DAYLIFF DS Installation instructions

Installation &
Operating Manual
DS/DSP/D3SP
Submersible Borehole Pumps

PUMP SPECIFICATIONS
Pump
Motor
1.
PUMP ACCESSORIES
Drop Cable
Riser Pipe
Well Head
3.
ELECTRICAL CONNECTIONS
General Information
Single Phase Motors
Three Phase Motors
4.
INSTALLATION
Pump Application
Pump Position
Pump Lowering
5.
PUMP OPERATION
6.
MAINTENANCE
7.
TROUBLE SHOOTING
8.
WARRANTY9.
2.
DELIVERY & STORAGE
Delivery
Storage & Handling
1
1
2
2
2
2
2
2
3
3
4
4
5
5
6
6
7
7
8
9
10
14
i)
ii)
i)
ii)
i)
ii)
iii)
i)
ii)
iii)
i)
ii)
iii)
INDEX
© Davis & Shirtliff Ltd 2020
Contents herein are not warranted

1
1. PUMP SPECIFICATION
HEAD (m)
3
FLOW (m /hr)
DSP1
D3SP1
DSP3 DSP5 DSP8 DS14
DS2
DS3
DS5
DS8
DS17
DS30
DS46
DS60
DS95
DS77
i) Pump
DAYLIFF DS and DSP submersible multistage centrifugal pumps are specially
designed for water supply from boreholes. DS pumps feature stainless steel
construction throughout while DSP pumps use engineering plastics for the hydraulic
components and feature a floating type impeller that gives superior sand handling
capabilities. Both pumps are made from quality materials providing high efficiency
operation and long life. Performance characteristics and other data of the model
selected should be checked on the specific data sheet, which will be supplied with the
pump.
DAYLIFF D3SP pumps are compact 3” diameter submersible multistage
centrifugal pumps specifically designed for small scale water supplies from
boreholes and wells. Material of construction is engineering plastic impellers
and diffusers, brass inlet and outlet chambers and stainless steel pump sleeve.
All pumps are provided with 20m cable and a control unit.
0 3
Max. Water Temp: 30 C Max. Sand Content: 50g/m
0
D3SP: 40 C
450
400
350
300
250
200
150
100
50
0110 100
Congratulations on selecting a Dayliff DS/DSP/D3SP. They are
manufactured to the highest standards and if installed and operated
correctly will give many years of efcient and trouble free service.
Careful reading of this Installation Manual is therefore important,
though should there be any queries they should be referred to the
equipment supplier.

Fig. 1 Pump position during storage
2
2. DELIVERY & STORAGE
i) Delivery
DAYLIFF DS/DSP/D3SP pumps are supplied from the factory in proper packing in
which they should remain until they are to be installed. During unpacking and prior
to installation, care must be taken when handling the pump to ensure that
misalignment does not occur due to bending.
ii) Storage and Handling
The pump should not be exposed to
direct sunlight. If the pump has been
unpacked, it can be stored either
horizontally if adequately supported as
shown in Fig 1. or vertically to prevent
misalignment of the pump. Ensure that
the pump does not roll or fall over.
ii) Motor
All pumps are fitted with sealed liquid cooled oil filled 2-pole asynchronous squirrel-
cage motors constructed principally of stainless steel. Single phase motors require
purpose designed control boxes while three phase motors require a remote starter.
DAYLIFF 'Drytek' Electronic Pump Controllers are recommended for total motor
protection.
Enclosure Class: IP68 Insulation Class: DS/DSP - F Speed: 2900rpm
WARNING
Any leakage on the pump tail cable or drop cable will lead
to motor failure
i) Drop Cable
3. PUMP ACCESSORIES
Suitable drop cable selection and attachment is vital to ensure proper pump
operation. The following should be noted:-
ŸOnly proper submersible cable of either PVC or rubber type must be used that is
specified for permanent water submersion. Other cable types will lead to water
ingress and motor failure.

