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K-Series   

I/O Manual

 

Prepared by. 

 

 

Rev. No. 

 

Date. 

11-Jan-11 

 

Page. 

7 / 25

 

 

 

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For intermittent operation, the pump must always be covered by the 
pumped liquid to the middle of the motor 

 
 

3.        CARRIAGE & TRANSPORT 

 

 

During  transportation  the  pump  should  be  secured  in  such  a  manner  as  to  avoid 
shocks which may damage the pump. 

 

Handle the pump carefully. Use the lifting eye provided or slings the pump from the 
body and moves the pump with the aid of a hoist or proper handling equipment. 

 

The  pump  should  never  be  moved  by  the  cable.  There  is  a  high  possibility  of 
damage which may result in an electric short and risk of shock. The cable and cable 
inlet  may  be  damaged  leading  to  loss  of  water  tightness  and  subsequent  severe 
damage to the motor. 

 

3.1 Lifting the pump 
 

• 

KJI pumps approximately weigh up to 10,000 kg without accessories. It is 
therefore important to use the right lifting equipment. 

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The pump weight is stated on the pump nameplate. 

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All lifting equipment must be rated for the purpose and checked for damage 
before any attempt 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 supply cables. It may result in electric short-
circuit and risk of electric shock when the pump is connected to the mains. The 
cables and cable entry may be damaged, leading to loss of water tightness and 
consequent severe damage to the motor. 

 

4.          STORAGE   

 

4 .1 Warehouse Storage 
 

• 

The warehouse must be free of excessive humidity, corrosive gases or vapours 
and free from vibration which might damage the pumps. 

• 

Store the pumps in a vertical position on a pallet or stand to keep the pump off 
the floor and facilitate easy removal.   

• 

The cable should be coiled and the open end should be tightly sealed with 
waterproof plastic and tape or a cable cap to prevent the penetration of moisture 
which may reach the motor and cause severe damage to the windings. 

• 

All unpainted surfaces should be given a light coat of oil or grease to prevent 
corrosion. 

• 

If the pumps is being stored for longer than two months the impeller must be 
turned by hand at least every two months to prevent the lower mechanical seal 
faces from seizing up. 

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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