PUMP OPERATION MANUAL

North America Exclusive Importer:

World Water Works, Inc.

Oklahoma City, Oklahoma
1-800-607-PURE

Nikuni Manual Rev 0507 Page 1 of 31

PREFACE

The Nikuni Pump is a regenerative turbine pump. Although the pump can be used for
many purposes, this manual is designed to provide operational and user information for
the Nikuni Pump for application as a dissolved air microbubble generating pump.

The Nikuni pump dissolves atmospheric air into water to significantly enhance the
performance of Dissolved Air Flotation systems. Enhancements witnessed may include
improved removal efficiencies, increased throughput, decreased maintenance
requirements, lower energy consumption, and optimized chemical usage. The degrees
of each of these benefits will depend upon the emphasis placed on each and the
type/condition of the Dissolved Air Flotation (DAF) system.

This manual has been developed to provide the operator with a conceptual
background of physical and chemical separation mechanisms; a general
overview of system operational controls and procedures; a list of
components; and an avenue to responsive customer service.

Qualification and Training of Operating Personnel

The personnel responsible for operation, maintenance, inspection and assembly must
be adequately qualified. Scope of responsibility and supervision of the personnel must
be exactly defined by the plant operator. If the staff does not have the necessary
knowledge, they must be trained and instructed, by qualified personnel. The plant
operator is to make sure that the contents of the operating manual are fully understood
by the personnel.

Nikuni Manual Rev 0507 Page 2 of 31

TABLE OF CONTENTS

1. Introduction ···································································································· 5
2. Safety Instructions ························································································ 6
3. Technology and Design ················································································ 7
3-1 Saturation
3-2 Bubble Size
3-3 Piping Design
3-4 Maintenance
4. To Measure the Dissolved Air Quality·························································· 9
5. Installation Guidelines ·················································································· 10
5-1 Process Description
5-2 Unloading Description
5-3 Installation Description
5-3-A Utility Requirements
5-3-B Control Logic
5-3-C Start-Up Check List
5-3-D Warranty Installation Pre Start-Up Check List
6. System Operations ························································································ 15
6-1 Start-Up
6-1-A First Time
6-1-B Normal
6-2 Operation
6-3 Shut Down
6-1-A Emergency
6-1-B Normal Shut-Down Procedures
7. Maintenance ··································································································· 17
7-1 Atmospheric Pressure
7-2 Cleaning
7-3 Other
7-3-A Bearings
7-3-B Mechanical Seal
7-3-C Gland Packing
7-4 Part Replacement
7-4-A Preparation
7-4-B Disassembly
7-4-C Assembly
7-4-D Spare Parts List
8. Trouble Shooting ·························································································· 25
8-1 Individual Pump Discharge Pressures
Nikuni Manual Rev 0507 Page 3 of 31
 8-2 Air/Pump Suction
8-3 Trouble Shooting
8-3-A Trouble During Start-Up
8-3-B Trouble Related to Pump
8-3-C Overload Problem
8-3-D Problems Related to Shaft Bearing, Shaft Seals & Others
9. Warranty of Quality························································································ 27
10. Customer Service ························································································ 29

Nikuni Manual Rev 0507 Page 4 of 31

INTRODUCTION

A Dissolved Air Flotation (DAF) Clarification system is used for bulk liquid/solids
separation. The goal of a DAF is to remove a majority of the Total Suspended Solids
(TSS); Fats, Oils and Greases (FOGs) and Insoluble Organics contained in the
wastewater. The DAF method involves dissolving air into water under pressure, and
then releasing the pressure to cause the air to release from the water in very fine
microbubbles in the water. The microbubbles or “whitewater” are injected into a
process or wastewater stream to float suspended solids to the surface of a vessel
providing liquid/solids separation.

This technology offers many benefits to conventional gravity settling due to its
efficiency. It is especially effective treating wastewater with fats, oils, and greases,
fibers and other low density materials. This technology has become known as the most
efficient means of bulk liquid/solids separation in the Pulp & Paper Industry, Food &
Beverage, Industrial Laundry and many other industries. Many advances in the
technology have led to vastly improved performance capabilities. This has reduced the
traditional large footprints required of DAF systems, reducing capital costs. It has also
reduced the amount of chemistry needed, reducing the operational costs.

One of the key components to achieving efficient flotation is the quality of the dissolved
air. The Nikuni pump provides one of the best air dissolving systems on the
marketplace by providing 20-30 micron bubbles up to 95%+ saturation efficiencies.

The Nikuni pump is a regenerative turbine pump. The design utilizes three forces to
generate high pressure in a single stage pump design. A friction force pushes the liquid
in the direction of rotation. A centrifugal force swings the liquid out in the crosswise
direction of rotation. An axial force pushes the liquid to both sides of the impeller. In
concert, the three forces cause a complex vortex to form which provides the air
dissolving action and high pressure desired. The result is a constant, stable, high
pressure flow in a compact design, with high saturation efficiencies and very fine
microbubbles (~20-30 micron).

