Grundfos KJI K Series Installation instructions manual

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 : [phone] (Rep.)
Web : www. kjipumps.co.kr

K-Series
I/O Manual
Prepared by.
Rev. No. 0
Date. 11-Jan-11
Page. 2 / 25
TABLE of CONTENTS
1. Overview
2. General Data
2.1 Information of the nameplate
2.2 Pump code designation
2.3 Maximum operating conditions
2.4 Safety Precautions
2.5 Applications
2.6 Operating Conditions
3. Carriage & Transport
3.1 Lifting the pump
4.
Storage
4.1 Warehouse storage
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
5.6 Horizontal installation
6. Commissioning & Operation
6.1 Initial Examination
6.2 Precautions
6.3 Insulation check
6.4 Control panel wiring
6.5 Thermal protection wiring
6.6 Changing the direction of rotation
6.7 Level switch & General wiring
7. Maintenance, Inspection and Overhaul
7.1 Maintenance
7.2 Inspection
7.3 Overhaul
8. Trouble Shooting

K-Series
I/O Manual
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Rev. No. 0
Date. 11-Jan-11
Page. 3 / 25
KSE & KSN USER MANUAL
1. OVERVIEW
Thank you for choosing KJI Pumps. This manual is designed to help you achieve the
best results from our products in terms of longevity, efficient usage and maintenance.
All users should read and be familiar with the contents of this manual.
All faults resulting from failure to install or maintain our product as described in this
handbook will be deemed to be faults arising from misuse of the product not covered
by warranty.
For any clarification required related to the contents of this manual, please contact KJI
office. Retain 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 nameplate is damaged, the pump will be identified by the serial number
stamped on the nameplate.
Model No.
H max
n
Motor
P 1 /P 2
A
min
-1
kg
~
Date
Temp. C
mQ
max
m /h
3
m
IP68
Isol.Class
/kW Cos.
VY AV
Hz
Manufactured for
1
3
5
8
2
4
7
10
6
9
11 12
13 14 15
16 16 17 17
Serial No.
Pos. Description
1 Serial number
2 Production date
3 Pump code
4 Maximum liquid temperature
5 Design head
6 Design flow
7 Low water level
8 Motor speed
9 Weight of the pump
10 Number of phases
11 Frequency
12 Insulation class
13 Power input
14 Shaft power
15 Power factor
16 Voltage/current
D.O.L connection
17 Voltage/current
Star-delta connection
fig.
1

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2.2 Pump code designation.
S 200 K S E 37 4 T 3
Volatage : 2=220V,230V / 3=380V / 4=415V,460V upto 6600V
Phase : S=Single Phase, T=Three Phase
Number of Poles : (Motor Synchronous Speed at 50Hz)
2=2850rpm, 4=1450rpm, 6=950rpm,
8=720rpm, 10=580rpm...etc
Motor Output in kW : (Horsepower Output=kW x 1.341)
Impeller Type : E=Enclosed, O=Open, V=Vortex,
SV=Semi-Vortex, PL:Propeller, M=Mixed
Pump Type : S=Sewage, W=Wastewater, D=Drainage,
A=Agitator, R=Aerator, M=Mixer
Manufacturer's Designation : K=K-Series
Discharge Size in mm
Materials of Construction : Blank=Standard Construction
S=All Stainless Steel, B=All Bronze
2.3 Maximum operating conditions.
The K-series submersible pumps are designed for pumping of unscreened wastewater
in municipal and industrial installations and for low to medium density sludge
pumping in sewage treatment plants. 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 corrosive liquids.
Pump usage is restricted by the following ambient conditions used as design criteria
limits:
-Maximum ambient and pumped liquid temperature is 40℃
-Storage temperature range is – 20℃… + 50℃
-Maximum allowable voltage fluctuation is ± 10% ~5% of nominal voltage
-Maximum submergence is 20 m.
ATTENTION!
Usage of the pumps in installations where conditions exceed those allowed in the
pump specifications may lead to pump malfunction and damage.
2.4 Safety Precautions
This pump contains hazardous moving parts. To prevent risk of injury, disconnect
power before servicing. Never put fingers near impeller when pump is connected to a
power source.
Installation should be performed by technicians with the appropriate qualifications as
required by local legislation.
This pump has not been approved for use in swimming pools and it should not be
installed in this type of application.
fig. 2