Fig. 2 Wellhead layout
Sleeve for
airline
Regulator Valve Test Tee
Junction Box
Cover Plate
Drop Pipe
3
iii) Wellhead
A robust sealed wellhead plate should
be fitted on the borehole top to prevent
borehole contamination, a DAYLIFF
w e l l h e a d a s s e m b l y b e i n g
recommended. The assembly includes
a delivery outlet with isolating valve and
test tee as well as drop cable entry and
optional provision for low-level
electrode cables and an airline to
measure borehole water depth.
ŸFor single phase pumps 3-core cable is suitable. For three phase pumps 3-core
can be used with steel pipes installation using the drop pipe for earthing. 4-core
must be used for plastic pipe installations.
ŸIt is important that the correct cable size is selected which is related to motor size
and total length. Voltage drop should not exceed 5% from the supply point. The
pump supplier should be consulted for the correct cable size.
ŸThe drop cable must be attached to the pump tail cable using a certified cable
joint. Leakage at this joint will cause motor failure.
ŸCare must be taken when fitting the motor tail cable to the motor. The connection
between the tail cable and the motor should be lubricated with a non-conducting
petroleum jelly and a secure fit made with the securing screws fully tightened.
i) Riser Pipe
Suitable selection and installation of the riser pipe is essential to avoid the risk of pipe
fracture and pump dislodging. This will then require expensive pump removal or
possibly borehole loss. The following should be noted:-
ŸEither MS galvanised steel pipe in 6m or 3m sections or DAYLIFF PVC borehole
piping in 3m section should be used for all installations below 50m. For shallow
well installations up to 50m single length Polypipe can be used.
ŸFor MS steel pipe ensure that all threads are properly cut and that the connecting
sockets are fully threaded. For deep boreholes (deeper than 100m) high tensile
'Crane' type sockets are recommended. Steel pipes are recommended for all 6''
pump installations.
ŸFor reasons of reduced friction, ease of installation and economy ‘DAYLIFF' PVC
borehole pipe are recommended for all 3”and 4'' pump installations up to 200m
depth. Standard PVC piping must never be used.

Before starting work on the pump, make sure that the electricity
supply has been switched off and that it cannot be accidentally
switched on.
Correct earthing for all borehole pump installations is essential for
safety and pump motor protection. Consult a licensed electrician for
advice on requirements.
The electrical connection should be carried out by an authorised
electrician in accordance with local regulations.
i) General Information
WARNING
WARNING
WARNING
4
4. ELECTRICAL CONNECTIONS
ŸThe rated maximum current, supply voltage and cosØ are given on a loose data
plate supplied with the pumps which must be fitted close to the installation site.
ŸThe required voltage quality for DAYLIFF DS motors measured at the motor
terminals is -10%/+10% of the nominal rated voltage during continuous
operation including variations in the supply voltage and cable losses.
Ÿ All motors must be fitted with a mains isolator and coarse current protection in
the form of an MCB or fuse. Coarse current rating should be approx 3X
maximum rated motor current.
ŸFor all three phase motors and single phase motors above 1.1kW a DOL starter
is required. Note that starting current is between 4X and 6X the rated motor
current which due to the low inertia of a submersible pump is reached in about
0.1 seconds. DOL starting is therefore recommended for motor starting up to
30kW motor sizes as the total system load is less than with a Star Delta
alternative. For alternative starting arrangements options of a soft starter or auto
transformer starter should be used.
ŸIt is essential to provide motor protection from high/low current conditions
outside the limits of +10%, -10% of the rated full load running current, high
current protection being provided by a DOL starter overload relay. Also
recommended for 3-phase motors is protection against phase loss, phase
asymmetry and high/low voltage variations (<+10%, >-10%) of nominal
supply voltage which can be provided by a multi-function relay.
ŸAlso generally recommended unless water availability is assured is low level
protection to prevent the pump running dry.

