AUTOMATIC BOOSTER PUMPS

KP-8 Series

INSTRUCTION MANUAL!

ISO 9001 Certified ISO 9001 Certified

KIKAWA PUMP CO., LTD KIKAWA PUMP CO., LTD

91800011/2010/01
§ CONSTRUCTION § INSTALLATION AND PIPING

NO PART NAME NO PART NAME NO PART NAME

1 MOTOR 10 SUCTION FLANGE CHECK VALVE FAUCET
18
2 PUMP CASING 11 FLANGE GASKET PLUG
INLET VALVE
3 CASING BOLTS 12 FLANGE BOLTS 19 GASKET
4 LOGO COVER 13 DISCHARGE FLANG E 20 ACCUMULATOR ACCUMULATOR
COCK
5 MECHANICAL SEAL 14 FLANGE GASKET 21 PRESSURE SWITCH
6 IMPELLER 15 PRIMING PLUG ACCUMULATOR SUCTION PIPE
22
7 IMPELLER BOLT 16 CHECK VALVE COVER BOLTS
SUCTION PUMP DISCHARGE PIPE
8 SEAL O RING CHECK VALVE 23 BASE DEPTH
17
9 FLANGE BOLTS SPRING 24 BASE BOLTS

Fig. 1

1. For stable operation, please mount and bolt the booster pump securely.
The installation place must be dry with good ventilation and adequate
space for future maintenance and service.
2. Protection rubber films within the center of suction/discharge flange
gaskets muse be removed during installation.
3. The pump should be installed as close as to the reservoir or well.
4. The depth from the pump center to the water level cannot exceed 8
meters. A check valve is required in the suction piping, and the
horizontal suction piping must slope from the pump to the reservoir.
5. Piping joints must be fitted carefully to prevent leak. Leak in the suction
piping will cause the pump suction capacity lost, while leak in the
discharge piping will cause a high frequency ON/OFF motor operation
while the faucets valves are closed.
6. Be careful not to allow the foreign objects (PVC adhesive gum, dirt,
sand etc) into the pump, otherwise the pump will be damaged and
shortened the life. It is recommended to use a strainer to prevent that.

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 § IMPORTANT NOTES

7. Open the plastic cover of wiring box by pushing its pins. Use the right 1. Before setting the power on after first installation or long term stop,
voltage and wiring according to the wiring diagram shown inside the please check whether the pump is locked due to rust or other objects. It
cover. Motor must be grounded in compliance with the local government
can be done by inserting a flat/crossed screw driver into the motor shaft
electrical code to avoid accident.
end, and turn the shaft several turns clockwise by hand, Fig. 2. If the
shaft is locked, remove and clean the pump (pump casing, impeller
mechanical seal etc.) in accordance with the assembly diagram shown
§ OPERATION
in the beginning of this manual. Do not forget to put the cover seal
O-ring back.
1. Remove the pump built-in check valve cover or priming plug, and pour
2. Be sure to arrange earth or circuit breaker against electric leakage in
water into the pump and suction piping, then secure them.
accordance with local government electrical code.
2. Insert a flat/crossed screw
3. Do not dry run, or pump hot water (more than 40oC) and the other liquid
driver into motor shaft end,
except water, because they will damage the mechanical seal. Special
and turn the shaft several
mechanical seal can be ordered to meet the hot water pumping
turns clockwise to check
requirement, please contact with us.
whether the pump impeller
4. Do not install pump in a hot environment. Ventilation is necessary for
and mechanical seal are
preventing the overheating of motor. If the pump is installed outdoors, it
free or locked by rust, sand
must be set up within a shelter. Exposure to rain will damage the
or other objects, Fig 2. Fig. 2
insulation of electrical wiring.
5. The overheating protector is mounted directly with motor winding. It will
3. Double check the voltage and wiring of the motor power, and then turn
stop the motor automatically when the motor temperature is up to
the power switch ON. Open faucet or water appliances on the discharge
abnormal, and restart the motor after the temperature back to normal.
piping side. The water should be delivered after several seconds.
6. Always keep the discharge faucets, valves, or water appliances opened
4. If the water does not be delivered after several minutes, turn off the
fully during water supply in order to get
pump immediately. Repeat pouring water into the pump and suction
more efficient pump performance. Do
piping, and switch power ON and OFF continuously.
not keep continuous operation under
5. Once the water is pumped out, close and open the water appliances on
of half or even smaller open, as shown
the discharge side repeatedly to check automatic ON/OFF operation.
in the Fig.3.
6. Measure the motor current and check with the data shown on the motor
7. The pump’s pressure switch has been
nameplate. If the motor is overload, try to reduce the delivery head or
set accurately. Please do not try to
set the valve full open. Fig. 3
adjust except by qualified personnel.

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§ TROUBLE SHOOTING § SPECIFICATIONS

1. MOTOR FAILS TO START

(a) Check electrical power source, fuse, and circuit breaker.
(b) Check if the pump is locked because of rust, or foreign objects. Model KP820 KP825 KP825X
(c) Check pressure switch setting, and adjust or replace it.
(d) Check if the motor is burnt out because of over loading. Capacitor running,
Motor Type
Single-phase induction motor.
2. PRESSURE SWITCH ADJUSTMENT (Fig. 4)
Power 1/4 HP 1/2 HP 1HP
(a) If the motor does not start after any of the
faucets or valves are opened, adjust the
Suction Head (m) 8 8 8
pressure setting screw to the “+” direction
(counterclockwise) until the motor starts. 50Hz 28 62
Max. Quantity 48
(b) If the motor fails to stop after all the
(l/min)
faucets and valves are closed, adjust the 60Hz 32 54 70
pressure setting screw to the “-“ direction
(clockwise) until the motor stops. Fig. 4 50Hz 18 (at 10m) 20 (at 20m) 30 (at 25m)
Quantity
(c) Repeat step (a) and (b) until the pump work normally. (l/min)
60Hz 20 (at 12m) 28 (at 20m) 38 (at 25m)
3. PUMP GIVES REDUCED OUTPUT OR NO WATER IS DISCHARGED
(a) Install level controller to detect insufficient water source or water Press. Switch 50Hz 1.0 ~ 2.0 1.2 ~ 2.4 2.0 ~ 3.0
level.
(b) Check and fix the leak in the suction piping. Kg/cm2 60Hz 1.2 ~ 2.4 1.4 ~ 2.8 2.5 ~ 3.5
(c) Clean pump built-in check valve, which may be held or jammed by
Suction Flange 3/4” (20mm) 1” (25mm) 1” (25mm)
dirt.
(d) Replace pump parts (impeller, mechanical seal), which are worn out Delivery Flange 3/4” (20mm) 1” (25mm) 1” (25mm)
by the pumping abrasives.
Weight ( Kgs ) 9.6 11.0 17.4
4. PUMP CYCLES FREQUENTLY WHILE ALL THE FAUCETS AND
VALVES ARE CLOSED Packing Dimensions
29x24x45 29x24x45 36x29x50
(a) Check and fix the leak in the discharge piping, faucets, and valves. LxWxH (cm)
(b) Check pressure switch which may be defective or out of adjustment.
(c) Clean pump built-in check valve, which may be leaking or opening.

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