Nikuni Manual Rev 0507 Page 5 of 31

SAFETY

PERSONAL PROTECTIVE EQUIPMENT

REQUIRED SUGGESTED
Non-Slip Steel Toe Shoes Safety Gloves
Safety Glasses Hard Hats
Hearing Protection

To ensure maximum safety, and to gain knowledge of this product, it is important that
any operator of the Nikuni Pump read and understand the contents of this manual
before this equipment is operated. Pay special attention to any caution or warning
stickers or symbols placed on the equipment. Failure to comply with the instructions can
result in damage to the system or personal injury.

The precautions mentioned in this manual are not intended to cover all of the warnings
or hazards that can exist in a plant or on these systems. Using safety mechanisms
requires the constant attention of everyone near these machines. Strong safety
practices must be used by plant personnel for this system or any other equipment.
Proper equipment maintenance and use of personal safety devices contribute as much
towards safety as will any number of mechanical safety devices.

Study this manual thoroughly before attempting to install, operate or maintain these
systems. Only competent, well-trained individuals should operate or maintain this
system.

Explain the operation of this system and its safety devices to a new operator or any one
attempting to operate this system before allowing them to do so. Be certain that he or
she fully understands these systems and corresponding devices and that they are
qualified to operate this system.

Develop a safety checklist for the devices of this system and perform regular
maintenance duties to ensure its proper operation. Example list provided below.

WARNING THIS PUMP IS CAPABLE OF PRODUCING HIGH PRESSURE.

PRECAUTION SHOULD BE TAKEN ACCORDINGLY

Nikuni Manual Rev 0507 Page 6 of 31

OTHER SAFETY TIPS AND SUGGESTIONS

• Safety instructions and decals are located on the equipment. Replace any
damaged decals.
• Do not operate unless safety devices or guards are in place and operating
properly.
• Follow all LOTO procedures when performing maintenance on Nikuni Pump by
disconnecting electrical power before servicing any part of the system (more than
one electrical connection may be involved).
• Do not operate system without eye protection.

SAFETY CHECKLIST
Proper House Keeping
Exposed Wiring or Electrical Connections
Proper Lighting
Operation of Safety Showers / Eye Wash
Proper PPE Available
Overhead / Bump Hazards
Proper Equipment Guards in Place
Damaged or Leaking Piping / Equipment
All Equipment, Chemicals, and or Pipes Properly Labeled
MSDS / LOTO Station Available and Up to Date

Nikuni Manual Rev 0507 Page 7 of 31

TECHNOLOGY AND DESIGN

The keys to a well performing Dissolved Air system are as follows:

1. Saturation
With high air/water saturation efficiencies, less energy is required and less
water is required to recirculate in the system. Recirculation of water in the
DAF reduces retention time, thus limiting capacity and/or performance.
Most systems have 20-50% saturation efficiencies. The Nikuni system is
up to 95% efficient. Thus, instead of an average of 30-50% recycles, 10-
20% recycle rates can be achieved. This allows more retention of the
water, thereby allowing more separation time, improving performance.

It is also important to have a consistent flow of air. In most plants,

compressed air is inconsistent. This will result in inconsistent saturation
and lead to inconsistent performance. The Nikuni system uses a vacuum
technique to Venturi atmospheric air into the pump. The result is a
consistent flow of air and a consistent air to water ratio. As a secondary
benefit, the need for compressed air is eliminated. DO NOT USE
COMPRESSED AIR WITH THIS PUMP. The amount of atmospheric
airflow is dependent upon several variables including water temperature
and the concentration of soluble materials in the water. However, the
range of airflow will be between 5-10% of the water flowrate.

2. Bubble Size
The size of the microbubble generated is a key to good performance: The
smaller the bubble - the smaller the particle that can be removed. If
smaller particles can be removed, less chemistry is necessary to
coagulate the products into a larger particle. Besides the operational cost
savings, reduced chemical consumption can yield dewatering benefits.

Many systems create 100+ micron bubbles. The Nikuni system develops
a 20 micron bubble. A quick check of the bubble size can be determined
by a rise rate test. The rise rate test is conducted by taking a known
volume sample of the whitewater and monitoring the time it takes for the
whitewater to fully dissipate. The saturation efficiencies can be measured
by the saturation test described later in this manual.

Nikuni Manual Rev 0507 Page 8 of 31

 3. Piping Design
The proper piping design of a system has a tremendous impact upon the
performance of the Dissolved Air System. The pressure created by the
system must be maintained right up to the point of injection into the feed
stream. The dissolved air mixture must be applied in a low shear
technique and well dispersed throughout the feed stream. IT IS VERY
IMPORTANT THAT ALL PIPING IS DESIGNED TO HANDLE A MINIMUM
OF 220 PSI.

