KSB Calio S Installation instructions

High-efficiency Circulator Pump
Calio S
Installation/Operating Manual

Legal information/Copyright
Installation/Operating Manual Calio 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.
Subject to technical modification without prior notice.
© KSB SE & Co. KGaA, Frankenthal 12/07/2022

Contents
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Contents
Glossary .................................................................................................................................................. 5
1 General.................................................................................................................................................... 6
1.1 Principles ...........................................................................................................................................................6
1.2 Target group.....................................................................................................................................................6
1.3 Other applicable documents............................................................................................................................6
1.4 Symbols .............................................................................................................................................................6
1.5 Key to safety symbols/markings.......................................................................................................................7
2 Safety...................................................................................................................................................... 8
2.1 General..............................................................................................................................................................8
2.2 Intended use .....................................................................................................................................................8
2.2.1 Prevention of foreseeable misuse.......................................................................................................8
2.3 Personnel qualification and training...............................................................................................................9
2.4 Consequences and risks caused by non-compliance with this manual .........................................................9
2.5 Safety awareness ..............................................................................................................................................9
2.6 Safety information for the user/operator.......................................................................................................9
2.7 Safety information for maintenance, inspection and installation ..............................................................10
2.8 Unauthorised modes of operation................................................................................................................10
3 Transport/Storage/Disposal ................................................................................................................ 11
3.1 Checking the condition upon delivery..........................................................................................................11
3.2 Transport.........................................................................................................................................................11
3.3 Storage/preservation......................................................................................................................................11
3.4 Return to supplier...........................................................................................................................................12
3.5 Disposal ...........................................................................................................................................................12
4 Description............................................................................................................................................ 13
4.1 General description ........................................................................................................................................13
4.2 Product information as per Regulation No. 1907/2006(REACH).................................................................13
4.3 Designation.....................................................................................................................................................13
4.4 Name plate......................................................................................................................................................14
4.5 Design details..................................................................................................................................................15
4.6 Configuration and function...........................................................................................................................16
4.7 Noise characteristics .......................................................................................................................................17
4.8 Scope of supply...............................................................................................................................................17
4.9 Dimensions and weight..................................................................................................................................17
4.10 Accessories ......................................................................................................................................................17
5 Installation at Site................................................................................................................................ 18
5.1 Safety regulations...........................................................................................................................................18
5.2 Checks to be carried out prior to installation...............................................................................................18
5.3 Installing the pump set ..................................................................................................................................19
5.4 Connecting the piping ...................................................................................................................................20
5.5 Fitting the enclosure/insulation.....................................................................................................................21
5.6 Electrical connection ......................................................................................................................................22
5.6.1 Connecting the power cable .............................................................................................................23
6 Commissioning/Start-up/Shutdown................................................................................................... 25
6.1 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
6.2 Operating limits..............................................................................................................................................27
6.2.1 Frequency of starts.............................................................................................................................27
6.2.2 Ambient temperature........................................................................................................................27
6.2.3 Minimum inlet pressure.....................................................................................................................27

Contents
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6.2.4 Maximum operating pressure ...........................................................................................................28
6.2.5 Fluid handled .....................................................................................................................................28
6.3 Shutdown........................................................................................................................................................29
6.3.1 Shutdown ...........................................................................................................................................29
6.3.2 Measures to be taken for shutdown ................................................................................................29
6.4 Returning to service .......................................................................................................................................30
7 Operation.............................................................................................................................................. 31
7.1 Control panel..................................................................................................................................................31
7.1.1 Display ................................................................................................................................................31
7.2 Operating modes............................................................................................................................................32
7.2.1 Information on settings.....................................................................................................................32
7.2.2 Constant-pressure control .................................................................................................................33
7.2.3 Proportional-pressure control ...........................................................................................................34
7.2.4 Open-loop control .............................................................................................................................36
7.3 Functions.........................................................................................................................................................37
7.3.1 Setback operation..............................................................................................................................37
7.3.2 Dynamic control.................................................................................................................................39
7.3.3 Protective functions...........................................................................................................................41
7.3.4 Saving data.........................................................................................................................................41
7.3.5 Fault messages ...................................................................................................................................41
8 Servicing/Maintenance........................................................................................................................ 42
8.1 Servicing/maintenance/inspection.................................................................................................................42
8.2 Drainage/cleaning ..........................................................................................................................................43
8.3 Removing the pump set from the piping .....................................................................................................43
8.3.1 Removing the power cable ...............................................................................................................45
9 Trouble-shooting.................................................................................................................................. 46
10 Related Documents.............................................................................................................................. 47
10.1 Sectional drawing with list of components ..................................................................................................47
11 UK Declaration of Conformity............................................................................................................. 48
Index ..................................................................................................................................................... 49

