KSB Calio Installation instructions

High-efficiency Circulator Pump
Calio
Rating 800Watt
Installation/Operating Manual

Legal information/Copyright
Installation/Operating Manual Calio
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 modication without prior notice.
© KSB Aktiengesellschaft, Frankenthal 09/01/2018

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
2 Safety...................................................................................................................................................... 7
2.1 Key to safety symbols/markings.......................................................................................................................7
2.2 General..............................................................................................................................................................7
2.3 Intended use .....................................................................................................................................................8
2.4 Personnel qualification and training...............................................................................................................8
2.5 Consequences and risks caused by non-compliance with this manual .........................................................8
2.6 Safety awareness ..............................................................................................................................................9
2.7 Safety information for the operator/user.......................................................................................................9
2.8 Safety information for maintenance, inspection and installation ................................................................9
2.9 Unauthorised modes of operation..................................................................................................................9
3 Transport/Temporary Storage/Disposal............................................................................................. 10
3.1 Checking the condition upon delivery..........................................................................................................10
3.2 Transport.........................................................................................................................................................10
3.2.1 Placing the pump set down...............................................................................................................10
3.3 Storage/preservation......................................................................................................................................11
3.4 Return to supplier...........................................................................................................................................12
3.5 Disposal ...........................................................................................................................................................12
4 Description of the Pump (Set)............................................................................................................. 13
4.1 General description ........................................................................................................................................13
4.2 Designation.....................................................................................................................................................13
4.3 Name plate......................................................................................................................................................13
4.4 Design details..................................................................................................................................................14
4.5 Configuration and function...........................................................................................................................15
4.6 Noise characteristics .......................................................................................................................................15
4.7 Scope of supply...............................................................................................................................................16
4.8 Dimensions and weights ................................................................................................................................16
4.9 Accessories ......................................................................................................................................................16
5 Installation at Site................................................................................................................................ 17
5.1 Safety regulations ..........................................................................................................................................17
5.2 Checks to be carried out prior to installation...............................................................................................17
5.3 Installing the pump set ..................................................................................................................................17
5.4 Piping ..............................................................................................................................................................19
5.4.1 Connecting the piping.......................................................................................................................19
5.5 Enclosure/insulation .......................................................................................................................................20
5.6 Electrical connection ......................................................................................................................................20
5.6.1 Connecting the electric cables ..........................................................................................................22
5.6.1.1 Power supply..................................................................................................................................23
5.6.1.2 “In operation” message................................................................................................................23
5.6.1.3 General fault message...................................................................................................................24
5.6.1.4 External analog 0-10VDC signal................................................................................................24
5.6.1.5 External start/stop .........................................................................................................................25
5.6.1.6 Connecting the Modbus system ...................................................................................................25
5.6.1.7 Connecting dual-pump configurations........................................................................................29
6 Commissioning/Start-up/Shutdown................................................................................................... 30
6.1 Commissioning/Start-up.................................................................................................................................30
6.1.1 Prerequisites for commissioning/start-up .........................................................................................30
6.1.2 Priming and venting the pump.........................................................................................................30