Many systems dissolve air into the feed stream which contains the
suspended particulate. Dissolving air into a clean stream (or the DAF
effluent) is a far superior process, because particles in the water interfere
with saturation efficiencies. The maximum solubility of air into water
basically depends on the saturation pressure, the water temperature, and
the water quality.

4. Maintenance
Obviously, the air dissolving technique must not be maintenance
intensive. This is a critical part of the DAF clarification process and must
be reliable. Many systems are not reliable. The Nikuni pump has proven
to be robust and highly reliable in a wide array of applications.

Nikuni Manual Rev 0507 Page 9 of 31

TO MEASURE THE DISSOLVED AIR QUANTITY

Water Tank T2
Flow diagram
Air save tank T1
Water gathered

W.tank Air gathered

T1
Air separation tank V1 Scales on surface

valve
bubble
Pressurized
water V2

Measurement method
This apparatus describes a method to measure the volume of air dissolved in 1 L
of pressurized water. The water pressurized by turbine pump is brought to air
separation tank where undissolved air is purged outside. The pressurized water
is directed to Pressure relief valve (V1) and lead to Air save tank (T1). When
pressurized water reaches to Air saving tank (T1), fine bubbles develop and air is
collected at top of Air saving tank (T1) and water is directed to Water tank (T2).

Water volume (water speed) is controlled by the pressure relief valve (V2) so that
there is no air coming to the Water tank (T2) from Air tank (T1). DO value
(density of dissolved oxygen) in Water tank (T2) is made to be DO = 100% and
above (super saturation), so that it stabilizes for measurement. Water
temperature is recorded.
Watch scale outside of Water tank (T2) and see 1 L water accumulating in Water
tank. Air volume accumulating in Air tank (T1) during the same time is
measured. This measured air volume is volume of air dissolved in 1 L of water.

Dissolved air volume is measured for each test. The judgment on test result is
based on measured air volume for saturated air volume for water temperature
and pressure, because volume of dissolved air varies depending on water
temperature.
Nikuni Manual Rev 0507 Page 10 of 31
INSTALLATION GUIDELINES

1: Process Description
Water will be abstracted from the outfall of the DAF and gravity feed to the Nikuni
pump. A vacuum will be created on the suction side by slightly closing a suction
side valve (preferably a gate or diaphragm valve). The discharge will be
pressurized to 50-70 psi by throttling a discharge valve located as close as
possible to the injection point back into the DAF feed wastestream. This design
maximizes separation efficiency through generating a highly saturated fine micro-
bubble.

2: Unloading Description

Unpacking check
Upon receipt of the pump, please check the following:

A. Confirm the model number on the nameplate matches the purchase

order.
B. Check and report any damage immediately to WWW. Please include
pump model and serial number.
C. Verify by hand the pump shaft turns freely.

The Nikuni pump(s) may be provided on a skid. The pump

should be lifted and moved by supporting the skid only. Do
not lift from the motor or the pump, this could cause
damage, stress or misalignment.

3: Installation Description
Depending upon the package purchased, the necessary valves, gauges, flow
meters, etc. will be fully installed on the pump skid; otherwise, the customer must
supply these items per the supplied drawing. The skid should be mounted level
and any influent and effluent piping should be independently supported. All
leveling plates must be well set. The fasteners must be tightened steadily after
the complete pump unit has been adjusted.

Please review all WWW furnished drawings prior to installation and startup.

Nikuni Manual Rev 0507 Page 11 of 31

 Pump Suction
It is recommended that the pump is supplied by gravity feed. If the design
requires a positive suction lift, please call World Water Works to review the
design prior to installation.

The feed line to pump must be equal to or larger than the pump inlet.

A suction gate valve must be installed between 5 and 10Xs the pipe diameter
from the pump’s inlet. There shall be no bends in the line between the suction
gate valve and the pump’s inlet.

A vacuum gauge must be installed between the suction gate valve and the
pump’s inlet.

Pump Air Inlet

An air flowmeter(s) should be mounted in a visible and reachable area. Tubing
3/8” – 3/4” should be installed between the discharge side of the air flow meter to
the supplied injection nozzle on pump. DO NOT USE COMPRESSED AIR. This
pump uses atmospheric air only.

Pump Discharge
There should be a minimum 5X’s the pipe diameter of straight pipe on the
discharge of the pump.

On the discharge side of the pump, a valve(s) should be installed as close to the
point(s) of injection into the system as possible. This will be the pressure control
valve. If this location is far from the pump(s), then another pressure gauge
should be installed between the valve and the pump. World Water Works
recommends splitting the header pipe into 2-3 injection points based upon the
flow rate of the pump.

