connected, the speed reference (se-
tup 1) or the reference of the controller (setup 2) is freezed (not possible to change with potentiometer). By discon-
necting the wire between terminals 5 and 6, reference (0-10V) to the terminal 2 / X101 is in use.
Terminal 9 - (8) / X101. Digital output signal (24VDC, max. 25 mA) - fault. The voltage in termina indicast the fault
in the pump / inverter. Voltage is zero, if the supply voltage is not connected or there is no fault. If the potential free
contact is needed, the separate relay (24 VDC, < 25 mA) is needed. Please check the wiring diagram in section 5.4.
This terminal is possible to program with separate local control panel (not included is standard delivery) to an other
digital or analog output. E.g. 0 (4) - 20 mA analog output for frequency, reference, feedback, etc.
Relay output: Terminals 1, 2 and 3 / X102. Terminals 1 and 2 are connected when motor is running. Terminals 1 and 3
are connected when motor is not running (or the supply voltage is not connected).
Terminal 1 / X101 analog input 0-20 or 4-20 mA (dierent possible functions)
Terminal 2 / X101 analog input 0-10V or digital input (dierent possible functions)
Terminals 3, 4 and 5 / X101 digital input (dierent possible functions)
Terminal 6 / X101 24 V DC supply for digital inputs and feedback (max. 150 mA )
Terminal 7 / X101 10 V DC supply for potentiometer (max. 15 mA )
Terminal 8 / X101 0 V for terminals 1-7 ja 9
Terminal 9 / X101 analog or digital input (dierent possible functions,
Relay output:
Terminals 1, 2 and 3 / X102 relay output (dierent possible functions), potential free change-over
contacts, max. 250 V / 5 A

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5.4.3 FCA -pump - speed reference from potentiometer
The speed of electric motor can be adjusted manually at the site.
Useful feature for commissioning of the pump. The pump will run
with constant speed. The reference can be freezed by connecting
wire between terminals 5 and 6.
Systems, where the duty point remains constant and where is no need for continuous automated regulation.
Applications
Pump, frequency converter and potentiometer.
Accessories
Operation principle
QH-curve of the pump is equal with that of single speed pump.
Pump curve
FACTORY DEFAULT: SETUP 1
SETUP 1 = speed reference (FCA)
SETUP 2 = controller of the frequency converter in use, e.g. FCB, FCC
Standard control connections
%
min.
30
50
70
90
max.
10
An example of curve plate of
FCA -pump.
m
l/s
The control range is shown in curve plate which is
located in cover of the frequency converter.
ATTN Mark the position of the potentiometer to the sticker
in cover of the frequency converter.

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5.4.4 FCB -pump - constant pressure between the pump flanges
The level of the constant pressure dierence between the pump flanges can be adjusted by potentiometer. The set
value for the pressure dierence can be found from the curve plate of the pump. The pump will run with variable
speed. When adjusting the flow of the system, the main control valve must be opened as open as possible and then
the flow is adjusted by potentiometer. The reference can be freezed by connecting wire between terminals 5 and 6.
Systems, where are variations in the flow and where pressure losses are generated mainly on the consumption
equipment. Heating circulation, where the pressure loss on the heat exchanger is small.
Applications
Pump, frequency converter, potentiometer and dierential pressure transducer with pipes to the pump flange.
Accessories
Operation principle and flow adjustment
QH-curve of the pump is controlled to a horizontal line.
Pump curve
FACTORY DEFAULT: SETUP 2
SETUP 2 = constant pressure dierence (FCB, controller of
the frequency converter in use)
SETUP 1 = speed reference (FCA)
Standard control connections
%
min.
30
50
70
90
max.
10
By disconnecting the wire from potentio-
meter to the terminal 2 and connecting the
external 0-10V signal to the terminals 2-8,
the reference for pressure dierence is gi-
ven externally. Please check section 5.4.7.
m
l/s
An example of curve plate of FCB -pump.
The control range is shown in curve plate which is
located in cover of the frequency converter.
dierential pressure
transducer
ATTN Mark the position of the potentiometer to the sticker
in cover of the frequency converter.