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Ebsray R Series Installation, Operation & Maintenance Instructions Manual

For submersible lpg applications (50hz & 60hz)
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EBSRAY PUMPS
INSTALLATION, OPERATION &
MAINTENANCE INSTRUCTIONS
R SERIES
MODEL RX10
.... For Submersible
LPG APPLICATIONS
(50Hz & 60Hz)
Publication # 1852-04 EN

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  • Page 1 Publication # 1852-04 EN EBSRAY PUMPS INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS R SERIES MODEL RX10 …. For Submersible LPG APPLICATIONS (50Hz & 60Hz)

  • Page 2: Table Of Contents

    EBSRAY RX10 SUBMERSIBLE PUMPSET..................5 "THREE-TIER" PROTECTION SYSTEM....................5  VALVE (POSITIVE PRESSURE VENTILATION VALVE)............6 BYPASS VALVE - EBSRAY MODEL RV18 NRV.................. 6 DIFFERENTIAL PRESSURE SWITCH....................6 CONTROL CONSOLE..........................6 EBSRAY LPG SYSTEM CONTROLLER ....................6 LIST OF SYSTEM COMPONENTS ....................... 6 a) COMPONENTS SUPPLIED BY EBSRAY ..................
  • Page 3 Federal, State and Local Codes, Regulations and Standards. Ebsray reserves the right to: a) Withdraw or alter any or all of the Ebsray Specifications within this publication and any other relevant Ebsray Documents without notification. b) Determine the validity of Any Warranty claims for Ebsray Equipment based on the Proper Application of Ebsray Supplied Equipment by the way of Adherence to the Ebsray Specifications within this Publication and any other relevant Ebsray Documents.

  • Page 4: Section 1 - General

    Ebsray Control Console and in change be contemplated, please confer with strict accordance with the system design and EBSRAY in order to verify the suitability of such a recommendations as set out in the current change. EBSRAY I.O.&.M Data supplied with each pumpset.

  • Page 5: Section 2 - System Description

    (Bearing Cooling and Lubrication system) and the EBSRAY "Three-Tier" Protection System ensures reliable operation over the intended periods between routine maintenance overhauls. The EBSRAY RX10 is designed as a 'fully serviceable' pumpset. Figure 1 2.2 EBSRAY RX10 SUBMERSIBLE LPG PUMPSET ...

  • Page 6: Ppv  Valve (Positive Pressure Ventilation Valve)

    (Refer EBSRAY for details) eliminate LPG drain-back when pump is idle. 2.9 LIST OF SYSYTEM COMPONENTS a) COMPONENTS SUPPLIED BY EBSRAY (refer P & ID Appendix A for corresponding Item #) ITEM # DESCRIPTION 1. EBSRAY MODEL RX10 - 3.7 kW SUBMERSIBLE PUMPSET............1 2.

  • Page 7: B) Components Supplied By Others

    8C x " OD x 1.2mm WALL U-TUBE - COPPER # C850600............1 9. EBSRAY 'RV18 NRV' (NON RETURN VALVE) BYPASS VALVE FLANGED 25mm NB ANSI 300LB, 500 - 900 kPa (5 – 9 Bar) DIFFERENTIAL PRESSURE RANGE ....1 11. 63mm, 0-2500 kPa (0 –25 Bar) PRESSURE GAUGE # C850400.............2 b) COMPONENTS SUPPLIED BY OTHERS (Refer to P &...

  • Page 8: Section 3 - Installation

    SECTION 3 - INSTALLATION CAUTION Installation and removal of this equipment should Clearance of 5mm (min) is required between bottom of be performed by qualified competent personnel in pumpset and bottom (inside) of pump housing. Should accordance with relevant directives, standards, underside of pump touch housing, electrical insulation codes, regulations and site restrictions - in will be ineffective.

  • Page 9: Electrical Conduit

    3.5 ELECTRICAL CONDUIT The Tube Connectors for electrical conduit supplied by and/or recommended by EBSRAY must be fitted and To determine minimum overall length of conduit secured in accordance with the manufacturer's (Refer to figure 4): (Swagelok or equal) recommendations. Ensure correct positioning prior to tightening.
  • Page 10 Figure 8 7. Carefully guide free ends of motor leads through discharge riser and out through the 1" (F) NPT port. 8. While keeping the motor leads taut, guide the discharge riser over the conduit taking great care not to damage the motor leads. 9.

