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User Manual EN - ND serie

1. gt 9 10 Troubleshooting Cause and Measure 10 11 Repair and Warranty 000000 esses eee eee e eee eeeeeees u Document Number S2MMB194 DOC 1 Introduction Thank you very much for using the KARYU turbo mixer KTM We have taken utmost care while manufacturing so that you can use this KTM safely However if this is used in a wrong manner it may result in unexpected accident Please use the KTM carefully and correctly by referring to this manual 2 Unpacking check Once you receive the KTM please check the following 1 Confirm whether the model number printed on the nameplate is the same as the one you had ordered for 2 Confirm whether no damages have occurred during the transportation and whether nuts and bolts are not loosened 3 Confirm that all accessories and spare parts exist If there is any problem please contact the seller by explicitly mentioning the model number printed on the nameplate and the manufacturing number serial number 3 Installation 3 1 Place of installation 1 Please install at the place with surrounding temperature within 40 C humidity within 95 and altitude within 1 000 m 2 Select a place with good air circulation and with less dust as much as possible 3 Select the place where maintenance and inspection is possible 4 Please use a fence or enclosure to ensure that non related persons do not access the KTM 5 Please install the KTM in a place
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3. be operated in safe manner 3 If there is danger of the occurrence of the water hammer you are needed to use the check valve to close rapidly or other measures to avoid it NOTE 3 Other instructions for piping plumbing 1 Support the piping enough in order to ensure that there is no unnecessary load on the KTM suction inlet and discharge outlet If piping is done when the position of the KTM suction inlet and the discharge outlet does no match with the position of the pipe there will be high force on the KTM and this may result in the breakage of the suction inlet or discharge outlet and this results in reduced life of the KTM 2 Implement the discharge piping in such a way that it is an erect piping at least 700 mm away from the discharge outlet Othewise the self primed air does not get discharged leading the long duration for the discharge of water and hence water does not get pumped 3 3 Electrical wiring WARNING Please go through the Electrical equipments technical standards and extension regulations and the follow them perfectly during the installation of Electric power equipments for the Motor and during the wiring Please avoid the incomplete wiring work earthing done by unqualified personnel since it is not only illegal but also very dangerous Also in order to prevent electric shock accidents the law forces the use of electric leakage breaker Further please install the Motor protection device in order
4. near to the water source so that the length of the suction pipe is short 3 2 Plumbing work 1 Suction piping 5 Please note that if particles like threading cuts welding slag sand etc are inside the pipe then the same would enter the KTM and this would reduce the life of the KTM considerably We recommend you to fix strainer around 100 meshes Please clean this strainer neatly 8 We recommend the fixing of the sluice valve to enable convenient disassembling and inspection in case of flowing and pushing at the inlet 2 Discharge piping 1 Implement the discharge piping so that the piping length from the discharge outlet is minimum If you cannot avoid creation of air locks please fix air vent valves at such positions However the air vent valves cannot be fixed at places with negative pressures such as in Suction pipe In such case the air would be sucked in Document Number S2MMB194 DOC NOTE 2 In case of KTM if the discharge pressure increases then load of the motor also increases Hence if due to some reason the discharge outlet is closed the motor power increases beyond limit If the motor is under operation in such situation for a long time the KTM temperature increases and this may lead to complete burn out of the motor To avoid this please fix the relief valve in between the KTM and the sluice valve to ensure that the discharge pressure does not exceed the specified limits With this the KTM can
5. 9 Do not loosen the plugs bolts or nuts during the operation This may result in scattering of the liquid inside the KTM or dislocation of the parts which is dangerous 4 4 Stop Open the discharge adjustment valve completely and switch OFF If there is a electric power failure during the operation please switch OFF the power immediately and open the discharge adjustment valve completely NOTE Irrespective of the long term stoppage and short term stoppage drain out the water completely without fail Document Number S2MMB194 DOC 5 Maintenance 5 1 General Precautions NOTE 1 Before inspecting the KTM please cutoff the main power without fail This is to avoid dangers like sudden start of the KTM due to Automatic operation etc 2 Do not allow persons other than repair technicians to disassemble repair renovate etc This may result in fire ignition abnormal operations which would be dangerous 3 Check whether the KTM is operating smoothly without vibrations 4 Check the water level in the tank and the pressure at the suction inlet 5 Compare the discharge pressure power value during the operation with the values printed on the nameplates on the KTM motor and check the operating load of the KTM 6 Please note the pressure gauge displays the value which is the sum of the head and the specific gravity 7 Open the cock of the pressure gauge vacuum gauge during the measurement and close after the