A whitewater sample valve should be placed inline between the pump discharge
and pressure throttling valve(s).

The whitewater should never be injected perpendicular to or against the

wastewater flow. The injection points should be installed so that the whitewater
is injected in the same direction as the wastewater flow into the DAF unit. This
injection point should also be at a place where the line is full.
Nikuni Manual Rev 0507 Page 12 of 31
 Pump Electrical
LOTO procedures should be followed prior to any work being performed. Prior
to pump startup, ensure the pump is filled with liquid. NEVER OPERATE THE
PUMP DRY. The pump must be connected in accordance with local electrical
codes. Voltage and frequency must correspond to the winding of the electric
drive. For details of the respective winding, see the type label. The motor must
not be operated without motor protection. For motors with explosion protection,
the range of temperature of the motor indicated on the type label must
correspond to the range of the fuel gas.

Switch on the motor briefly in order to check the direction of rotation. The motor
must not reach its operational speed. The direction of rotation must
correspond to the arrow indicating the direction of rotation on top of the pump. If
the direction of rotation is not correct, perform the relevant modifications at the
phase-sequence to correct the problem.

Please complete the WWW supplied Nikuni Installation Check List and
submit to WWW for approval prior to starting up pump!

A: Utility Requirements
Either 240V or 480 V, 3 Phase must be supplied to the pump at the amperage
rating noted on the motor.

B: Control Logic
The Nikuni Pump shall have an (on/off) capability on the central control screen
and/or at a local disconnect.

The pump should not be operated in a dry mode. Thus, a pressure

transmitter should be located on the discharge header which will be monitored for
low pressure, signaling lack of flow or the pump operation should be tied into a
level control on the feed tank that will make a contact upon low level. When this
occurs an alarm should flash and the DAF Pump shall be deactivated. If the
pressure switch technique is used, the program logic should provide a delay
timer to allow the pumps to build up in pressure when first started (~120
seconds). The program will also require the signal from the pressure switch to
be below the set point for (~60 seconds) before an alarm is initiated. It is also
advisable to have a high pressure pump shut-off. This should occur at a

Nikuni Manual Rev 0507 Page 13 of 31

 pressure of ~120 psi. There should be less than a 5 second delay on this shut-
off function. This will prevent dry operation of the pump.

The pumps should also have motor failure alarms. If pump is selected, but not
running, or circuit breaker has tripped, alarm will activate.

Nikuni Manual Rev 0507 Page 14 of 31

INITIAL START-UP CHECK LIST

PRIOR TO INTIAL FILL-UP

Aeration Pumps:

 Check Rotation
 Proper Auto Valves Open / Close
 Proper Manual Valves Open / Close
 Air Flow Meters Installed Properly
 Ensure the pump is fully primed
 The pump must by no means be operated without liquid.

Notes:

There is only a minimal or invisible loss of leakage if the mechanical

seals function correctly. Gland packing should drip slightly.

DURING INTIAL FILL-UP

 Note Any Leaks

Location(s):

Nikuni Manual Rev 0507 Page 15 of 31

INSTALLATION WARRANTY VERIFICATION
Customer
Nikuni Model
Nikuni Serial
Number
Filled In By ________________________Phone____________
Report Date________________________
YES NO
1 Is the motor protection sized properly for the Nikuni motor?
2 Is the motor rotation counter clockwise (looking from the motor towards the
pump)?
3 Has the pump motor alignment been confirmed since completion of
plumbing tie-ins?
4 Does the suction side of the pump have positive head pressure?
5 Is this sufficient to provide the required amount of water (by gravity) to this
model pump?
6 Is the suction line diameter equal to or greater than the pump's inlet?
7 Is there a minimum of 5 times the pipe diameter of straight pipe connecting
to the pump's inlet?
8 Is there a gate valve or globe valve to regulate the vacuum pressure to the
pump?
9 Is the valve used to regulate the vacuum to the pump installed between 5
and 10 times the pipe diameter from the pump's inlet?
10 Is a vacuum gauge installed between the above valve and the pump?
11 Is the air intake line 3/8" diameter or larger?
12 Is the pump using atmospheric air? (NO COMPRESSED AIR)
13 Is there at least 10 times the pipe diameter of straight pipe (prior to any 90,
45, etc) on the Nikuni outlet?
14 Is the Nikuni's discharge pipe diameter equal to or greater than the pump's
outlet?
15 Is a sample point installed in the discharge line?
16 Is a pressure gauge installed on the discharge line?
17 Is the valve used to regulate the discharge pressure a gate, globe or
diaphragm valve?
18 Is (are) the discharge pressure regulating valve(s) installed as close as
possible to the point of injection to the wastewater stream?
19 Are these injection points either tangential to or with the direction of flow of
the wastewater?
20 Is the wastewater line at the point of whitewater injected always full during
operation?