  • Page 11: Lpg/Product Discharge Pipe Fittings

    2. After this ball valve, a 25 mm NB (min) branch is 17. Fit pump housing cover to turret cover with required for the EBSRAY RV18 NRV Bypass appropriate cathodic insulators/washers for bolts Valve. This Bypass Valve mounts between 25 mm and nuts.

  • Page 12: Ppv Valve

    2. All construction is to be strictly in accordance with relevant directives, standards, codes, regulations and site restrictions. (in Australia, AS3000 wiring rules apply, other countries, as applicable) 3. EBSRAY control console is only to be installed in a non-hazardous area requiring IP55 (or less) rated enclosures.

  • Page 13: Differential Pressure Switch (Dps)

    (Six core plus ground cable can Gland on Junction Box as per manufacturer's be accommodated with modifications. For information instructions. contact EBSRAY) 2.5 mm (min). Cores One (1) through Seven (7) connect to respective Junction Box 6. Connect leads from armoured cable to terminal terminals.

  • Page 14: Section 4 - Operation

    4.1 DESCRIPTION WARNING Do not run pump dry. Severe internal damage to 1 Pump the pump and motor will result. The EBSRAY Model RX10 pumpset is a compact close-coupled Submersible Regenerative Turbine 5. Valves should be in the following positions: pump-motor unit, designed for pumping LPG of (see P&ID Appendix A for locations)
  • Page 15 4. Switch "ON" Q1 circuit breaker in Control Console. WARNING 5. Turn 'RESET' key clockwise to verify Fault Running-in Period Indicator Lamp functionality i.e. Lamp test Due to the precision manufacturing tolerances and sequence. (One green and all three Red Fault the nature of the sleeve bearing material, the pump Indicators should light) should be run-in under automatic (dispenser...

  • Page 16: Section 5 - Control Console - Description, Operation & Adjustment

    SECTION 5 - CONTROL CONSOLE - DESCRIPTION, OPERATION & ADJUSTMENT...

  • Page 17: Operational Features Of The Control Console - A) Fascia

    The Control Console (Item # C860001) controls the The reason for the shutdown is indicated by one of the RX10 Pumpset and monitors the pumping system. If 'fault' indicators on the Fascia of the Control Console. the Control Console detects that various aspects of the These 'fault' indicators cannot be turned off without a pumpset or the pumping system are operating out of keyed reset such that the fault indication is preserved...
  • Page 18 4. High Bearing Temperature Switch (HBT) TEST = The Pumpset will start and continuously - Red Indicator Lamp run regardless of a signal from the Dispenser/ Communications System via Operation of the Pumpset will be halted if fluid terminals X and Y (see wiring diagram within the BCL System exceeds a preset Appendix C).

  • Page 19: Operational Features Of The Control Console - B) Interior

    5.2 OPERATIONAL FEATURES OF THE CONTROL CONSOLE - b) INTERIOR Motor Contactor - Labelled KM1 Coil operated contactor sends three phase power 12. Run Relay - labelled KA1 to pumpset when its coil is energised via a signal KA1 is actuated under the control of the from the PLC (TSX07) (Item 13 this section) and dispenser/communication system via terminals X the Motor Run Relay (KA1) (Item 12 this section).
  • Page 20 I/O LED (RED) INPUT Status LED 3 "off" , No fault condition: PLC is OK Run Relay (KA1) - [normally open] in "on" fault detected with the PLC inputs or conjunction with Run-Off-Test Mode Selector outputs. Switch ON = KA1 is closed, the Run-Off-Test 13.B.
  • Page 21 See Installation Section Example 2: In the figure above the timer is seconds Recommended initial setting 13.E. PLC Communication Port Allows communication via the PLC for other devices such as modems, loggers etc. For more information about this feature, please contact EBSRAY.