6. Document Number S2MMB194 DOC User Manual KARYU turbo mixer KTM_ND Series KTMISND KTM20ND KTM25ND KTM32ND KTM40ND Thank you for purchasing the KARYU turbo mixer Please read the user manual completely before using the KARYU turbo mixer and use the KARYU turbo mixer correctly and safely After reading the manual please store in the place so that it is accessible easily Please ensure that the person using this can access this manual easily In order for you to use this KARYU turbo mixer safely The usage method and the points to take care are described in this user manual Since it may result in unexpected problems if used in a wrong manner please read the manual carefully before installation wiring operation maintenance and inspection of the KARYU turbo mixer and then use correctly In order to prevent harm injury or any damage to the user and the people in the vicinity in a precautionary way the safety instructions are classified into ranks like Warning and Note In case of wrong usage it may result in the death or serious injury of the user or the persons Warning nearby Hence please understand the contents of this manual completely and please follow the instructions exactly In case of wrong usage it may result in the medium or slight wound to the user or the Note persons nearby or in the physical damage Hence please understand the contents of this manual completely and please fo
7. Noise becomes severe Abnormal sound is generated Note 2 O ring During disassembly inspection Note 1 The average replacement frequency of the mechanical seal is 1 2 years However it varies depending on the usage Refer 5 2 3 Note 2 In case of such symptom even other parts are damaged 10 Troubleshooting Cause and Measure 1 Trouble during Startup Motor does not rotate Electrical power related problem Once in 2 3 years Motor breakdown Motor growls and does not rotate Rotating parts touch something else Rotating part is rusted Rotating part is in seizure Foreign body clogged in the rotating part 2 Trouble related to Pumping Water priming is not done Disassemble inspect and then repair Get it repaired by the manufacturer Specified discharge volume specified Sluice valve is closed and partially open Open the valve completely head not met Water is pumped initially but stops Actual head is more than the KTM head Suction lift is too much for this KTM Reduce the actual head Reduce the suction lift immediately Air vent valve is closed Open the air vent valve Suction pipe end is not submerged in the water Immerse the suction pipe end into the water Direction of rotation is reverse Correct the wiring and confirm the direction using the arrow mark on the KTM Operating under 50Hz instead of 60Hz Adjust to the specifi
8. The strainer is blocked Inspect the strainer and clean it 4 Problems related to Shaft bearing Shaft seal and others Overheat or abnormal noise is gen erated in the Shaft bearing Overleakage of water from the shaft seal portion 5 Causes for unstable microbubbles Centering is not correct Redo the centering and adjust correctly Shaft bearing is damaged Replace the shaft bearing Shutoff operation for long duration Wrong fixture of mechanical seal Stop the shutoff operation Mechanical seal is damaged Shaft is wom out Shaft is bent Shaft bearing is damaged Get it repaired by the manufacturer Direction of rotation is reverse Replace the motor and KTM Correct the wiring and confirm the direction using the arrow mark on the KTM Rotating parts are touching other things The shaft is bent Get it repaired by the manufacturer Replace the motor Replace the motor and KTM Cavitations has occurred Improve the suction piping Piping is resonating Improve the piping Install flexible pipe vibration isolating rubber cushion Descending pipe or arch piping after releasing the discharge pressure Improve the piping Inappropriate air injection rate Adjust the air injection rate appropriately Inappropriate suction discharge pressure Adjust the suction discharge pressure Clogged piping after releasing the discharge pressure El
9. e case of long term stoppage of operation but also due to the freezing of the liquid during winter even if operation is stopped for a short duration Please completely drain out the liquid of KTM inside 2 Please follow 4 Operation when resuming the operation 5 4 Precautions for Long term Storage 1 Please implement 2 Unpacking check without fail 2 Please ensure that foreign bodies do not enter into suction inlet and the discharge outlet Document Number S2MMB194 DOC 6 Disassembly Refer Fig 2 KTM_ND Cross section diagram NOTE Shut off the POWER before disassembling assembling the KTM This is to avoid dangers like sudden start of the KTM due to Automatic operation etc D 2 3 4 5 Remove the bolt used to fix the cover 103 to the body 102 and detach the cover 103 and the O ring 123 Loosen the hexagon socket setscrew 164 holding the impeller 107 and detach the impeller 107 Note If it is difficult to detach the impeller then screw in the bolt into the Tap hole of the impeller and then remove the impeller by pulling this bolt Detach the key 116 attached to the shaft 108 of the motor and detach the rotating part of the mechanical seal 051 Remove the bolt holding the motor and the body 102 and detach the body 102 Detach the low head cap 151C from the body 102 and detach the mechanical seal holder 049 and the fixed part of the mechanical seal 051 Detach the slin
