Related Manuals for EBARA DSC4 Series
Summary of Contents for EBARA DSC4 Series
- Page 1 Submersible Wastewater, Sewage Pump Model DSC4, DSCa4 Operating Instructions, Installation & Maintenance Manual Ebara Fluid Handling Ebara International Corporation...
- Page 2 INSTRUCTION MANUAL 1. Preface Design of this EBARA pump is based on superior engineering and long experience. To prevent trouble and provide satisfactory operation and long life, it is important to understand the EBARA pump thoroughly by careful study of this manual. If any questions arise regarding this manual, please direct them to EBARA.
- Page 3 INSTRUCTION MANUAL 2. Acceptance Inspection Upon arrival of the pump – (1) Check the nameplate information for agreement with specifications in respect to model identification, head, pumping capacity, speed, output, voltage and frequency. (2) Check the pump has not been damaged during shipment and all plugs and fastening bolts properly tightened.
- Page 4 INSTRUCTION MANUAL If the guide pipe holder is attached directly to the concrete, use hole-in anchor bolt as shown in Fig. 3. Hole-in anchor bolt Fig. 2 Fig. 3 CAUTION : IF THE CABLE LEAD-OUT ELBOW IS TOO SMALL IN DIAMETER, THE CABLE MAY BE HEATED WHERE IT RUNS THROUGH THE ELBOW.
- Page 5 INSTRUCTION MANUAL Fig 4 Support the guide pipe with bushings on discharge elbow and the guide pipe holder. If the guide pipe requires a length exceeding 5.5m (18ft), an extension or intermediate support may become necessary, in which case we are available for consultation.
- Page 6 INSTRUCTION MANUAL Fig. 5 3.5 Water Level Switch Installation (Fig. 6) Install a water level switches for use during automatic operation. If a float type switch is used, each pump will required a total of 3 (or 4) for starting, stopping, (low level alarm) and high-level alarm.
- Page 7 INSTRUCTION MANUAL 3.6 Check the Followings Points (1) through (6) Prior to Pump Installation (1) Ensure that the mechanical seal chamber is filled with specified amount of oil. *ICS opt. Ensure that the coolant chamber is filled with specified amount of coolant. (2) All plugs and fastening bolts are properly tightened.
- Page 8 INSTRUCTION MANUAL Pour the specified oil into the sealing chamber through the “oil port” until the oil flows out of the “air vent”. (See Table 1) After the sealing chamber is filled to the specified level, put a sheet gasket between the plug and the boss, and tighten the plug.
- Page 9 INSTRUCTION MANUAL Table 1 Approx. Approx. Pump Model Pump Model Oil Capacity Oil Capacity Model Code Model Code (liter) (liter) AC-46050 FC-66050 AO-46050 FO-66050 AC-46060 FC-66060 AO-46060 FO-66060 AC-46075 GC-66075 300DSC4 AO-46075 GO-66075 BC-46100 EEC-66175 BC-46120 EEC-66200 CC-46120 EEC-66215 CC-46145 EEC-66245 CC-46175 D1C-106050...
- Page 10 INSTRUCTION MANUAL *ICS opt. 3.6.1 Coolant Supply (Fig. 7c, 8c and 9c) Mech. Oil port Coolant supply hole Mech. Air vent. Mech. Air vent. Mech. Oil port Air vent & full level check hole Fig. 7c Fig. 8c The motor shaft is sealed with a mechanical seal. The coolant chamber provided between the two sealing stages can be filled with coolant by standing the pump vertically and unplugging “Coolant supply hole”...
- Page 11 INSTRUCTION MANUAL P.10 Coolant The ingredients of the coolant are to be as follows. Turbine Oil ISOVG32 : Propylene glycol : Water Oil funnel Floor surface Fig. 9c Table 1c Approx. Approx. Pump Model Coolant Pump Model Coolant Model Code Capacity Model Code...
- Page 12 INSTRUCTION MANUAL P.11 3.6.2 Insulation Resistance Measurement WARNING : ALL ELECTRIC WORK SHOULD BE PERFORMED BY A QUALIFIED ELECTRICIAN AND ALL NATIONAL AND LOCAL ELECTRICAL CODES MUST BE OBSERVED. Although insulation resistance of this pump has been shop tested, it should be rechecked prior to installation, using the following procedure.
- Page 13 INSTRUCTION MANUAL P.12 *Single Power Cable (50HP – 175HP models) Power cable Motor Protective device cable P1 P2 P3 P4 G *Dual Power Cable (200HP - 245HP models) Fig. 11 PM32U...
- Page 14 INSTRUCTION MANUAL P.13 3.6.3 Other Checks Requiring Particular Attention (1) Minimum operating water level Be sure that the pump stop level is not lower than the minimum operating water level specified in the technical document. If the stop level is lower, a vortex flow can occur causing the pump to intake air, resulting in noise and vibration.