  • Page 22: Section 6 - Maintenance

    CAUTION Control Console and Ancillary Equipment. Prior to any system disassembly or service, verify All equipment supplied by EBSRAY can be serviced by that all requirements of statutory standards, competent (qualified ) persons, or returned to EBSRAY directives, codes or regulations are met and that for Factory Service.

  • Page 23: Section 7 - Trouble Shooting

    Faulty Differential Pressure Switch Replace Differential Pressure Switch Control Circuit not Circuit/Communications outside Check Circuit/Communications, repair or functioning correctly EBSRAY Control Console faulty replace as required Cables / connections between Main Check cables/connections, repair or Switch Board, EBSRAY Control replace as required...
  • Page 24 Switch Board, EBSRAY Control replace as required indicates that Console and Pumpset (HBT the fault is switch) faulty still present Fault in EBSRAY Control Console See Control Console below i.e. HBT switch has not reset Excessive pump Too frequent repeat run signal from...
  • Page 25 Reconditioning (Certified Persons Flashing ON service ONLY) or Service Exchange Pumpset 4.5 sec OFF required. 0.5 sec) Control Circuit not Fault in EBSRAY Control Console See Control Console below NOTE: This functioning correctly indicates that locked rotor current has been...
  • Page 26 Control Possible Indicator/ Problem Possible Cause Remedy Symptom Excessive Obstruction in Dirt/debris/contaminate lodged in Clean Tank/ Pump Chamber. If Pump Noise and/or Pumpset impeller Pump will not run after reset, contact Factory Vibration or Representative Faulty EFV on inlet, EFV Spring faulty or Check EFV(s), repair or replace as Bypass or Discharge EFV ports partially blocked...
  • Page 27 Y Check and/or Repair Dispenser / Console (See Wiring Diagram) Communications System as required Fault Power Supply faulty Supply Power to EBSRAY Control Check Power Supply: Indicator Console faulty a) To Main Board Lamps (red) b) To EBSRAY Control Console...

  • Page 28: Section 8 - Appendices

    SECTION 8 - APPENDICES APPENDIX A - TYPICAL INSTALLATION P & ID...
  • Page 29 APPENDIX B - EBSRAY RX10 3.7 KW SUBMERSIBLE PUMPSET OUTLINE DIMENSIONS AND SPECIFICATION...

  • Page 30: Appendix Ctypical Wiring Schematic And Connection Diagram

    APPENDIX C - TYPICAL WIRING SCHEMATICS AND CONNECTION DIAGRAM...
  • Page 31 APPENDIX D - RX10 SYSTEM PRE-STARTUP COMMISSIONING CHECKLIST Date:_____________________ Location:_______________________________ Pumpset Serial No. _______________________ Installation Company:___________________________________ Installer's Name: ______________________________________ Indicate Inspection Satisfactorily Completed with a [ in the appropriate ......Check that all electrical wiring is insulated from the ground, conduits, tank etc......
  • Page 32 APPENDIX E - EBSRAY RX10 INSPECTION/RUN LOG SITE INSTALLED BY COMPANY/PERSONNEL RX10 PUMPSET CONTROL CONSOLE DATE NUMBER OF HOSES SERIAL No. SERIAL No. COMMISSIONED SERVED INSPECT TANK PUMP MOTOR CURRENT NOTES HOURS SYSTEM VAPOUR DISCHARGE (AMPS) TEMP (NAME) PRESSURE PRESSURE (°C)
  • Page 33 APPENDIX E (CONTINUED) - EBSRAY RX10 INSPECTION RUN/LOG INSPECT TANK PUMP MOTOR CURRENT NOTES HOURS SYSTEM VAPOUR DISCHARGE (AMPS) TEMP (NAME) PRESSURE PRESSURE (°C) (kPa) (kPa)
  • Page 34 APPENDIX F - COPIES OF CERTIFICATIONS & DECLARATIONS FOR RX10 PUMP/MOTOR AUSTRALIAN CERTIFICATE...
  • Page 35 APPENDIX F - COPIES OF CERTIFACATIONS & DECLARATIONS FOR RX10 PUMP/MOTOR ATEX CERTIFICATE...
  • Page 36 NOTES...

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