Glossary
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Glossary
Discharge line
The pipeline which is connected to the discharge
nozzle
Pump
Machine without drive, additional components or
accessories
Pump set
Complete pump set consisting of pump, drive,
additional components and accessories
Setback operation
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

1 General
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1 General
1.1 Principles
This operating manual is valid for the type series and variants indicated on the front
cover.
The operating manual describes the proper and safe use of this equipment in all
phases of operation.
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. (ðSection2.3,Page9)
1.3 Other applicable documents
Table1: Overview of other applicable documents
Document Contents
Data sheet Description of the technical data of the pump (set)
For accessories and/or integrated machinery components, observe the relevant
manufacturer's product literature.
1.4 Symbols
Table2: 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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1.5 Key to safety symbols/markings
Table3: 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.
Warning: Strong magnetic field
In conjunction with one of the signal words this symbol indicates a
hazard involving magnetic fields and identifies information about
protection against magnetic fields.
Warning for persons with pacemaker
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.

2 Safety
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2 Safety
!DANGER
All the information contained in this section refers to hazardous situations.
In addition to the present general safety information the action-related safety
information given in the other sections must be observed.
2.1 General
▪This operating manual contains general installation, operating and maintenance
instructions that must be observed to ensure safe operation of the system and
prevent personal injury and damage to property.
▪Comply with all the safety instructions given in the individual sections of this
operating manual.
▪The operating manual must be read and understood by the responsible specialist
personnel/operators prior to installation and commissioning.
▪The contents of this operating manual must be available to the specialist
personnel at the site at all times.
▪Information and markings attached directly to the product must always be
complied with and kept in a perfectly legible condition at all times. 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.
2.2 Intended use
▪The pump (set) must only be operated in the fields of application and within the
use limits specified 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 rate and maximum flow rate indicated in the data
sheet or product literature (e.g. to prevent overheating, cavitation damage,
bearing damage).
▪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.
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.

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2.3 Personnel qualification and training
All personnel involved must be fully qualified to transport, install, operate, maintain
and inspect the equipment 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.
This device may be operated by children from the age of 8 as well as by persons of
limited physical, sensory or mental abilities or lacking experience and knowledge,
provided that they are supervised, they have been instructed on how to use this
device safely and they understand the hazards it presents. It is impermissible for
children to play with this device. Children must not clean the device or perform any
service work to be carried out by the operator at the device without supervision.
2.4 Consequences and risks caused by non-compliance with this manual
▪Non-compliance with these operating instructions 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
2.5 Safety awareness
In addition to the safety information contained in this operating manual and the
intended use, the following safety regulations shall be complied with:
▪Accident prevention, health regulations and safety regulations
▪Explosion protection regulations
▪Safety regulations for handling hazardous substances
▪Applicable standards, directives and laws
2.6 Safety information for the user/operator
▪Fit protective equipment (e.g. contact guards) supplied by the operator for hot,
cold or moving parts, and check that the equipment functions properly.
▪Do not remove any protective equipment (e.g. contact guards) during operation.
▪Provide the personnel with protective equipment and make sure it is used.
▪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.)
▪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.

2 Safety
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2.7 Safety information for maintenance, inspection and installation
▪Modifications or alterations of the pump (set) are only permitted with the
manufacturer's prior consent.
▪Use only original spare parts or parts/components authorised by the
manufacturer. The use of other parts/components can invalidate any liability of
the manufacturer for resulting damage.
▪The operator ensures that maintenance, inspection and installation are
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.
▪Only perform work on the pump set when it has been disconnected from the
power supply (de-energised).
▪The pump (set) 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. (ðSection6.3.2,Page29)
▪Decontaminate pumps which handle fluids posing a health hazard.
▪As soon as the work has been completed, re-install and re-activate any safety-
relevant devices and protective devices. Before returning the product to service,
observe all instructions on commissioning. (ðSection6.1,Page25)
2.8 Unauthorised modes of operation
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.