- Page 15 INSTRUCTION MANUAL P.14 3.7 Pump Installation (Fig. 12) WARNING : WHEN LIFTING THE PUMP, USE APPROPRIATE CRANE (OR HOIST) AND LIFT SYSTEM. CHECK POSITION AND TIGHTNESS OF LIFT SYSTEM SO THAT WEIGHT OF THE PUMP IS NOT UNBALANCED. FAILURE TO OBSERVE THIS PRECAUTION CAN RESULT IN SERIOUS ACCIDENTES.
- Page 16 INSTRUCTION MANUAL P.15 3.8 Cable Installation (Fig. 13) When the pump has been installed, pull out the power cable, protective device cable, water level switch cable, etc. from the cable lead-out elbow on the floor and connect them to the control panel. FLOOR PLATE CABLE LEAD-OUT ELBOW Fig.
- Page 17 INSTRUCTION MANUAL P.16 4. Electric Wiring 4.1 Power Cable Connection WARNING CHECK THAT THE POWER IS LOCKED OFF AND DISCONNECTED BEFORE WORKING ON PUMP. The electric wiring for a submersible motor is no different from that of an ordinary motor, except that the direction of rotation cannot be easily verified. Wiring to wrong terminals results in a reversed motor, and to prevent this and to achieve best results, the following wiring procedure is recommended.
- Page 18 INSTRUCTION MANUAL P.17 Ground wire Ground terminal Ground plate Fig. 14 Table 2 (Example) Motor Grounding Grounding line classification resistance diameter AC 600V below 10Ω φ 1.6 mm (Source : Electrical Equipment Technical Standards, Ministry of International Trade and Industry). 4.3 Protective Device Cable Connection (Fig.
- Page 19 Three (or four) float switches are required for single unit operation, whereas four (or five) are necessary for two-unit alternating operation. If you desire our Ebara Water Level Control Float Switch, ask us for a catalog. Alarm (abnormal high level) Alarm (abnormal low level) Fig.
- Page 20 INSTRUCTION MANUAL P.19 Alarm (abnormal high level) ON (2nd Unit) ON (1st Unit) Alarm (abnormal low level) Fig. 17 Two-Unit Alternating Operation 5. Operation 5.1 Operational Limitations This pump is designed to operate under the following conditions: Liquid temperature : max. 40ºC (104 F） Liquid : This pump must not be used with sea water and corrosive chemicals or combustible liquids.
- Page 21 INSTRUCTION MANUAL P.20 5.2 Checking Rotation Direction (Figs. 18 and 19) Check the motor for rotation direction by the following procedure after the pump has been installed in the pump pit. A reversing pump is no problem if operation is not prolonged. If the pump performance curve is available.
- Page 22 INSTRUCTION MANUAL P.21 Motor Motor Fig. 19 Change of Connections for Normal Pump Performance WARNING : CHECK THE PUMP TO REDUCE THE TORQUE PRODUCED BY A LARGE SIZED PUMP. (2) If the pressure gauge or compound pressure gauge is not installed on discharge pipe.
- Page 23 INSTRUCTION MANUAL P.22 5.3 Cautions of Operation Closed valve operation of the pump is no problem if operating is not prolonged. Otherwise, the pump not only becomes overheated but also is caused to rattle and vibrate by backward flow of the liquid at the suction port. Avoid closed valve operation as much as circumstances allow.
- Page 24 INSTRUCTION MANUAL P.23 6. Maintenance and Overhaul While the life of the pump depends largely on the ambient conditions, daily servicing and inspection helps extend service life considerably. To achieve that, carry out the maintenance as follows : 6.1 Daily Checks Check the following items at least once a week.
- Page 25 INSTRUCTION MANUAL P.24 WARNING : BEFORE PULLING THE PUMP, DISCONNECT ALL CABLES AND ENSURE THAT THE PUMP IS ISOLATED FROM THE POWER SUPPLY. WARNING : ALWAYS LIFT THE PUMP BY THE LIFTING LUGS, NEVER BY THE MOTOR CABLE. WARNING : WHEN LIFTING THE PUMP, USE APPROPRIATE CRANE (OR HOIST) AND LIFT SYSTEM.
- Page 26 INSTRUCTION MANUAL P.25 (c) If a very small quantity of oil leaks out, there is no practical problem. If water or oil containing water, in excess of 1 liter (after one year of use), leaks out the mechanical seal must be replaced. (d) If much water is emitted, the mechanical seal or others components may be damaged, and an overhaul is necessary.