Please fax back to 914-371-4130 prior to pump startup to validate warranty.

Nikuni Manual Rev 0507 Page 16 of 31
SYSTEM OPERATIONS

1: START-UP
A: Initial Startup
1. Verify proper installation.
2. OPEN the Valves between the DAF Effluent Line (Nikuni Water
Supply) and the Nikuni Pump.
Allow the pump’s suction line to completely fill. Opening the
whitewater sample valve will help bleed any air from the line.
Any isolation valves on the suction side of the pump must be
completely open. If the pump is operated with out proper
water priming, this becomes a cause for damage to the pump.
3. OPEN the any discharge isolation valves associated with the
pump.
4. OPEN INJECTION VALVES at the injection points.
5. TURN THE PUMP ON.
6. GRADUALLY THROTTLE CLOSED INJECTION LINE VALVE(S)
to achieve ~50-70 psi.
Approximately thirty (30 sec) seconds after reaching operating
speed, slowly close discharge valves closest to the points of
injection. Throttle valves proportionally to achieve an
operating point of 50-70 psi on the discharge pressure gauges
located at the discharge of the pump. DO NOT SHUT
VALVE, if pressure buildup does not occur – PUMP IS NOT
FULLY PRIMED.
7. Adjust (if necessary) the SUCTION GATE VALVE.
This is done to achieve a vacuum (approximately 2-7” Hg, not
to exceed 15” Hg) in the suction pipeline viewed on the
suction vacuum gauges. Closing the suction gate valve may
be required to generate the proper vacuum.
8. OPEN the NEEDLE VALVE on the AIR FLOWMETER to 5-10%
of pump flowrate.
The air flowrate should be 5-10% of pump’s water flowrate.
Adjust the air flowmeter as follows.

Nikuni Manual Rev 0507 Page 17 of 31

 B:NORMAL - START – UP
The Nikuni Pump should start and stop with the DAF
feed pump. All manual valves should remain in the same
position and should not require manual adjustment under
normal operating conditions.

2: OPERATION
Once properly set the system should operate continuously
without major adjustments. The critical operating parameter is
to insure an ample supply of recirculation water is feeding the
pumps in order to prevent starving of the pumps. Never run
the pumps dry. If pressure drops below 10 psi or above 120
psi then the automatic pressure transmitter (when installed as
part of the system) should automatically shut the system
down.

3: SHUT-DOWN
A: EMERGENCY SHUT-DOWN
DO NOT OPERATE PUMPS DRY. In an emergency case
when the pumps are being starved (running dry) shutdown the
system immediately. To shut down pumps, turn off power
switches. If a check valve has been installed, all valves may
remain in partially open position to facilitate the next startup
procedure.

B: NORMAL SHUT-DOWN PROCEDURES

In the case of a plant shutdown a procedure should be
followed to insure an easy re-start of the DAF system (avoid
the clarifier filling with solids). The recommended Shutdown
procedure is outlined below.

A. Stop the equipment that feeds water to the DAF.

B. Turn off Nikuni Pump.

Nikuni Manual Rev 0507 Page 18 of 31

MAINTENANCE

The www/NIKUNI system is designed for durability and long-life. However, following
some basic maintenance procedures will assure the long life of the pump. It is always
recommended to maintain a clean and safe environment.

1- ATMOSPHERIC PRECAUTIONS
This NIKUNI is extremely durable and can perform well in many
environments. However, it is recommended that the system be protected
from freezing as water in pipes and other areas may expand and cause
damage.

2- CLEANING

Atmospheric Air Lines

The Nikuni Venturi’s atmospheric air through an air flowmeter(s) into the
Pumps. Periodically the tubing and the air flowmeter should be checked
to assure that debris has not restricted to flow of air. In some cases it may
be easier to replace the tubing rather than clean it, when fouling occurs.

3- OTHER

Installed backup pumps must be powered on and off briefly once a week
in order to guarantee that they are ready for operation.

A: Bearings
Under normal operation conditions, replace the motor bearings after
20.000 hours of operation or at the latest after 2.5 years. In the case of
bad operation conditions, as e.g. a high environmental temperature or a
corrosive and dusty environment, the motor bearings must be checked at
an earlier date and, if necessary, be replaced. Pump bearings with a
lubrication device must be checked every 5000 hours of operation. Dirty
bearings must be cleaned and filled with new lubricant. The free space in
the bearing and casing should be filled by 30-50% with lubricant. Do not
use resinous or acid lubricants. Its consistencies (NLGI grade) should
correspond to a worked penetration of 265 to 295 mm/10.
Lithium-base soap lubricants with a drop point of more than 185°C are to
be used for pumped liquids which have a maximum temperature of 110°C.