10. ed rotation speed Number of poles in the motor is different Change the motor Voltage drop Supply the correct voltage Strainer or the foot valve is blocked Remove the foreign bodies Pipe is blocked Remove the foreign bodies Air is being sucked Inspect the suction pipe shaft seal part and repair accor dingly Leakage in the discharge pipe Horizontal pipe is very long Impeller is corroded Cavitations has occurred Get it repaired by the manufacturer Check the body also Improve the suction piping Too much pressure loss in piping Reduce Air is accumulated locked inside the dischar ge pipe Provide air vent Entrained air from the Gland packing part 10 Close the gland packing Inject water into the gland 3 Overload problems Operating under 50Hz instead of 60Hz Document Number S2MMB194 DOC Adjust to the specified rotation speed Number of poles in the motor is different Change the motor Voltage drop Supply the correct voltage Foreign bodies have entered into the intemal portion of the KTM Remove the foreign bodies Head is very high and discharge flow volume is very less Open the discharge valve Shaft bearing is damaged Get it repaired by the manufacturer Rotating parts are touching other things Get it repaired by the manufacturer The shaft is bent Replace the motor Replace the motor and KTM
11. ger 081 attached to the shaft 108 of the motor This completes the disassembly process 7 Assembly It is fine if you can assemble in the reverse order of the disassembly However please assemble each part perfectly using the following procedure D 2 3 4 5 6 7 Insert the slinger 081 into the shaft 108 of the motor up to the shaft level Attach the fixed part of the mechanical seal 051 to the body 102 tighten the mechanical holder 049 uniformly using the low head cap 151C and fix it Insert the assembled set of parts of the body in Step 2 into the motor shaft tighten uniformly using the bolts and attach to the motor flange Insert the rotating part of the mechanical seal 051 till it touches the fixed part Please ensure that there are no foreign bodies attached to the sliding surface of the mechanical seal by wiping using alcohol etc Insert the key 116 into the key groove of the motor shaft 108 and assemble the impeller 107 During this time please ensure that the pin of the rotating part of the mechanical seal 051 is inside the hole of the impeller 107 Fix the impeller 107 using the hexagon socket setscrew 164 During this adjust the position of the impeller 107 so that it does not touch the body 102 and the cover 103 Fit the O ring 123 into the cover 103 fix this uniformly using the bolt and fix to the body 102 This completes the assembly Further please take care ab
12. ges suddenly vibration of the pressure gauge needle the vibration of the Vacuum Gauge needle reduction in water level change in electric current value abnormal sound and this enables you to detect the problem at an early stage and also allows you to rectify the problem at an early stage and hence serves as the measure to prevent big accidents 5 Please confirm whether the actual measured values in 4 meets the discharge volume head power value being used The pressure gauge displays the value multiplying the head and the specific gravity Also ifthe specific gravity viscosity of the water is high the electric current value increases NOTE 6 Inorder to protect the mechanical seal use with the discharge head head of at least 10 m If the head is less than 10 m please contact the dealer or our company Please avoid the idle run of the KTM 7 Once the lifetime of the mechanical seal is over the leakage increases very rapidly It is strongly recommended to have a spare with you Please ensure that you run the spare KTM once in a while in order to ensure that it is in the working condition 8 If the KTM is operated continuously the temperature of the shaft bearing increases However if it can be touched by hand then there is no concern The tolerable increase in temperature of the shaft bearing on the surface of the bracket is within surrounding temperature 40 C and the maximum temperature is within 75 C NOTE