Contents
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6.1.3 Start-up...............................................................................................................................................31
6.2 Operating limits..............................................................................................................................................31
6.2.1 Ambient temperature........................................................................................................................32
6.2.2 Minimum inlet pressure.....................................................................................................................32
6.2.3 Maximum operating pressure ...........................................................................................................32
6.2.4 Fluid handled .....................................................................................................................................32
6.2.4.1 Permissible fluids ...........................................................................................................................32
6.2.4.2 Density of the fluid handled.........................................................................................................33
6.2.4.3 Fluid temperature..........................................................................................................................33
6.3 Shutdown/storage/preservation ....................................................................................................................33
6.3.1 Measures to be taken for shutdown ................................................................................................33
6.3.2 Shutdown ...........................................................................................................................................34
6.4 Returning to service .......................................................................................................................................34
7 Operation.............................................................................................................................................. 35
7.1 Structure of the pump control system ..........................................................................................................35
7.2 Control panel..................................................................................................................................................35
7.3 Display.............................................................................................................................................................36
7.4 Mode of operation.........................................................................................................................................37
7.4.1 Information about settings ...............................................................................................................37
7.4.2 Constant-pressure control .................................................................................................................37
7.4.3 Proportional-pressure control ...........................................................................................................39
7.4.4 Eco Mode............................................................................................................................................40
7.4.5 Open-loop control .............................................................................................................................41
7.5 Functions.........................................................................................................................................................43
7.5.1 External start/stop..............................................................................................................................43
7.5.2 External analog 0-10VDC signal ....................................................................................................43
7.5.3 Dual-pump operation (DUAL) ...........................................................................................................45
7.5.4 Modbus...............................................................................................................................................46
7.5.5 Setback operation..............................................................................................................................50
7.5.6 Ramps .................................................................................................................................................51
7.5.7 Deblocking the impeller ....................................................................................................................51
7.5.8 Protection against excessive temperature........................................................................................51
7.5.9 Saving data.........................................................................................................................................52
7.5.10 General fault messages......................................................................................................................52
7.6 Resetting the factory setting .........................................................................................................................53
8 Information about settings ................................................................................................................. 54
9 Servicing/Maintenance........................................................................................................................ 55
9.1 Maintenance/inspection.................................................................................................................................55
9.2 Drainage/cleaning ..........................................................................................................................................55
9.3 Removing the pump set from the piping .....................................................................................................55
10 Trouble-shooting.................................................................................................................................. 57
11 Related Documents.............................................................................................................................. 59
11.1 Exploded view with list of components........................................................................................................59
11.2 Wiring diagram...............................................................................................................................................59
12 EU Declaration of Conformity............................................................................................................. 60
Index ..................................................................................................................................................... 61

Glossary
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Glossary
Discharge line
The pipeline which is connected to the discharge
nozzle
Noise characteristics
The noise characteristics are indicated as surface
sound pressure level 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
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 centre to
maintain the right to claim under warranty.
Noise characteristics see (ðSection4.6,Page15)
1.2 Target group
This operating manual is aimed at the target group of trained and qualified specialist
technical personnel. (ðSection2.4,Page8)
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

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 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.
2.2 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.
The safety information in all sections of this manual must be complied with.
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 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
▪Warnings

2 Safety
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The operator is responsible for ensuring compliance with all local regulations not
taken into account in this operating manual.
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.
▪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.
Prevention of foreseeable misuse
▪Never exceed the permissible operating limits specified in the data sheet or
product literature regarding pressure, temperature, etc.
▪Observe all safety information and instructions in this manual.
2.4 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.
2.5 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

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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 regulations and safety regulations
▪Explosion protection regulations
▪Safety regulations for handling hazardous substances
▪Applicable standards, directives and laws
2.7 Safety information for the operator/user
▪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.
▪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 shutting down 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.
2.8 Safety information for maintenance, inspection and installation
▪Modifications or alterations of the pump are only permitted with the
manufacturer's prior consent.
▪Use only original spare parts or parts authorised by the manufacturer. The use of
other parts can invalidate any liability of the manufacturer for resulting damage.
▪The operator ensures that maintenance, inspection and installation is 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 casing 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,Page33)
▪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30)
2.9 Unauthorised modes of operation
Never operate the pump (set) outside the limits stated in the data sheet and in this
manual.
The warranty relating to the operating reliability and safety of the supplied pump
(set) is only valid if the equipment is used in accordance with its intended use.

3 Transport/Temporary Storage/Disposal
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3 Transport/Temporary 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
DANGER
The pump (set) could slip out of the suspension arrangement
Danger to life from falling parts!
▷Always transport the pump (set) in the specified position.
▷Observe the information on weights, centre of gravity and fastening points.
▷Observe the applicable local accident prevention regulations.
▷Use suitable, permitted lifting accessories, e.g. self-tightening lifting tongs.
To transport the pump/pump set suspend it from the lifting tackle as shown.
Fig.1: Proper pump transport
Fig.2: Incorrect pump transport
3.2.1 Placing the pump set down
WARNING
Insufficient stability
Risk of crushing hands and feet!
▷During assembly/dismantling, secure the pump (set)/pump parts to prevent
tilting or tipping over.
Place the pump set down as illustrated.