5
WARNING
Motor Size
0.37kW
Type Start Capacitor Run Capacitor
0.75kW
1.1kW
1.5kW
2.2kW
PSC
PSC
PSC
CS/CR
CS/CR
-
-
-
200-250
200-250
16
25
35
40
60
ii) Single Phase Motors
Conventionally this is provided by a relay connected by cable to sensors in the
borehole water, though wireless electronic protection is also available.
ŸDS/DSP/D3SP motors can be used with inverters for power by DC sources,
particularly solar modules and also variable speed operation. Further
information can be obtained from the pump supplier if there is a particular
installation requirement.
All single phase motors are supplied with control units including capacitors and a
switch. PSC motors are fitted with one combined start/run capacitor while CS/CR
motors are fitted with separate start and run capacitors with a change-over relay.
Specifications are as follows:-
Correct connection of terminals and identification of the start,
run and common windings is essential or else the motor will
burn out. Extra care must therefore be taken when connecting
and if in doubt the pump supplier should be consulted.
Small single phase motors (up to 1.1kW) are fitted with inbuilt thermal overload
protection though for added motor security it is advisable to fit a voltage protection
unit such as a Dayliff AVS. For motors larger than 1.1kW a DOL starter is required
and this can be provided by a separate DOL contactor and overload unit or
alternatively by a DAYLIFF Drytek controller which includes over/under current
protection plus multi-function power input protection and wireless low level
protection by cosØ monitoring. Digital indications of operating parameters are
also provided including current, voltage and cosØ. For full motor protection a
Drytek controller is recommended.
iii) Three Phase Motors
All three phase motors require DOL starting and overload protection. Drytek
controllers as detailed for single phase motors are recommended for enhanced
protection and prolonged life.

Not
Allowed
Allowed
Fig. 3 Pump Axis Limits
6
5. INSTALLATION
i) Pump Application
ŸA wide range of pump models are available and the pump selected must be
matched to the borehole output to provide optimal operating performance. This
should be done with reference to the borehole drillers report in consultation with
a borehole installation specialist. As a rule pump output should not exceed 65%
of maximum tested borehole yield.
ŸMinimum Borehole Diameter 3”pumps -100mm, 4”pumps-110mm, 6”pumps-
160mm, DS30-200mm.
ŸMaximum Pump Immersion Depth - 200m for DSP, 250m for DS and 35m for
D3SP.
ŸPumped liquid should be clean, thin and non-explosive containing no solid 3
particles or fibres. Sand content should not exceed 50gm/m or else pump life
will be reduced and any warranties will be invalidated.
0
ŸLiquid temperature should not exceed 40 C in order to preserve rubber
components. Also for high temperatures one motor size larger should be fitted to
prolong motor life due to high operating
temperatures.
ŸPumps can be installed either vertically or
horizontally, though if installed horizontally the
discharge outlet should never fall below the
horizontal plane. For all horizontal installations
a flow sleeve should be used and also there
should be a minimum of 0.5m water depth
above the pump to prevent the formation of a
vortex.

Borehole Measurement Parameters
L1.Minimum installation depth below
dynamic water level
L2. Depth to dynamic water level (DWL)
L3.Depth to static water level (SWL)
L4.Draw down. This is the difference
between the dynamic and the static
water levels
L5. Installation depth
L6. Distance of pump from well bottom
Fig. 4 Borehole Measurements
L5
L4
L1
L2 L3
L6
ii) Pump Position
7
ŸWhen positioning the pump it is important to ensure adequate motor cooling
through water flow past the motor. This will be achieved by installing the pump
suction above the borehole main aquifer or well screen and if not possible or in
cases of open water installation a cooling sleeve must be used. Recommended
3
minimum flow rate past the motor is 0.2m /sec.
ŸIt is recommended that the complete pump is submerged at least 3m the
dynamic water level and if possible the pump should be installed at least 3m
from the bottom of the borehole to prevent silting damage. As a rule the pump
should be positioned mid-way between the bottom of the borehole and the
dynamic water level assuming that the main aquifer is below this level. If in doubt
consult the pump supplier.
iii) Pump Lowering
It is recommended that a fully equipped borehole service vehicle be used for
pump lowering and removal in order to minimize risk of pump dislodging.
However, for shallow boreholes (less than 50m) a manual tripod arrangement
can be used. When moving the pump the following procedures should be
followed:-
ŸBefore starting pump lowering it is important to check the borehole depth and
straightness to ensure it is as expected and there is unobstructed passage.
The pump should be carefully lowered into the borehole and if an