13. iminate foreign substances Unstable air suction Insufficient negative load Mixed large bubbles Install a separation tank option 1 1 To generate more stable microbubbles use a microbubble generator MBG 11 Repair and Warranty In case of repair or maintenance of the product please contact the seller or our company We are at your service For this product we guarantee our product as per the WARRANTY LETTER FORM as attached 11 Document Number S2MMB194 DOC THE WARRANTY LETTER FORM Dear Sirs WARRANTY OF QUALITY We hereby guarantee the quality of our product supplied to you in the following conditions D 2 3 4 5 Nikuni warrants our product to be free of defects in material and workmanship for a period of one 1 year of our shipment from our factory in Japan or our factory in China Any parts which fails during the warranty period due to defective material or workmanship will be replaced without charge Ex Go Nikuni factory provided a the claim for warranty is given in writing describing details of the defect within warranty period b Nikuni accept to return of defective part s for service and c the defective part s is delivered to Nikuni transportation charge prepaid in accordance with instruction of Nikuni In case of difference of opinion of the parties concerned regarding the warranty is applicable or not the judgement of Nikuni is final Nikuni s liability is limited
14. llow the instructions exactly NIKUNI Co Ltd Head office 843 5 Kuji Takatsu ku Kawasaki Kanagawa Japan Postal code 213 0032 TEL 044 833 1121 FAX 044 822 1115 Osaka Office 10F 1 7 10 Doshou machi Chuo ku Osaka shi Osaka Japan Postal code 541 0045 TEL 06 6205 7001 FAX 06 6205 7031 Nagoya Office 5F Asai Bldg 4 15 3 Imaike Chikusa ku Nagoya Shi Aichi Japan Postal code 464 0850 TEL 052 741 7301 FAX 052 741 7303 Nagano Office 102 Garden Square 1920 Yoshikawanomizo Matsumoto Nagano Japan Postal code 399 0003 TEL 0263 85 1330 FAX 0263 85 1332 Document Number S2MMB194 DOC Table of Contents 1 Introduction eee mercer eceereesescecresesesesereseseceeesesccce 3 2 Unpacking check eee were e reece erereresrererereeeesrereserere 3 3 Installation ee rr 2 3 3 1 Place of installation 3 2 Plumbing work 3 3 Electrical wiring 4 Operation Co eee rererereresresesreseresreseseseresesreseseses 4 4 1 Attention when starting 4 2 Operating procedure 4 3 Attention when driving 4 4 Stop 5 Maintenance ccccc ccc sce eee ete eee eens 7 5 1 General precautions 5 2 Inspection of the shaft seal 5 3 Precautions in the case of long term stoppage 5 4 Precautions for Long term Storage 6 Disassembly tte sess eeereereereeereereerresseeseereee 8 7 Assembly enn 8 8 Mounting the Gas suction nozzle sss sees esses eee eens 9 9 Ordering of the spare parts and the consumables
15. measurement If it were left open always then the instruments would be damaged due to the abnormal pressure of the water hammer etc For the measurement of the pressure of the polluted water measure via U tube with water if the pressure is below 0 1 MPa gauge or measure using the instrument with diaphragm 8 Make notes of the standard control values of the gas injection rate and the compound gauge and pressure gauge indication values to check them periodically 5 2 Inspection of the shaft seal Mechanical Seal NOTE 1 After implementing the priming completely start the operation Please avoid the idle operation 2 Confirm that there is no abnormal noise vibration and heat generation during the operation 3 Since the mechanism of the mechanical seal is in such a way that the tight sealing is achieved by liquid membrane is created on the sliding surfaces due the lubrication of the liquid used even though there is no leakage visible there would be a minute leakage of the liquid Due to this mechanism the leakage of the liquid may occur due to the nature of the liquid pressure operation method etc If you face liquid leakage problem you have to either install the drain piping drain pan or replace the mechanical seal upon consulting the dealer or our company Please refer to Section 8 2 Consumables for the replacement 5 3 Precautions in the case of long term stoppage 1 There is a danger of damage to the KTM not only in th
16. out the following points NOTE Confirm that the motor fan turns smoothly by turning it by hand If the rotation is abnormal or if it does not rotate properly there is a problem in the parts or the assembly Please re inspect the same Document Number S2MMB194 DOC 102 a 103 Cover 164 Hexagon socket setscrew 081 102 Body 151C Low head cap 081 slinger 123 O ring 123 S 051 Mechanical Seal 116 Key 049 Mechanical seal holder 108 Shaft Oz I A e E 032 Collar 107 Impeller No Name No Name 164 Fig 2 KTM_ND Cross section diagram 032 ae 151C 051 8 Mounting the Gas Suction Nozzle Upper pipe joint Mark here lower pipe joint Impeller Fig 3 Mounting the Gas Suction Nozzle 9 Ordering of the spare parts and the consumables 1 Order Please mention the KTM model number and the serial number printed on the nameplate correctly when ordering the spare parts and the consumables Also please specify the Part number and the Part name of the required spare parts and the consumables by referring to the Fig 3 Cross Section diagram 2 Consumables Please replace the consumables regularly based on the Table 1 as the indication Table 1 Replacement of consumables Document Number S2MMB194 DOC Consumable parts Symptom of consumption Mechanical seal Increase in liquid leakage Once in a year Note 1 Bearings