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✔
Fig.3: Placing the pump set down safely
3.3 Storage/preservation
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken:
CAUTION
Damage during storage due to humidity, dirt, or vermin
Corrosion/contamination of the pump (set)!
▷For outdoor storage cover the packed or unpacked pump (set) and accessories
with waterproof material.
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.
Store the pump (set) in a dry, protected room at constant atmospheric humidity.
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 been operated, observe the instructions in
(ðSection6.3.1,Page33) .
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/Temporary 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 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.

4 Description of the Pump (Set)
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4 Description of the Pump (Set)
4.1 General description
▪High-efficiency circulator pumps 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 Designation
Example: Calio 40-180
Table5: Designation key
Code Description
Calio Type series
40 40 DN40
50 DN50
65 DN 65
80 DN80
100 DN100
180 Head
180 Head1) × 10
Example: 18m × 10 = 180
4.3 Name plate
1~230V 50/60 Hz
1~230V 50/60Hz PN 6/10 0,20 - 2,70A TF110
Class F IP44 46 - 611W EEI ≤0.20
1
2
3
4
5
6
7
8
9
10
11
12
Fig.4: Name plate (example)
1 Type series, size 7 Current input
2 Mains voltage, frequency 8 Pressure class
3 Thermal class 9 Temperature class
4 Enclosure 10 Energy efficiency index EEI
5 Material number 11 Input power
6 Production number 12 QR code
Key to the production
number
Example: 29134313-201630-12345
Table6: Key to the production number
Number Description
29134313 Material number
2016 Year of production
1) At Q = 0 m³/h

4 Description of the Pump (Set)
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Number Description
30 Week of production
12345 Consecutive number
4.4 Design details
Design
▪Maintenance-free high-efficiency wet rotor pump (glandless)
Drive
▪High-efficiency electric motor with continuously variable differential pressure
control
▪Electronically commutated synchronous motor with permanent magnet rotor
▪Integrated motor protection
▪1~230VAC +/- 10%
▪Frequency 50 Hz
▪Enclosure IPX4D
▪Thermal class F
▪Temperature class TF110
▪Energy efficiency index EEI ≤0.23
▪Interference emissions EN61000-6-3
▪Interference immunity EN61000-6-1
Bearings
▪Product-lubricated special plain bearing
Connections
▪Flanged connection
Operating modes
▪Constant-pressure control
▪Proportional-pressure control
▪Open-loop control via setpoint setting
▪Eco Mode with dynamic differential pressure setpoint adjustment
Automatic functions
▪Continuous output adjustment depending on the mode of operation
▪0-10V with external differential pressure/speed setpoint
▪Dual-pump operation
▪Setback operation
▪External start/stop
▪Deblocking function
▪Self-venting function
▪Soft start
▪Full motor protection with integrated trip electronics
Manual functions
▪Setting the operating mode
▪Setting the differential pressure setpoint
▪Setting the speed level
▪Locking the control panel (with the KSB Service Tool only)

4 Description of the Pump (Set)
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Signalling and display functions
▪Periodically alternating display of flow rate and electrical input power
▪Error codes indicated on the display
▪General fault message
▪Head displayed in addition
▪“In operation” message
▪Modbus
4.5 Configuration and function
8
7
9
10
11
12
4
5
6
1
2
3
Fig.5: Description and sectional drawing of the pump set
1 Thermal insulation shell 7 Discharge nozzle
2 Control panel 8 Radial plain bearing
3 Connections for control cables 9 Impeller
4 Display 10 Motor shaft
5 Control element (dial and control
button)
11 Motor
6 Connections for power supply, "in
operation" message and general
fault message
12 Suction nozzle
Design The pump is designed with a radial fluid inlet (suction nozzle) and a radial 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 lubricating system, high-quality graphite bearings and
precision-balanced rotor 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 (9). In the flow passage of the pump casing
the kinetic energy of the fluid is converted into pressure energy. The fluid is pumped
to the discharge nozzle (7), where it leaves the pump. The shaft runs in radial plain
bearings (8), which are supported by the motor (11).
4.6 Noise characteristics
Average sound pressure level <45dB(A)2)
2) Calio 100-60 < 49 dB (A)