Nikuni Manual Rev 0507 Page 19 of 31

 For pumped liquid with a higher temperature, use silicon lubricants with a
lithium-base soap and with a drop point of more than 215°C.
If necessary, the bearings can also be lubricated with lubricants of a
different soap base. For this based on different soaps must not be mixed.
The required relubrication periods must then be adapted to the type of
lubricant used.

B: Mechanical Seal
The mechanical seals are maintenance-free. If leakages occur after a
longer period of operation, replace the complete seal.

C: Gland Packing
Gland packing are low-maintenance parts and must leak slightly during
operation. Do not over tighten a gland packing after its first operation.
Considerable leakage at the beginning disappears by itself. If greater
leakages occur during operation, the gland lid or insert must be slightly
tightened, however it must never be tightened at a slant. It must be
possible to rotate the slide slightly after having tightened the lid or insert. If
tightening of the gland lid or insert results in the pump being heated
excessively or if it is not possible to tighten the gland lid or insert any
further, the gland packing must be replaced completely. If the gland lid or
insert is tightened too much the shaft will be damaged.

4- PART REPLACEMENT

A: Preparation
In order to make sure that the pump cannot be started, separate the
power cable from the motor and/or use standard Lockout/Tagout
procedures. Secure the unit against accidental switch-on. Close the stop
valve of the pressure and suction pipelines. Please assure pump is not
under pressure before disassembling. The pump casing must have
reached the environmental temperature and be drained of liquid and
pressure. In the case of pumps in unit-construction with mounting flange,
the container must be drained completely.

B: Disassembly: Refer cross section drawing attached.

1) Remove 103-cover and 123A-O-ring. When it is not easy to

dismantle the cover, bolt is inserted into the tap.

Nikuni Manual Rev 0507 Page 20 of 31

 2) Remove 114-impeller nut, 113-impeller washer, 048-adjustment
collar, 116-impeller key. In case impeller is not easily unfasten, bolt
should be screwed into the tap on the impeller and pull the bolt to
unfasten the impeller.
3) Unfasten the 102-body. 061-gland packing, 065-seal cage, 109-
gland holder come out attached to the body. The gland packing can
be changed at this stage.
4) 120-sleeve and 081-slinger are unfastened.
5) Remove 074-key and 030-bearing cover. 023C-oil seal comes out
with the bearing cover.
6) Remove 027-bearing at motor side, and 030-bearing washer.
7) Remove 027-bearing holder. 023A-oil seal comes out with the
bearing holder.
8) 108-shaft is hit by wooden hammer from motor side and drawn to
the pump side.
9) Remove 029-bearing nut at pump side and 030-bearing washer.
10) Remove 021A-ball bearing from the shaft and 021B-ball bearing
from the bracket. This is end of disassembling.

C: Assembly

Assembling is made in reverse order of disassembling. Please make

sure to take each step in firm manners.

Make sure there is no damage on fit face and installation face and
there is no dust and other foreign items on their faces, at time of
assembling.

1) Drive 021A-ball bearing into 108-shaft and to fit 030-bearing

washer into the 108-shaft. To secure 029-bearing nut tightly. The
brim of 030-bearing wash should be bent into the hollow of 029-
bearing nut, to prevent turning. 108-shaft is fit into 025-bracket
from pump side.
2) 023A-oil seal and 123C-O-ring are assembled to the 027-bearing
holder, and fix to the 025-bracket. (When 023A-oil seal is inserted,
the lip is placed to the ball bearing side, and hit the metal part only,
and evenly, by way of using pipe like tool.)
3) Drive 021B-ball bearing and fix 030-bearing washer, and secure
029-bearing nut. At this time, the brim of 030-bearing washer is
bent into hollow of 029-bearing nut, to prevent turning.
Nikuni Manual Rev 0507 Page 21 of 31
 4) Assemble 023C oil seal and 123C-O-ring onto 036-bearing cover,
and fix it to 025-bracket. When 023C-oil seal is incorporated, the lip
should be facing to the ball bearing side.
5) 081-slinger is installed.
6) 061-gland packing and 065-seal cage are inserted into 102-body,
and 109-gland holder is installed. At this time, inner diameter of
the gland packing is enlarged so that 120-sleeve can move easily.
*If the gland packing’s inner diameter is too small, it may become a
cause of high temperature of gland, during running.
7) Aforementioned body is installed to 025-bracket.
8) Install 120-sleeve and 048-adjustment collar.
9) Install 116-impeller key and 107-impeller.
10) Fit 113-impeller washer and secure by the 114-impeller nut. The
brim of 113-impeller washer is bent into hollow of 114-impeller nut,
to prevent turning.
11) Assemble 123A-Oring into 103-cover, and fix into 102-body.

Please take note of followings:

Warning: 048-adjustment collar should not be lost. When assembling
at manufacturer’s facility, 048-adjustment collar is adjusted to fit into
each pump.
Warning: Make sure the coupling is turned smoothly by human hand
without difficulty. If there is any abnormality when turning, there
should some problem of parts or problem at assembling.

