Dover PSG Ebsray R Series Installation, Operation & Maintenance Instructions Manual
For submersible lpg applications
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- Page 1 Publication # 1859-15 EN EBSRAY PUMPS INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS R SERIES MODEL RX10 …. For Submersible LPG APPLICATIONS (50Hz & 60Hz)
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Page 2: Table Of Contents
CONTENTS SECTION 1 – GENERAL .............................. 4 INTRODUCTION ........................... 4 TRANSPORTATION AND PACKING ....................4 RECEIVING INSPECTION ........................4 HANDLING ............................4 WARRANTY ............................4 SECTION 2 – SYSTEM DESCRIPTION ........................5 EBSRAY RX10 SUBMERSIBLE LPG PUMPING SYSTEM ..............5 EBSRAY RX10 SUBMERSIBLE LPG PUMPSET ................. - Page 3 IMPORTANT NOTES This Publication is TYPICAL ONLY and only relates to the specifications of the minimum equipment required to ensure the optimum performance, maximum life and trouble-free operation of the EBSRAY RX10 Submersible Pumpset and the Pumping System in general. Products with the mandatory European CE mark affixed indicate conformity to the essential health and safety requirements via their applicable EU Directives (e.g.
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Page 4: Section 1 - General
SECTION 1 – GENERAL INTRODUCTION WARNING Never allow water or any This publication is intended to assist those involved corrosive product to enter the Pumpset, Motor or with the installation, operation and maintenance of electrical conduit. This may damage the Pumpset EBSRAY Model RX10... -
Page 5: Section 2 - System Description
5. To validate Warranty conditions, a completed copy Refer to EBSRAY or Appointed Representative for of the RX10 Pumpset Run Log, Appendix E clarification or further details on the RX10 New or MUST BE Service Exchange Pumpset Warranty conditions. completed in full and returned to EBSRAY for registration. -
Page 6: Dps (Differential Pressure Switch)
2. 'DPS' (Differential Pressure Switch) Operation of the 1. Maintains Pump System differential pressure as system will be halted if differential pressure falls required for optimum flow rate into vehicles. below a preset level during operation or is not 2. -
Page 7: Port Alignment
The top of the Discharge Riser (above flange) must be 3.1.3 Port Alignment fitted with a coaxial splitting arrangement which NOTE: provides a 1" (F) NPT thread for the conduit exit, Accurate alignment of the Pumpset inlet concentric and parallel with the Discharge Riser plus a port with the Pump Housing port is critical for discharge connection efficient Pumpset operation. -
Page 8: Pumpset & System Piping Connections
4. Fit conduit to compression tube fitting and tighten 3.1.6 Pumpset & System Piping Connections nut on fitting as shown in Figures 6 & 7 (2.5 mm Refer to Appendix A - P&ID for system arrangement hex key used as a no-go gauge which is and relative positioning of components. -
Page 9: Discharge Pipe Fittings
9. Fit Discharge Riser assembly to the Pumpset with a) Remove Junction Box cover. appropriate thread sealant or tape. With the b) Fit DPS to Junction Box (For Junction Boxes Pumpset stationary, screw Discharge Riser into which are not fitted with a 1/2" NPT(F) thread, use Pumpset ensuring full... -
Page 10: Bypass Valve
B. External Mounting: Alternate 'External Mounting' 3. The line from the valve must be split with a 'Tee' arrangement. One side of the 'Tee' feeds an inlet is possible (e.g. retrofits to existing equalisation pressure gauge (0-2500 kPa) (0 – 25 Bar) and the pipes). -
Page 11: Junction Box
Figure 10 3.2.1 Junction Box 3.2.4 Pump Controller The Junction Box houses all electrical terminations The Pump Controller houses all electrical terminations between the Pumpset, the DPS and the Pump between the main switch board and the Zone 1 Controller. compliant Junction Box. -
Page 12: Section 4 - Operation
SECTION 4 – OPERATION 5. Valves should be in the following positions: DESCRIPTION (see Appendix A – P&ID for locations) The RX10 Pumpset is designed to provide trouble- Pump Housing Inlet Valve ......OPEN free & safe operation in potentially explosive Isolation Valve ......... - Page 13 6. Check system functionality, Pumpset should 17. Inspect Pumpset/Pumping System frequently immediately begin to build differential pressure during the first few hours of operation, then up to approximately 500 - 600 kPa. (5 – 6 Bar) periodically thereafter. Record discharge pressure in the commissioning Record observations from these inspections in the section of the Pumpset Run Log.
