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K-Series   

I/O Manual

 

Prepared by. 

 

 

Rev. No. 

 

Date. 

11-Jan-11 

 

Page. 

11 / 25

 

 

 

  Following items are required:   

- Guide bars consisting of two hot dip galvanized or stainless steel pipes. 
-  Sliding  Bracket  for  attaching  the  guide  bars  to  the  access  frame  or  the  upper 

part of the sump. 

- Level regulators or other control equipment for start, stop and alarm. 
-  Cable  holder  for  holding  the  cable  and  regulating  the  height  of  the  level 
regulators. 
-  Access  frame  (with  covers)  to  which  the  Sliding  Rail  supporter  and  cable 

holder can be attached. 

-  Discharge  connection  for  connecting  the  pump  to  the  discharge  line.  The 

discharge  connection  has  a  flange  which  fits  the  pump  casing  flange  and  a 
bracket for attaching the guide equipment. 

-  Bushes  for  vibration  damping  between  the  guide  bars  and  the  discharge 

connection. 

 
Instructions 

- Provide a barrier around the pump pit, for example a guardrail. 
- Arrange for a cable between the sump and the electric control box.   
- Make sure that the cables are not sharply bent or pinched. 
- Place the access frame in position. 
- Align the access frame so that it is horizontal and then grout it in place. 

Grout  the  anchor  bolts  in  place.  Be  careful  when  aligning  and  positioning  the 
discharge connection in relation to the access frame. 

- Place the discharge connection in position and tighten the nuts. 
- Secure the guide bars in the bracket. 
- Check that the guide bars are placed vertically by using a level or a plumb line. 
- Connect the discharge pipe to the discharge connection. 
-  Bolt  the  cable  holder  to  the  access  frame.  Thread  the  level  regulator  cables 

through  the  holes  in  to  the  cable  holder  and  adjust  the  height  of  the  level 
regulators. 

- Protect bolts and nuts with corrosion preventive compound. 
- Lower the pump along the guide bars. 
- Fasten the lifting chain (stainless steel) on the access  frame and the  cables on 

the  cable  holder.  Make  sure  that  the  cables  can  not  be  sucked  into  the  inlet  of 
the pump.   

- Support straps are required for deep installations. 
- Run the cables up to the electric control box. 
- Clean out debris from the sump before starting up the station. 
 

The  pump  can  be  hoisted  up  along  the  guide  bars  for  inspection  without  any 
connections having to be undone. 

 

 

 

 

 

Summary of Contents for KJI K Series

Page 1: ...r e v i s i o n 0 0 K Series Instruction Operation Manual for KJI PUMPS 750 18 Jangnok dong Gwangsan gu Gwangju Korea Tel 82 62 602 8400 Rep Web www kjipumps co kr...

Page 2: ...4 2 Storage in the pit system not in use 5 Installation 5 1 Points for attention during installation 5 2 Cable joints 5 3 Wet pit ADC installation 5 4 Dry pit installation 5 5 Portable installation 5...

Page 3: ...tain this manual for future reference 2 GENERAL DATA 2 1 Information of the nameplate All pumps can be identified by means of the nameplate on the top cover or frame of the motor see fig 1 If the name...

Page 4: ...The pumps are also suitable for various raw water pumping duties where the conditions call for submersible pumps to be installed Different pump material specifications are available for use in corrosi...

Page 5: ...mandatory under local regulations Please check local requirements 2 5 Applications KJI Pumps are designed for the pumping of sewage and wastewater in a wide range of municipal and industrial applicati...

Page 6: ...eplate Install an additional level switch to ensure that the pump is stopped in case the stop level switch is not operating For a short period of time it is allowed to use the pump to pump down the wa...

Page 7: ...pt to lift the pump The lifting equipment rating must under no circumstances be exceeded Always lift the pump by the marked lifting points or by designated equipment Never lift the pump by the power s...

Page 8: ...trol panel when the pump is not in service If the pump is disconnected from the control panel when not in service the cable end should be tightly sealed 5 INSTALLATION 5 1 Points for attention during...

Page 9: ...mp must be earthed by connecting the earth green wire Verify the grounding continuity by checking that the grounding wire green labelled as E is electrically conductive with the bolt on the motor pain...

Page 10: ...er Paste each individual wire joint with glue and wind with a strip of natural rubber Then wind with waterproof vinyl Secondary Insulation layer Gather together all the individual wires into one cable...

Page 11: ...nched Place the access frame in position Align the access frame so that it is horizontal and then grout it in place Grout the anchor bolts in place Be careful when aligning and positioning the dischar...

Page 12: ...The pump is equipped with a cooling jacket In addition to the following items are required Plate and anchor bolts for anchoring the pump to a concrete base Base stand and suction connection are integr...

Page 13: ...watertight and will not be damaged if the installation site is flooded with water The pump is equipped with a cooling jacket The Pump stand will be manufactured in factory and the template will be fa...

Page 14: ...and ensure that the pump is not stressed by the pipe work Adjust the length of the motor cable by coiling it up on a relief fitting to ensure that the cable is not damaged during operation Fasten the...

Page 15: ...n the commercial invoice and purchase order Before start up Rotate the propeller by hand clockwise seen from the motor side When started the motor will kickback the pump in the opposite direction of t...

Page 16: ...cautions After installing the control panel and pump connect the power supply and carry out the following procedure 6 2 1 Check the input voltage with a Multi Tester Ensure it complies with the volta...

Page 17: ...k the system and provide the details listed below to KJI See fig 12 The current and voltage during operation Nature and viscosity of the liquid Piping layout and configuration H1 H2 H3 H4 Number and t...

Page 18: ...a phase symbol as shown below The measured resistances are interdependent on each of the phases being measures and only one reading should be 0 Meg Ohm see fig 14 below If not avoid motor damage do n...

Page 19: ...20 Kilo Ohm Do not use Mega Tester for this test 6 3 2 3 Bearing Temperature Sensor There are two wires both red and the identification marking is BS Bearing Sensor The resistance measured with a Mult...

Page 20: ...OL TYPE OUTPUT PROCESS WIRES Motor Current Control Under 3 7 kW When overload current flows motor protector stops pump Not exposed Control Panel Thermal Control Over 5 5 kW If motor temperature rises...

Page 21: ...al Prepared by Rev No 0 Date 11 Jan 11 Page 21 25 6 6 2 Star Delta 6 7 Level switch general wiring 6 7 1 Level switch general wiring for general drainage purposes to operate one pump automatically fig...

Page 22: ...7 1 1 Current and Voltage Check the pump current and voltage If the ammeter reading exceeds the rated value or is far lower than rated value there is a problem with the pump Voltage should be stable w...

Page 23: ...ump Remove the bolts nuts of the discharge piping and lift the pump out of the well with the hoist 7 2 2 Inspection Procedure 7 2 2 1 Mechanical Seal Check the resistance of mechanical seal sensor wit...

Page 24: ...ve clearance Replace or repair as necessary Recommended clearance is 0 5mm to 0 9mm 7 3 OVERHAUL Pumps requiring overhaul should be repaired by an authorized KJI service workshop Procedure of the gene...

Page 25: ...starts but stops after a short period of operation 1 Prolonged dry operation has activated motor protection 2 High liquid temperature has activated motor protector 1 Adjust raise the pump stop water...

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