DESCRIPTION Part Number DESCRIPTION Part Number

Pump Side Bearing -021A Body (Cast Iron) -102
Motor Side Bearing -021B Cover (Cast Iron) -103
Oil Seal -023A Body (SCS13) -102
Bracket -025 Cover (SCS12) -103
Bearing Holder -027 Side Plate (104-142007) -104
Bearing Nut -029 Side Plate (104-112107) -105
Bearing Washer -030 Impeller (304) -107
Bearing Cover -036 Impeller (316) -107
Adjustment Collar (304) -048 Shaft (304) -108
Adjustment Collar (316) -048 Shaft (316) -108
Mechanical Seal Holder (304) -049 Impeller Washer -113
Mechanical Seal Holder (316) -049 Impeller Nut -114
Mechanical Seal -051 O-Ring Set (FPM) -123
Slinger (NBR) -081
Nikuni Manual Rev 0507 Page 22 of 31
Nikuni Manual Rev 0507 Page 23 of 31
 D: Spare Parts List

1) When ordering: Please inform pump model number, pump serial

number written on the name plate of the pump.
2) Consumables: Please replace the parts referring following table.

DESCRIPTION Part Number

Pump Side Bearing M80F(S)P-021A
Motor Side Bearing -021B
Oil Seal -023A
Bracket -025
Bearing Holder -027
Bearing Nut -029
Bearing Washer -030
Bearing Cover -036
Adjustment Collar (304) -048
Adjustment Collar (316) -048
Mechanical Seal Holder
(304) -049
Mechanical Seal Holder
(316) -049
Mechanical Seal -051
Gland Packing -061
Lantern Ring -065
Slinger (NBR) -081
Body (Cast Iron) -102
Cover (Cast Iron) -103
Body (SCS13) -102
Cover (SCS12) -103
Side Plate (104-142007) -104
Side Plate (104-112107) -105
Impeller (304) -107
Impeller (316) -107
Shaft (304) -108
Shaft (316) -108
Gland Holder -109
Impeller Washer -113
Impeller Nut -114
Sleeve -120
O-Ring Set (FPM) -123
Nikuni Manual Rev 0507 Page 24 of 31
TROUBLESHOOTING NIKUNI OPERATION
Below are basic trouble-shooting approaches that address general operational issues
as they may occur with system operation or system start-up.

Individual Pump Discharge Pressure

If pump discharge pressure is too low:

-Insure proper reading of pressure gauge by adjusting the discharge pressure
valves.
-Insure gate valve prior to pump is fully open.
-If the pump does not pressure up, an air lock likely occurred. Turn the pump off.
Open all valves fully. Open the whitewater sample valve and let pump fill with
water over several minutes. Then, restart pump according to first-time set up
instructions.

Air/Pump Suction

If pump/air suction is too low (less than 5% of pump flowrate):

-Insure air gauges are set to the open position (left turn is open). Check if
air is entering into the gauges by placing a finger over the inlet. If air is
flowing, the air gauge should be replaced.
-Insure discharge pressure of the pump is proper. If it is not, follow
trouble-shooting steps to correct discharge pressure problems prior to
correcting the pump suction issues.
-If the vacuum gauge at the pump suction reads greater than 2 “ Hg, then
the pump should be vacuuming atmospheric air in through the air gauges.
Disconnect the air line at the pump to determine if suction does exist. If it
does the “air line” is clogged, if it does not move to next step.
-With the air line/gauge open, throttle down the gate valve closest to the
suction of the pump. Prior to closing the gate valve 30%, a vacuum
should develop and air should be pulled in from the atmosphere.

If pump suction is too high (greater than 10-15” Hg):

-Water re-circulation to feed to the pumps is probably to low signifying a
closed valve(s). Check valves.

Nikuni Manual Rev 0507 Page 25 of 31

TROUBLESHOOTING (Cause and Countermeasure)

1-Trouble During Startup

Symptom Cause Countermeasure

. Motor does not rotate . Electrical power related problem Inspect and repair
. Motor growls and does not . Motor breakdown Disassemble, inspect and then repair
rotate . Rotating parts touch something else Get it repaired by the manufacturer
. Rotating part is rusted
. Rotating part is in seizure
. Foreign body clogged in the rotating
part