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Do not work alone. Use proper safety equipment including antiseptic masks if
necessary.
Ensure that there is no toxic or explosive gas in the wet well before entering or
welding or using electric tools.
Use approved lifting equipment and slings and do not stand under the pump while it
is being lifted. The cable is not designed to lift the pump and the pump must not be
maneuvered by use of the cable.
Ensure the cable particularly the exposed end is kept dry during installation.
The use of an earth leakage circuit breaker is highly recommended and may be
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 applications.
Depending on the installation type, the pumps can be used for submerged or dry,
horizontal or vertical installation. Maximum solids size can be changed, depending
on impeller type.
KJI Pumps Description Accessories
K-Series
-Waste Water
-
Municipal Sewage Treatment Plants
-Storm Water
-Industrial Effluent
-
Process Water Handling
-ADC, Flange
-Hose coupling
-Cooling Jacket
-Explosion proof
-Smart Lift
2.6 Operating conditions
2.6.1 pH value
All pumps can be used for pumping liquids with a pH value between 6 and 10.
-Liquid temperature(0°C to +40°C)
-Explosion-proof pumps must never pump liquids with a temperature
higher than +40°C.

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2.6.2 Ambient temperature(0°C to +40°C)
-For explosion proof pumps, the ambient temperature on the installation
site must be in the range between 0°C to +40°C.
2.6.3 Level of pumped liquid
• For pumps fully submerged pumps without cooling jacket, the lowest stop level
must be above the stator housing.
-The pump weight is stated on the pump nameplate.
• 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 water
level to remove the float layer. For explosion proof pumps it is not allowed to
go below the stop levels.
• For a submerged pump, the lowest stop level must always be above the pump
housing. To ensure adequate cooling of the motor during operation, the
following minimum requirements must be met :
-For continuous operation, the pump must always be covered by the
pumped liquid to the top of the motor
fig.
3

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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.
-The pump weight is stated on the pump nameplate.
• 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.

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• For long periods of storage the pump must be protected against moisture and
heat.
• Make sure the cooling jacket is empty before storing the pump.
• After a long period of storage, inspect the pump before putting it into operation.
Make sure that the impeller can rotate freely. Pay special attention to the
condition of the shaft seals and the cable entry.
4.2 Storage in the pit-system not in use
If an installed pump is not in operation for an extended period of time, the insulation
resistance should be measured and the pump runs for 30 mins each month.
If the pump cannot be run due to lack of water in the sump it should be inspected and
turned over by hand each month & prior to being put back into service. If the
insulation resistance drops below 10 Mega-Ohm, contact your local Grundfos office.
The power source must be shut off and isolated at the control 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 installation
• Check that the dimensions of the sump are correct and large enough so that the
pump can be installed and removed for servicing.
• Thoroughly clean and remove all rubbish from the sump and general
installation area to prevent clogging the impeller causing possible motor failure.
• Check the accessories and controls are complete.
• Carry the pump only as described in Clause 3.
• The extra nameplate supplied with the pump should be fixed at the installation
site.
• All safety regulations must be observed at the installation site, for instance the
use of blowers for fresh air supply.
• Prior to installation, check the oil level in the oil chamber.
• The start and stop levels are specified during the design stage. Always check
that the start/stop levels function and possibly alter them when commissioning
the pump in order to ensure good operation .
• To ensure adequate pull-out strength we recommend to use anchor bolt.

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To prevent mechanical damage,all cables laid under ground must be properly
installed in underground electrical conduit specifically designed for this purpose,
cables must not be installed directly in the ground or in
concrete. (see fig. 4).
The pump 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 (paint to be stripped).
Ensure all electrical cables are securely supported and that there is no loose cable
which could be sucked into the pump inlet.
After installing the pump, secure the lifting chain or wire rope to a wall or other
rigid surface, outside of the pit, to prevent submerged in wastewater.
fig. 5
fig.
4

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5.2 Cable Joints
If it is necessary to extend the pump supply cable ensure that the cross sectional area
of the extension cable used keeps sufficient cross sectional area to absorb voltage
drop. Ensure that the cable joint is waterproof and secure.
Connect each pair of wires (R-U, S-V, T-W) using a Sleeve Joint and staggering the
joints as shown below in fig. 5.
Primary Insulation layer:
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 and repeat the above insulating
procedure on the complete cable ensuring that the insulation covers the original cable
insulation at both ends by a minimum of 220mm.
The thickness of the joint must be less than twice the original cable diameter.
5.3 Wet pit ADC installation
In the Wet pit installation, the pump is installed on
the Automatic Discharge Connection (ADC) and
operates completely or partially submerged in the
pumped liquid.
fig. 6
fig. 7