4 Description of the Pump (Set)
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4.7 Scope of supply
Depending on the model, the following items are included in the scope of supply:
▪Pump set
▪Two-piece thermal insulation shell (single pump)
▪2 gaskets
▪Installation/operating manual
4.8 Dimensions and weights
For dimensions and weights please refer to the data sheet of the pump (set).
4.9 Accessories
▪BACnet MS/TP communication module
▪Spacer

5 Installation at Site
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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!
▷The pump materials are not suitable for drinking water and foodstuff
applications.
Never use the pump for drinking water or foodstuff applications.
5.2 Checks to be carried out prior to installation
Before beginning with the installation check the following:
▪Check the data on the name plate of the pump to make sure it can be operated
on the power supply network available. (ðSection4.3,Page13)
▪The fluid to be handled matches the description of suitable fluids.
(ðSection6.2.4.1,Page32)
5.3 Installing the pump set
DANGER
Leakage at the pump
Hot fluids escaping!
▷Fit the sealing elements and make sure they are positioned correctly.
CAUTION
Ingress of fluid into the motor
Damage to the pump set!
▷Install the pump set with the pump shaft in a horizontal position. Connect the
piping without transmitting any stresses and strains.
▷Never install the pump set with the motor terminal box pointing downwards.
▷Undo the hexagon socket head cap screws. Then turn the motor 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
We recommend installing shut-off valves upstream and downstream of the pump.
Make sure that no leaking water can drip into the pump motor or terminal box.

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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.
Positioning the control unit
WARNING
Insufficient stability
Risk of crushing hands and feet!
▷During assembly/dismantling, secure the pump (set)/pump parts to prevent
tilting or tipping over.
✔
Fig.6: Placing the pump set down safely
The control unit can be turned through 360°. The position must be effected with the
pump set removed from the system.
üThe pump set is secured against tipping over.
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.
Permissible installation positions
✔
✔
Fig.7: Permissible installation positions

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DANGER
Leakage at the pump
Leakage of hot fluids!
▷Insert the O-ring in the correct position.
Flanged 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. Bolt the pump flange to the pipe flange.
4. Tighten the bolts hand-tight with an assembly tool (e.g. wrench).
5. Accurately insert the sealing element on the opposite side.
6. Bolt the pump flange to the pipe flange.
7. Tighten the bolts hand-tight with an assembly tool (e.g. wrench).
5.4 Piping
5.4.1 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.

5 Installation at Site
20 of 64 Calio
NOTE
Installing check and shut-off elements in the system is recommended, depending on
the type of plant and pump. However, such elements must not obstruct proper
drainage or hinder disassembly of the pump.
üSuction lift lines have been laid with a rising slope, suction head lines with a
downward slope towards the pump.
üThe nominal diameters of the pipelines are equal to or greater than the nominal
diameters of the pump nozzles.
üThe pipelines have been anchored in close proximity to the pump and connected
without transmitting any stresses or strains.
1. Thoroughly clean, flush and blow through all vessels, pipelines and connections
(especially of new installations).
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!
▷Insulate the volute casing.
▷Fit protective equipment.
NOTE
The pump is supplied with a thermal insulation shell.
5.6 Electrical connection
DANGER
Electrical connection work by unqualified personnel
Risk of fatal injury due to electric shock!
▷Always have the electrical connections installed by a trained and qualified
electrician.
▷Observe the IEC60364 regulations as well as any regional regulations.
DANGER
Electrostatic charging
Danger of death from electric shock!
▷Provide potential equalisation between the pump set and the foundation.