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Page 14: Section 5 - Pump Controller
SECTION 5 – PUMP CONTROLLER Figure 11 All control voltages within the Pump Controller are 220/240 Vac DANGER Door Latch Key and/or ‘RUN-OFF-TEST’ key should only be accessed by suitably CAUTION trained and qualified personnel (e.g. Service Maintainer) DANGER ‘VIEW SETTINGS AND LOGS’ Push Button may be operated without the need to have key access. NOTE: Item Description... -
Page 15: Actions
To View Settings & Set ‘Run-On’ Time ACTIONS 5.2.4 (Valid Options 0 or 2mins) 5.2.1 Initial Settings There are six buttons on the PLC as per: Menu/OK Main Settings Reset Logs Enter Shift Menu The following instructions will refer to the buttons as Press ... -
Page 16: Run-On' Time
the Pump Controller displays ‘DPS Time’ in seconds. the Pumpset and indicate a fault warning on the LCD This time displayed is the actual time it has taken for screen (See Troubleshooting for Evaluation and the Pumpset to build the minimum required differential Rectification of all indicated Faults) pressure after each re-start. -
Page 17: Preventative Faults
5.4.1.3 HBT Faults The Pump Controller monitors 5.4.4 Pumpset/Pumping System Diagnostics the Pumpset’s Bearing Cooling and Lubrication The Pump Controller stores various information in the (BCL ) liquid temperature via the High Bearing which useful system diagnostics, Temperature (HBT) switch, embedded in the Motor. maintenance, troubleshooting, etc. -
Page 18: Section 6 - Maintenance
SECTION 6 – MAINTENANCE Prior system CAUTION disassembly or service, SERVICE EXCHANGE DANGER verify that all requirements of relevant Codes, EBSRAY maintains RX10 Service Exchange Pumpsets Regulations, Standards or Directives are met and to facilitate rapid and economical changeover should that specific site requirements etc are satisfied. -
Page 19: Section 7 - Troubleshooting
SECTION 7 – TROUBLESHOOTING Error Possible Possible Cause Remedy Condition Problem Insufficient LPG in Storage Tank Fill Storage Tank Differential Pressure too low *** DPS FAULT *** Incorrect Bypass Valve setting. Adjust (Increase) Bypass Valve setting to achieve required AFTER DPS BYPASS differential pressure. - Page 20 Error Possible Possible Cause Remedy Condition Problem Insufficient LPG in Storage Tank Fill Storage Tank Pumpset has not reached minimum Excessive inlet restriction Check/open Inlet Valve *** DPS FAULT *** differential - Inlet Isolation Valve not opened Check, repair or replace Inlet BEFORE DPS BYPASS pressure.
- Page 21 Error Possible Possible Cause Remedy Condition Problem MOL Relay set too Incorrect setting on MOL Relay Reset MOL setting to FLA of Motor as per Specification (See *** MOL FAULT *** AFTER STARTUP AND Section 4.3) SWITCH NOT RESET Differential Incorrect Bypass Valve Setting.
- Page 22 Error Possible Possible Cause Remedy Condition Problem Pumpset operating but Vehicle Tank already full No problem exists fails to deliver LPG No Vehicle Insufficient LPG in Storage Tank Fill Storage Tank Fill Excessive pressure in Vehicle Tank Allow Vehicle Tank to cool until pressure compared to Storage Tank decreases or increase vapour pressure in Storage Tank, or increase bypass...
- Page 23 Error Possible Possible Cause Remedy Condition Problem Insufficient LPG in Storage Tank - Fill Storage Tank Pumpset cavitating Pumpset Inlet (suction) Port not fully "Pulsing" (restriction at inlet to covered with liquid Flow Pumpset) Excessive Inlet (suction) restriction Check / Open Inlet Valve, repair or replace Excess Flow Valve as required - Inlet Valve not opened fully - Faulty Inlet Excess Flow Valve...
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Page 24: Appendix A - Typical Installation P&Id
APPENDIX A – TYPICAL INSTALLATION P&ID... -
Page 25: Appendix B - Rx10 3.7Kw Submersible Pumpset - Outline Dimensions And Specifications
APPENDIX B – RX10 3.7kW SUBMERSIBLE PUMPSET – OUTLINE DIMENSIONS AND SPECIFICATIONS... -
Page 26: Appendix C - Typical Wiring Schematic And Connection Diagram
APPENDIX C – TYPICAL WIRING SCHEMATIC AND CONNECTION DIAGRAM... -
Page 27: Appendix D - System Pre-Startup Commissioning Checklist
APPENDIX D – SYSTEM PRE-STARTUP COMMISSIONING CHECKLIST Date:________________ Location:__________________________ Pumpset Serial No. _______________________ Installation Company:______________________________ Installer's Name: _________________________________ Indicate Inspection Satisfactorily Completed with a in the appropriate box 1. Check that all electrical wiring is insulated from the ground, conduits, tank etc............... -
Page 28: Appendix E - Ebsray Pumpset Run Log
APPENDIX E – EBSRAY PUMPSET RUN LOG INSTALLATION RECORD PUMPSET PUMP CONTROLLER DATE NUMBER OF HOSES SITE INSTALLED BY COMPANY/PERSONNEL SERIAL No. SERIAL No. COMMISSIONED SERVED COMMISSIONING RECORD MOTOR CURRENT TANK PUMPSET NOTES INSPECT (AMPS) VAPOUR DISCHARGE (NAME) SYSTEM TEMP HOURS PRESSURE PRESSURE...
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