Nikuni Manual Rev 0507 Page 26 of 31

 2-Trouble Related to Pump

Symptom Cause Countermeasure

Cannot pump the water Water priming is not done Do water priming
Specified discharge volume, Sluice valve is closed and partially Open the valve completely
specified open
pump head not met Actual head is more than the pump Reduce the actual head
Water is pumped initially, but head
stops Suction lift is too much for this pump Reduce the suction lift
immediately Air vent valve is closed Open the air vent valve
Suction pipe end is not submerged in Immerse the suction pipe end into the water
the
water
Direction of rotation is reverse Correct the wiring, and confirm the direction
using the arrow mark on the pump
Operating under 50Hz instead of
Adjust to the specified rotation speed
60Hz
Number of poles in the motor is
Change the motor
different
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 accordingly
Leakage in the discharge pipe Inspect and repair
Horizontal pipe is very long Reduce the length
Impeller is corroded Replace the impeller
Get it repaired by the manufacturer
Impeller is worn out
Check the body also
Cavitations has occurred Improve the suction piping
Too much pressure loss in piping Reduce
Air is accumulated (locked) inside the
Provide air vent
discharge pipe

Nikuni Manual Rev 0507 Page 27 of 31

 3-Overload Problems
Symptom Cause Countermeasure
Overload Operating under 50Hz instead of 60Hz Adjust to the specified rotation speed
Number of poles in the motor is different Change the motor
Voltage drop Supply the correct voltage
Centering of the shaft coupling is not Readjust the centering
done
Foreign bodies have entered into the Remove the foreign bodies
internal
portion of the pump
Pump head is very high and discharge flow Open the discharge valve
volume is very less
Shaft bearing is damaged Replace the shaft bearing
Rotating parts are touching other things Get it repaired by the manufacturer
and the
shaft is bent
The strainer is blocked Inspect the strainer and clean it

4-Problems related to shaft bearing, shaft seals and others

Symptom Cause Countermeasure

Overheat or abnormal noise is Centering is not correct Redo the centering and adjust correctly
generated in the Shaft Shaft bearing is damaged Replace the shaft bearing
bearing Shutoff operation for long duration Stop the shutoff operation
Over leakage of water from Wrong fixture of mechanical seal Fix correctly
the Mechanical seal is damaged Replace the mechanical seal
shaft seal portion Shaft is worn out Replace with new one
Shaft is bent Replace with new one
Vibration of the pump Foundation is incomplete Repair the foundation
High operating sound Installation, centering is defective Repair the installation and centering status
Shaft bearing is damaged Replace the shaft bearing
Correct the wiring, and confirm the direction
Direction of rotation is reverse
using the arrow mark on the pump
Rotating parts are touching other things Get it repaired by the manufacturer
and the shaft (axis) is bent
Cavitations has occurred Improve the suction piping
Piping is resonating Improve the piping
Install flexible pipe, vibration isolating rubber
cushion
Shaft coupling rubber is deteriorated, Replace the shaft coupling rubber
worn out or abraded on one side

Nikuni Manual Rev 0507 Page 28 of 31

WARRANTY

Since we design and build our products to provide you with many years of satisfaction,
all World Water Works products are guaranteed against defects in materials and
workmanship for a period of one year, excluding all wear parts.

We hereby guarantee the quality of our product supplied to you in the following
conditions:

1) WWW warrants our product to be free of defects in material and workmanship for a
period of twelve (12) months following installation up to a maximum of eighteen (18)
months following of our shipment from Oklahoma City, OK. Any part(s) which fails
during the warranty period due to defective material or workmanship will be replaced
for shipping cost only provided (a) the claim for warranty is given in writing
describing details of the defect within warranty period; (b) WWW accepts the return
of defective part(s) for service and (c) the defective part(s) is delivered to WWW with
transportation charge prepaid in accordance with instructions provided by WWW. In
case of a difference of opinion between the parties concerned regarding whether or
not the warranty is applicable, the judgment of WWW is final.
2) WWW’s liability is limited to the replacement or repair (at our option) of the defective
parts as originally supplied by WWW. WWW 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 WWW
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.
3) 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
WWW in writing); (b) subject to misuse, neglect or accident; or (c) used to pump
materials which it was not designed to handle, which may attack or harm the
materials used in construction of the pump, or which may otherwise harm the
operation of the pump.
4) 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 or installation, natural causes or acts of God; or (c) any field expense
for service or replacement of parts.
Nikuni Manual Rev 0507 Page 29 of 31
This warranty is WWW’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.

This warranty gives you specific legal rights. If you have any questions or comments
regarding this guarantee or your World Water Work product, you may reach us at 1-
800-607-PURE or www.WorldWaterWorks.com. You will find that we apply the same
standard of excellence to our customer service as we do our products.

Nikuni Manual Rev 0507 Page 30 of 31

CUSTOMER SERVICE

World Water Works believes that responsive customer service is as important to

customer satisfaction as is proficiency of the system design. Thus, we welcome
customer calls.

Customer Service Department:

WORLD WATER WORKS

CUSTOMER SERVICE DEPARTMENT
4061 NW 3rd Street
Oklahoma City, Oklahoma 73107
800-607-PURE

Nikuni Manual Rev 0507 Page 31 of 31