3 Transport/Storage/Disposal
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3 Transport/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 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
CAUTION
Damage during storage due to humidity, dirt or vermin
Corrosion/contamination of pump (set)!
▷For outdoor storage cover the pump (set) and accessories with waterproof
material and protect against condensation.
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.
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken for pump (set) storage.
Store the pump (set) in a dry, protected room where the atmospheric humidity is as
constant as possible.
If properly stored indoors, the equipment is protected for a maximum of 12months.
New pumps/pump sets are supplied by our factory duly prepared for storage.
For storing a pump (set) which has already been operated, observe the instructions
in (ðSection6.3.2,Page29) .
Table4: Ambient conditions for storage
Ambient condition Value
Relative humidity 80% maximum
Ambient temperature 0°C to + 40°C
▪Well-ventilated
▪Dry
▪Dust-free
▪Shock-free
▪Vibration-free

3 Transport/Storage/Disposal
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3.4 Return to supplier
1. Prior to returning the product to the supplier, flush and clean it, particularly if it
has been used in noxious, explosive, hot or other hazardous fluids.
2. If the product has been used in fluids whose residues could lead to corrosion
damage in the presence of atmospheric humidity or could ignite upon contact
with oxygen, the product must also be neutralised and treated with anhydrous
inert gas to ensure drying.
3. Always complete and enclose a certificate of decontamination when returning
the product.
Indicate any safety measures and decontamination measures taken.
NOTE
If required, a blank certificate of decontamination can be downloaded from the
following web site: www.ksb.com/certificate_of_decontamination
3.5 Disposal
DANGER
Strong magnetic field in the pump rotor area
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.
WARNING
Fluids handled, 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 fluid residues.
▷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.
Electrical or electronic equipment marked with the adjacent symbol must not be
disposed of in household waste at the end of its service life.
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.

4 Description
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4 Description
4.1 General description
▪High-efficiency circulator pump with continuously variable speed control
▪Non-self-priming in-line pump with integrated permanent magnet motor and
electronic variable speed system
▪Pump for handling clean, non-aggressive fluids which are not chemically and
mechanically aggressive to the pump materials
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
25 Connection
15 Rp1/2
25 Rp1
30 Rp 11/4
40 Head H1) [m]
40 Head × 10
Example: 4m × 10 = 40
130 Overall length
130 130mm
-2) See dimensions
1At flow rate Q = 0m³/h
2Blank

4 Description
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4.4 Name plate
P/N: 291349XX
Calio S 25-60
1~230 V - 50 Hz
0,06 - 0,43 A
Class F IPX4D
EEI ≤ 0,20
1
2
3
4
5
PN 16
6
TF 95
6 - 25 W
7
8
9
10
11
12
Made in Turkey | KSB SE & Co. KGaA
Johann-Klein-Str. 9 67227 Frankenthal (Germany)
S/N: 291349XX-A201920-XXXX1
Fig.1: Name plate (example)
1 Type series, size 7 Production number
2 Mains voltage, frequency 8 Current input
3 Thermal class 9 Pressure class
4 Enclosure 10 Temperature class
5 Power input 11 Energy efficiency index EEI
6 Material number 12 QR code
Key to the production
number
Example: 291349XX-A201920-XXXX1
Table6: Key to the production number
Code Description
291349XX Material number
2019 Year of production
20 Week of production
XXXX1 Consecutive number

4 Description
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4.5 Design details
Design
▪Maintenance-free high-efficiency wet rotor pump (glandless)
Drive
▪High-efficiency permanent magnet synchronous motor, brushless, self-cooling,
with continuously variable differential pressure control
▪1~230VAC +/- 10%
▪Frequency 50Hz/60Hz
▪Enclosure IPX4D
▪Thermal class F
▪Temperature class TF95
▪Energy efficiency index EEI ≤0.20
▪Interference emissions EN 55014-1
▪Interference immunity EN 55014-2
▪Interference immunity IEC 60335-2-51
Bearings
▪Ceramic bearings
Connections
▪Screw-ended
Operating modes
▪Automatic mode with constant-pressure control or proportional-pressure control
▪Open-loop control via setpoint setting
Automatic functions
▪Continuously variable speed adjustment depending on the mode of operation
▪Soft start (limitation of starting current)
▪Full motor protection with integrated trip electronics
▪Setback operation
▪Dynamic Control in Proportional-pressure Control operating mode dp-v
Manual functions
▪Setting the operating mode
▪Setting the discharge head setpoint
▪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