- Page 27 INSTRUCTION MANUAL P.26 (d) Replug the “oil port” as carefully as the other ports. (e) To replace either upper or lower mechanical seal, the pump must be disassembled. As the mechanical seal is a cartridge type, removing the retaining ring permits seal removal as a complete assembly. After the mechanical seal has been replaced with a new one, reassemble the pump and supply the specified oil through the “oil port”...
- Page 28 INSTRUCTION MANUAL P.27 *ICS opt. (2) Mechanical seal (upper) (a) Lift the pump out of the pump pit by lifting procedure described above, and stand it on the floor in a vertical position. Unplug “Leak check hole” in the intermediate casing of the pump. (b) If no liquid leaks from “Leak check hole”, the mechanical seal (upper) is in satisfactory condition.
- Page 29 INSTRUCTION MANUAL P.28 *ICS opt. (3) Mechanical Seal (lower) (a) Unplug “Coolant drain hole” (shown in Fig. 20c) and “Air vent” (shown in Figs. 7c and 8c) and drain all internal coolant. (Refer to “Changing Coolant”, *ICS opt. Para 6.6). (b) If the drained coolant is muddy, or milky-white, it contains pumped liquid.
- Page 30 INSTRUCTION MANUAL P.29 (4) Rotor (a) After checking the oil, put your hand through the pump discharge and turn the impeller. If it turns smoothly, the rotating components should be in satisfactory condition. (b) If the impeller resists or feels locked, the pump requires overhaul. 6.3.3 Reinstallation After the pump has been thoroughly inspected, reinstall it by reversing the lifting procedure.
- Page 31 INSTRUCTION MANUAL P.30 WARNING : DURING PUMP DISASSEMBLY AND REASSEMBLY, ENSURE THAT THE CABLES ARE DISCONNECTED AND ISOLATED FROM THE POWER SUPPLY. 6.5.1 Preparation for Disassembly and Reassembly An adequate workspace should be found which is as wide as possible, and has a rigid floor.
- Page 32 INSTRUCTION MANUAL P.31 (2) Protect surfaces of mating flanges and the corners of spigot and socket. (3) Cover the shaft threads to protect from damage after disassembly. (4) After disassembly, apply temporary rust prevention to the machined surfaces such as lifted surfaces, threads, shafts, etc. (5) Be careful not to drop tools and parts into the sump pit.
- Page 33 INSTRUCTION MANUAL P.32 *ICS opt. 6.6 Replacing Components (1) Changing coolant Stand the pump in a vertical position, and unplug “Coolant drain hole” (shown in Fig. 20c) and “Air vent & full level check hole” (shown in Figs. 7c and 8c). Drain all the coolant from “Coolant drain hole”.
- Page 34 INSTRUCTION MANUAL P.33 (2) Impeller disassembly Remove the impeller bolt cap and impeller bolt with special tools. Remove the impeller with special pull out tool. (Refer to Fig. 23) Special pull out tool (Left hand screw) Fig. 23 (3) Mechanical seal replacement (Refer to Fig. 24) Remove the snap ring (A) from intermediate casing.
- Page 35 INSTRUCTION MANUAL P.34 *ICS opt. Mechanical seal replacement (Refer to Fig. 24c) When removing "1. Lower stationary side & rotating side assy" or "5. Upper stationary side assy", use two push bolts (M5). (There are two female threads (M5) on the flange part of each assy.) For assembly, reverse the above steps.
- Page 36 INSTRUCTION MANUAL P.35 The disposition of the casings seen from the opposite side of the motor is as follows. The standard direction should be matched with the discharge direction. Discharge direction One hollow showing the standard direction of the INTERMEDIATE assembly CASING INNER...
- Page 37 INSTRUCTION MANUAL P.36 The situation after the completion of the assembly of the mechanical seal is as follows. Fig. 26c PM32U...
- Page 38 INSTRUCTION MANUAL P.37 (4) Torque table Table 4 Torque kg.m (Ft.lbs.) Bolt Size Without anti seized With anti seized compound compound 1.1 (8) 0.8 (6) 2.2 (16) 1.5 (11) 3.8 (28) 2.6 (18) 9.1 (66) 6.2 (45) 17.8 (129) 12.1 (88) 24.0 (174) 16.2 (117) 30.8 (223)
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Page 39: Troubleshooting
INSTRUCTION MANUAL P.38 7. Troubleshooting Symptoms Probable Causes Remedies Pump fails to o Defective cable or motor. o Lifts pump and replace cable or motor. start o Malfunction inside control panel. o Inspection made by competent electrician. o Power source trouble. o Inspection made by competent electrician. - Page 40 Contact your dealer or supplier for more information about other Ebara products: Ebara Fluid Handling 1651 Cedar Line Drive • rock Hill, SC 29730 (803) 327-5005 (t) • (803) 327-5097 (f) www pumpsebara com © 2015 Ebara International Corporation EICDSC4x 0415...