8
6. PUMP OPERATION
ŸFit the first starter pipe into the pump outlet and ensure a tight leak free joint
while the pump is on the surface. The thread on the starter pipe should not be
longer than the threads in the pump outlet or it will interfere with operation of the
non-return valve.
ŸScrew the starter pipe into a robust adaptor hook attached to the winch or tripod
cable and lower the pump and pipe section into the borehole. When fully
lowered hold the pipe below the socket with a clamp, disconnect the lifting hook
and attach to the next pipe length ensuring a water tight connection. Ensure the
pipe joint is fully home and repeat until all pipes are lowered.
ŸWhile the pipes are being lowered bind the drop cable, low level cable (if fitted),
and airline (if fitted) to the drop pipes with a PVC cable clip at 2m centres.
When the pump has been connected correctly and is submerged in water proceed as
follows:-
ŸFirst check the direction of rotation by starting the pump and observing a normal
water flow. If low or uneven change the direction of rotation by switching two
phase connections.
ŸThe pump should then be run with the discharge valve restricted to
approximately 1/3 of its maximum volume of water. Observe if there are
impurities in the water and then gradually open the valve until the water is
observed to be clear. If the water continues to be silted the pump is installed too
low in the borehole and it should be raised until it is in a position of clear water
availability. Alternatively a borehole problem is indicated and a driller should be
consulted.
ŸAs the valve is being opened, the water output should be monitored to ensure
that the pump output does not exceed the borehole capacity as indicated by the
pump starting and stopping on the low level relay (if fitted) or uneven water flow
at the outlet. If this occurs the pump should either be changed to one of suitable
specification or throttled on the outlet valve to a sustainable output. Note that
the dynamic water level should always be above the suction interconnector of
the pump.
ŸAfter the water flow settles the pump overload relay should be set. This is carried
out by reducing the overload setting to the cutout condition and then increasing
by +10%.
ŸDuring regular operation the pump operating current should be regularly
monitored and if a substantial change is noted (±10%) it should be investigated
by a service technician. Pump output should also be monitored and if the flow
rate or consistency changes investigations should be made.

9
7. MAINTENANCE
ŸIn order to obtain maximum pump life the number of starts should be controlled
and should not exceed 30 per hour. It is also necessary to start the pump at least
monthly to prevent seizure.
ŸNo regular maintenance is required though periodically, recommended every 3
months, the installation should be inspected to check operating parameters
including running current, water output, closed head pump pressure and water
quality as well as switchgear condition. Rectification should be carried out as
necessary. Interpretations of various operating problems are given in the Fault
Finding Guide.
ŸAlso important is a periodic check of motor winding and insulating resistance,
especially if there is an abnormal operating current or voltage reading. For three
phase motors winding resistance between each pair of phases should not
exceed 10%. For insulating resistance a satisfactory reading is >100MOhm
and if below this some deterioration in motor winding insulation, cable integrity
or cable joint security is indicated. Generally it is satisfactory to keep running the
motor until resistance drops to below 0.5MOhm when the equipment should be
removed and checked.
ŸAs a rule periodic lifting and checking of borehole installations is not
recommended until an operating fault is noted as equipment is designed for
continuous operation for an indefinite period.

Problem Possible Cause Solution
The pump
does not
run
The fuses are blown
Replace the blown fuses. If
the replacements blow too,
the electric installation and
the submersible drop cable
should be checked
The ELCB or the voltage-
operated ELCB has tripped
out
Re-set the circuit breaker
The motor overload has
tripped out
Reset the motor starter
overload. If it trips again,
check the voltage and if
normal call service technician
Motor starter/contactor
defective
Repair the motor starter/
contactor
The control circuit has been
interrupted or is defective
Check the electric installation
No electricity supply Contact the power supply
provider
The dry running protection
has cut out the pump due to
low water level
Check the water level. If it is in
order check the water level
electrodes/level switch
The pumps submersible drop
cable is defective
Repair/replace the pump/
cable
11
8. TROUBLE SHOOTING GUIDE
The protection relay has
tripped due to power
inconsistencies
Contact the power supply
provider