17. r its rotating direction and any abnormalities vibrations noise etc and then start continuous operation If it rotates in the reverse direction reconnect the wires so that it will rotate in the forward direction 4 Start the KTM 5 Seeing the discharge pressure gauge PG close the discharge pressure control valve V2 gradually to adjust to the specified pressure 6 Seeing the compound gauge CPG close the suction pressure control valve V1 gradually to adjust to approx 0 04 to 0 05MPa G 7 Open the airflow meter s Q knob to inject the air by approx 5 to 10 of a discharge rate Too high an air injection rate will result in idling causing a mechanical leakage etc 8 If the suction pressure is raised to 0 02MPa G by injecting the air close the suction pressure control valve V1 gradually If as a result the discharge pressure is lowered to 0 02 to 0 03MPa G from the specified pressure close the discharge pressure control valve V2 gradually to finely adjust to the specified pressure and the air injection rate as well 9 Solenoid valve SV when attached to the suction nozzle N Option Purpose Prevention of counterflow of the fluid to the airflow meter Q when the pump is stopping Control This has been set to Open at the time of power on In case of forcing ensure that the solenoid valve will be opened ON by turning on the system interlocked with the motor and closed OFF by turning off the
18. system In case of suction however when starting the KTM use the solenoid valve in combination with a flow switch so that it will be opened ON after pumping has been completed or open it ON 30 to 60 seconds after starting the KTM and close it at the same time of stopping the KTM If the air is injected prior to successful operation of the KTM pumping will not be performed y Q Airflow meter CV Check valve SV Solenoid valve PG discharge pressure gauge N Suction nozzle vos Compound gaugs V2 discharge pressure control valve V1 Suction pressure control valve Fig 2 KTM KARYU turbo mixer 4 3 Attention when driving WARNING 1 Please do not touch the rotating body to prevent the danger 2 Check whether the KTM is operating smoothly without vibration and noise The small metallic sound such as Kiiinn is the characteristic sound of the KTM and it is not an abnormality 3 Use the pressure gauge cock and vacuum gauge cock after squeezing in order to protect these instruments If they are left open always the instruments may be damaged due to the water hammering action during ON OFF of the KTM In order to measure the pressure of the polluted water use the instruments with diaphragm Document Number S2MMB194 DOC 4 Please pay attention to the pressure KTM discharge volume power value operating sound If foreign bodies get clogged up in the Foot valve Strainer impeller etc these values chan
19. to prevent the burn out due to motor overload etc 4 Operation 4 1 Attention when starting WARNING 1 Please confirm that the vicinity of the body of rotation is not dangerous when it drives 2 If the electric power switch and the KTM are far from each other then please do this work with the help of 1 or more persons and confirm that the region around the body of rotation is not dangerous NOTE 3 Confirm that there is no problem with rotation direction and the operation no vibration and no noise by switching ON Off of the switch 1 2 times inching If everything is fine then proceed for the continuous operation If the rotation is in the opposite direction do the wire connection so that the rotation direction is corrected 4 Please check whether there is no water leakage air entry at each plug cock packing material pipe comnection joints etc 4 2 Operating Procedure 1 Rotate the KTM by hand to check if it rotates lightly If it does not move smoothly the vanes may be interfered 2 Be sure to prime the KTM to fill the pump with water If operated without priming the KTM will go out of order Fully open the suction pressure control valve V1 and discharge pressure control valve V2 They should never be fully closed Fully close the airflow control knob of the airflow meter Q Document Number S2MMB194 DOC NOTE 3 Be sure to turn on off inch the switch once or twice to check the KTM fo
20. to the replacement or repair at our option of the defective parts as originally supplied by us We shall not be liable for any loss damage or expenses directly or indirectly related to the use of its products or from any other cause or for consequential damages including without limitation loss of time inconvenience and loss of production It is expressly understood that Nikuni is not responsible for damage or injury caused to other products machinery buildings property or persons by reason of the installation or use of its products The warranty shall be null and void if any component of a product has been a tampered with disassembled repaired or altered except as may be authorized by Nikuni in writing b subject to misuse neglect or accident or c used to materials which it was not designed to handle which may attack or harm the materials used in construction of the product or which may otherwise harm the operation of the product The warranty does not cover or apply to a the effects of corrosion abrasion or normal wear b repairs or service adjustments required due to lack of proper maintenance natural causes or acts of God or c any field expense for service or replacement of parts This warranty is Nikuni s sole warranty and in lieu of all other warranties express or implied which are hereby disclaimed including in particular all warranties of merchantability or fitness for a particular purpose Yours faithfully

User Manual EN - ND serie

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