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
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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

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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

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•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.

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5.4 Dry pit installation
• In the Dry pit installation, the pump will be installed in a stationary position of
the dry well next to the wet sump.
• The pump has a watertight motor therefore wouldn’t be damaged in the event
of flooding .
• 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 integrated .
-Bolt the suction cover to the concrete base by means of four grouted-in
anchor bolts .
-Bolt the pump to the suction connection .
-Check that the pump is vertical .
-Connect the motor cable, suction line and discharge line .
• Make sure that the weight of the pump does not bear on the system piping.
fig. 8

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5.5 Portable installation
In the Portable installation, the pump is
transportable and intended to operate completely
or partially submerged in the pumped liquid.
The pump is equipped with a connection for hose
or pipe.
The pump stands on a base stand.
WARNING!
Watch for the starting jerk which can be powerful.
5.6 Horizontal installation
• For the Horizontal installation, the pump is mounted on a support stand and a suction
pipe is connected to the inlet pipe.
• The pump motor is enclosed and 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 fabricated
in site with the specification of template provided by KJI.
• Horizontal pumps do not normally require special considerations for the start levels,
if the suction pipe is designed to prevent air pockets form forming, see fig. 10.
• The minimum pump stop level will be the same level as discharge area level that is
required to avoid the formation of vortices at the suction pipe and thus to avoid air
getting sucked into the pump. Air in the pumped liquid may cause vibrations,
cavitations and loss of pump performance.
f
Template
Pump stand
fig. 9
fig. 10

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5.6.1 Procedure of the Horizontal installation
-Mark and drill mounting holes in the concrete floor/concrete foundation.
-Fit the bracket or base stand to the pump.
-Fasten the pump with anchor bolts.
-Check that the pump type is right.
-In order to facilitate service on the pump, isolating valves should be fitted
on either side of the pump.
-Fit the suction and discharge pipes and isolating valves, if used, 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 relief
fitting to a suitable hook. Make sure that the cables are not sharply bent
or pinched.
-Connect the motor cable and the monitoring cable, if any.
• Following items are required:
- Support stand for anchoring the pump to the base.
- Shut-off valves for permit when the pump should be removed for service.
- Level regulators or other control equipment for start and stop, alarm.
WARNING!
The risk of freezing is particularly great at certain Dry pit or Horizontal installation.

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6. COMMISSIONING & OPERATION
6.1 Initial Examination
Physically inspect the pumps for any signs of transport damage, paying particular
attention to bolted joints and the cable if fitted.
Confirm that the details on the name plate of the pump agree with the ordered
product paying particular attention to voltage, frequency and starting method.
Check that all accessories and spare parts are included as described in 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 the
direction of rotation.
WARNING! The resulting kickback of large pumps can be powerful.
• Check that the supply voltage and frequency correspond to the values stated on
the pump nameplate. If not, do not start the pump.
• Check that the outer cable sheath is intact so that water cannot enter the junction
box through the cable.
• If refitting the cable, cut off a short piece to ensure that the cable entry sealing
sleeve does not clamp around the cable at the same point again.
fig. 11

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• Check that cable entry sealing sleeve and washers correspond to the outside
diameter of cable. When preparing power cable conductors for connection to the
pump and control panel, it is essential that the earth conductor is at least 50mm
longer than the other conductors after connection. This is to ensure that if the
cable is accidentally pulled out, the earth conductor connection will be the last
to be interrupted.
• Your pump is delivered connected for the voltage and frequency on the
nameplate and was factory tested prior to shipment under these conditions
6.2 Pre-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 voltage
of the product.
6.2.2 Check the insulation resistance with a Mega Tester to ensure it is over 10 Meg-
Ohm. (Refer to section 7.2 WIRING CHECK).
6.2.3 Ensure that all cables from the pump including sensor cables have been
securely connected to the appropriate terminals in the control box.
6.2.4 Check that the Pit or Sump is clean and free from rubbish.
6.2.5 Start the pump using the following sequence of events.
-Open the gate valve.
- Set the THR and Timer. (For Star-Delta starting, set the timer to 7 – 9 seconds
and set the THR to the rated current).
-Turn on the main supply isolator in the control panel. Set the selector switch
fig. 12
fig. 13

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to manual and jog the pump by momentarily starting it before fully starting.
- Check that the direction of pump rotation is anti clockwise when viewed from
above the motor fan cover, (clockwise when viewed looking at the impeller).
If rotation is in the wrong direction correct as per section 6.6.
- Start the pump and read the current variation while opening the discharge
valve slowly. Check if the current is within the rated current of the pump with
the discharge valve fully open.
- If the current exceeds the rated current, record the voltage and current then
stop the pump. Check 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 type of all
bends valves tees and fittings.
- Diameter and total length of the pipe
- If the operating current is within the rated current, monitor the variation over
1 hr of continuous operation. If it remains stable stop the pumps and set the
level switch positions to complete commissioning.
6.3 Insulation Check
This section describes how to check for correct wiring and how to identify the
individual cables when the original tags have been removed during installation.
6.3.1 Insulation check of Power Cable Wiring
6.3.1.1 For both DOL and SD start ensure that the insulation resistance between
each phase and earth exceeds 10 Meg-Ohm
fig. 14

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6.3.1.2 Direct On Line (D.O.L) Connect one of the three phase wires to the
Earth Link of a Mega Tester and measure the insulation resistance of the
remaining two wires. The insulation resistance should be infinity (see
fig 14 below). If not, to avoid motor damage do not operate the pump.
6.3.1.3 Star-Delta Starting Connect one of the six wires to the Earth Link of a
Mega Tester and measure the insulation resistances between the
remaining five wires and attach 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 not operate the pump.
DOL SD STARTING
6.3.1.4 When checking pumps wired Star-Delta to D.O.L or Reactor, Follow
the table below.
U,Z (1,6)--R
V,X (2,4)--S
W,Y(3,5)--T
6.3.2 Insulation check of Sensor Wiring
6.3.2.1 Motor Protection Sensor
There are two wires, both white and the identification marking is TP
(Thermal Protection).
Connect one of the wires to a Multi Tester. The resistance measured must
be 0 Ohm.
In any case, do not use Mega Tester.
If measured by Mega Tester, the sensor might be damaged and would
not operate properly.
fig. 15

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6.3.2.2 Leakage Sensor
There are two wires, both black and the
identification marking is SS (Seal Sensor). The
resistance measured with a multimeter should be
over 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 Multi-Tester should be between 100
Ohm-120 Ohm. Tested by Multi Tester.
(Do not use Mega Tester for this test).
6.4 Control Panel wiring
6.4.1 Wiring of Inlet, Outlet and Motor Protector
6.4.1.1 Direct On Line (D.O.L)
fig.
1
7
fig. 18
fig. 16

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6.4.1.2 Star – Delta
6.5 Thermal Protection Wiring
Most K-series control systems are equipped with thermal protection. There are two
types one is installed in the motor and the other in the control panel (Except for KP
type).
POSITION CONTROLTYPE 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
above 100oC the device
operates and disconnects the
circuit in the Control
Panel.
(for B Class Insulation)
1.25 – 2.0 sq
(White)
6.6 Changing the Direction of Rotation
6.7
To change the direction of rotation, interchange two of the phases in the control panel
as shown below.
6.6.1 Direct On Line.
fig. 19
fig. 20