The pump
runs but
gives no
water
The non-return valve is stuck
in its shut position
The discharged valve is
closed
No water or very low level in
borehole
The inlet strainer is choked up
The pump unit is defective
The pump
runs at
reduced
capacity
Leakage in the pipework
Pipes are leaking
Pull out the pump and clean
or replace the valve
Open the valve
Increase the installation
depth of the pump, throttle
the pump or replace it with
a smaller model to obtain
reduced capacity
Pull out the pump and clean
the strainer
Replace or repair the pump
The valves in the discharge
pipes are partly closed or
blocked
Check and clean or replace
the valves and discharge
pipe
Wrong direction of rotation Change direction of rotation
The pump is defective Repair or replace the pump
Check and repair the pipe
work
The non-return valve of the
pump is partly blocked
Pull out the pump and check
or replace the valve
The pump and the riser
pipe are partly choked by
impurities
Pull out the pump. Check
and clean or replace the
pump if necessary
The draw down is larger than
anticipated
Increase the installation
depth of the pump, throttle
the pump or replace it by a
smaller model to obtain a
smaller capacity
Replace pipes
12

Pump NRV faulty
Frequent
starts and
stops
The water level electrodes
or level switches have not
been installed correctly
Riser pipe leakage
Check and repair riser pipe
Lift pump and rectify NRV
Adjust the intervals of the
electrodes to ensure suitable
time between the cutting-in
and cutting-out of the pump.
If the intervals between
stop/start cannot be changed
automatically, the pump
capacity may be reduced by
throttling the discharge valve
changed
Pull out the pump and clean
or replace the non-return
valve
The non-return valve is
leaking or stuck half open
Long
period until
water flow
after start
Increase the installation
depth of the pump, throttle
the pump or replace it with a
smaller model to obtain a
smaller capacity
The pump is oversized for
borehole
Water hammer
Fit a surface non-return valve
and a diaphragm tank on
the surface delivery piping
Loud noise
in the
pipework
Pump cavitation due to low
system head resulting in
operation at insufficient
pressure
Throttle the pump or replace
it with a lower pressure
alternative
Mechanical
damage to
pump and
motor
13

ii) Standard Warranty
General Terms
If equipment failure occurs in the normal course of service having been
competently installed and when operating within its specified duty limits warranty
will be provided as follows:-
• Up to one year - The item will be replaced or repaired at no charge.
• Over one year, less than two years - The item will be replaced or
repaired at a cost to the customer of 50% of the Davis & Shirtliff market
price.
The warranty on equipment supplied or installed by others is conditional upon
the defective unit being promptly returned free to a Davis & Shirtliff ofce
and collected thereafter when repaired. No element of site repair is included in
the warranty and any site attendance costs will be payable in full at standard
chargeout rates. Also proof of purchase including the purchase invoice must be
provided for a warranty claim to be considered.
9. TERMS OF WARRANTY
i) General Liability
• In lieu of any warranty, condition or liability implied by law, the liability of Davis
& Shirtliff (hereafter called the Company) in respect of any defect or failure of
equipment supplied is limited to making good by replacement or repair
(at the Company's discretion) defects which under proper use appear therein
and arise solely from faulty design, materials or workmanship within a
specified period. This period commences immediately after the
equipment has been delivered to the customer and at its termination all
liability ceases. Also the warranty period will be assessed on the basis of the
date that the Company is informed of the failure.
ŸThis warranty applies solely to equipment supplied and no claim for
consequential damages, however arising, will be entertained. Also the
warranty specifically excludes defects caused by fair wear and tear, the effects
of careless handling, lack of maintenance, faulty installation, incompetence
on the part of the equipment user, Acts of God or any other cause beyond the
Company's reasonable control. Also, any repair or attempt at repair carried
out by any other party invalidates all warranties.
14

INS 278C - 08/18