4 Description
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4.6 Configuration and function
1
2
4
5
6
7
3
8
9
10
11
12
13
Fig.2: Illustration of the pump set
1 Pump casing 8 Discharge nozzle
2 Thermal insulation shell 9 Radial plain bearing
3 Control panel 10 Impeller
4 Display 11 Motor
5 Control element (3control buttons) 12 Suction nozzle
6 Vent plug/ deblocking 13 Motor shaft
7 Plug-type connector for power supply
Description The pump is designed with a radial fluid inlet (suction nozzle) and a radial fluid
outlet (discharge nozzle) arranged on the same axis. The impeller is rigidly connected
to the motor shaft. Mechanical sealing is not required as the rotating assembly is
completely isolated from the stator winding. The rotating assembly is lubricated and
cooled by the fluid handled. The electronic system housing is equipped with a plug-
type connector. The lubricating system and high-quality ceramic bearings ensure
smooth running and a long service life. The integrated continuously variable
differential pressure control and operating software enable an optimum adjustment
of the pump to changing operating conditions and minimise operating costs. The
combination of an efficient hydraulic system with a high-efficiency electric motor
makes sure that the input power is converted into hydraulic energy as efficiently as
possible.
Function The fluid enters the pump via the suction nozzle (12) and is accelerated outward in a
cylindrical flow by the rotating impeller (10). In the flow passage of the pump casing
the kinetic energy of the fluid is converted into pressure. 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).

4 Description
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4.7 Noise characteristics
Average sound pressure level ≤30dB(A)
4.8 Scope of supply
Depending on the model, the following items are included in the scope of supply:
▪Pump set
▪Sealing elements
▪Electrical plug-type connector with straight and angled plug housing
▪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.

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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.
DANGER
Use for drinking water or foodstuff applications
Danger of poisoning!
▷Never use the pump for drinking water or foodstuff applications.
CAUTION
Improper installation of the pump set
Damage to the pump set!
▷Observe the permissible ambient conditions and the pump set’s type of
enclosure.
▷Observe the permissible ambient temperatures. Ambient temperatures < 0°C
are not permitted.
▷In the event of outdoor installation, fit a protective roof to protect the pump
set from the weather (e.g. sun, rain, snow).
5.2 Checks to be carried out prior to installation
Before beginning with the installation check the following:
▪All structural work required has been checked and prepared in accordance with
the dimensions in the outline drawing.
▪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)

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5.3 Installing the pump set
DANGER
Leakage at the pump
Leakage of hot fluids!
▷Fit the sealing elements and make sure they are positioned correctly.
CAUTION
Fluid entering the electronic system housing
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 electronic system housing pointing upwards
or downwards.
▷Undo the hexagon socket head cap screws. Then turn the electronic system
housing.
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
Installing shut-off valves upstream and downstream of the pump set is
recommended. Make sure that no leakage drips onto the pump set.
NOTE
The direction of flow of a vertically installed pump should be upwards.
NOTE
Do not install the pump at the lowest point of the system to prevent any impurities
from collecting in the pump.
The control panel can be turned. The position must be effected with the pump set
removed from the system.
1. Undo and store the 4 hexagon socket head cap screws.
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.

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Permissible installation positions
Fig.3: Permissible installation positions
Screw-ended pump 1. Position the pump set as indicated in an easily accessible place.
ðAn arrow on the pump casing and thermal insulation shell indicates the
direction of flow.
2. Accurately insert the sealing element.
3. Connect the pump and piping with a pipe union.
4. Tighten the pipe union hand-tight with a suitable tool.
5. Accurately insert the sealing element in the opposite pipe union.
6. Tighten the pipe union hand-tight with a suitable tool.
5.4 Connecting the piping
WARNING
Hot surface
Risk of burns
▷Never touch a pump set when it is in operation.
WARNING
Impermissible loads acting on the pump nozzles
Risk of burns by hot fluids escaping!
▷Do not use the pump as an anchorage point for the piping.
▷Anchor the pipes in close proximity to the pump and connect them without
transmitting any stresses or strains.
▷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.