DAYLIFF DSD Series Installation instructions

DSD
SUBMERSIBLE BOREHOLE PUMP
Installation &
Operating Manual

PUMP SPECIFICATIONS
1.
1
2.
DELIVERY AND STORAGE 3
i Delivery
INDEX
© Davis & Shirtliff Ltd 2020
Contents herein are not warranted
3
ii Storage & Handling 3
3. PUMP ACCESSORIES 3
i Delivery Pipe 3
iii Well Head 4
4. ELECTRICAL CONNECTIONS 4
i General Information 4
5. INSTALLATIONS 6
i Pump Application 6
ii Pump Position 7
iii Pump Lowering 7
6. PUMP OPERATION 8
7. MAINTENANCE 9
8. TROUBLE SHOOTING 10
9. TERMS OF WARRANTY 13
ii Electric Cable 3

1
1. PUMP SPECIFICATIONS
Congratulations on selecting a Dayliff DSD borehole Pump. 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.
50
100
150
200
400
DSD3/50
350
DSD3/40
DSD3/30
DSD3/18
DSD3/13
DSD3/7
300
250
50
100
150
250
450
400
300 DSD5/40
DSD5/24
DSD5/56
200
350
10
30
20
40
50
0
60 ETA%
ETA%
1
1
2
2
5
5
4
4
0
0
3
3
10
20
30
60
50
40
70
PUMP HEAD (m)
3
FLOW RATE (m /hr)
3
FLOW RATE (m /hr)
ETA%
PUMP HEAD (m)
ETA%
6
PUMP HEAD (m)
ETA%
3
FLOW RATE (m /hr)
1 2 11 4
03 5 6 7 8 9 10
50
100
150
250
300
200
10
30
20
40
50
0
60 ETA%
DSD8/23
DSD8/33
DSD8/45

2
PUMP
Dayliff DSD range of Submersible Multistage centrifugal pumps are specially
designed for domestic and small scale water supply from wells and boreholes.
Material of construction include polycarbonate impellers and diffusers, cast iron
delivery and suction chambers and AISI 304 stainless steel pump housing, shaft
and shaft coupling. These quality materials together with the polycarbonate
impellers provide the pumps with excellent sand handling capabilities for a
longer life. DSD 3/7, 3/13 and 3/18 are supplied complete with 30m cable and
control box.
MOTOR
The pump is coupled to a sealed liquid cooled 2-pole asynchronous squirrel-
cage motor constructed of stainless steel. Single phase motors should be
supplied with purpose designed Dayliff SCM control boxes for operation and
protection against overload, dry running and over/under voltage. Three phase
motors require a remote DOL starter; A DAYLIFF SCT electronic Pump Controller
is recommended for comprehensive pump control including low level, motor
overload and irregular power supply protection.
Enclosure Class: IP68 Insulation Class: B Speed: 2850rpm
OPERATING CONDITIONS
Pumped liquid: Thin, clean, chemically non-aggressive liquids with a max.
sand content of 0.25%
0
Max. Water temperature: +35 C
Max. immersion depth: 150m
Min. borehole diameter: 110m
PUMP DATA
Model Power Current
(A)
kW HP
DN
(”)
Dimensions (mm) Weight
(kg)
Istat
IA D
DSD 3/13 0.75
0.37
16.2
0.5
1x240
3.7
568
410
920
717
144
104
DSD 3/7
1¼
DSD 3/18 1.1
2.2
3
4
1.5
3
4
5.5 3x415
8
15
8
10
673
10474
13417
16047
1065
1564
1923
2261
17
4
27
32
38
DSD 3/30
DSD 3/40
DSD 3/50
Voltage
(V)
DSD 5/40 4
2.2
5.5 10 7
31x240 15 4
1454
957
2111
1474
36
26
DSD 5/24
1½
DSD 5/56 7.5 10 17 6.5 19 15 2787 47
3x415

Model Motor Current
(A)
kW HP
DN
(”)
Dimensions (mm) Weight
(kg)
Istat
IA D
DSD 8/33 5.5
3
7.5 13 6.3
486.9
1586
1093
2264
1675
35
28
DSD 8/23
2
Voltage
(V)
3x415V
DSD 8/45 7.5 10 17 6.5 1955 2791 49
Fig. 1 Pump position during storage
2. DELIVERY & STORAGE
i) Delivery
DAYLIFF DSD 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. The cable and
control box should be checked to ensure they are intact before installation.
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.
3. PUMP ACCESSORIES
i) Delivery Pipe
The delivery pipe should be matched to the pump outlet unless the
installation demands. A flexible delivery hose may be used for the majority of
applications while G1 pipes in 6m or 3m lengths may be used where the
pump is installed at greater depths and pumping to higher heads.
ii) Electric Cable
Proper selection of power cables should be done in accordance to standard
sizing table. The cable should be checked for physical damage arising from
transport and storage if damaged, they should be replaced before
installation.
3

Fig. 2 Wellhead layout
i) General Information
WARNING
WARNING
WARNING
4. ELECTRICAL CONNECTIONS
Do not lift or lower the pump by using power cables,
otherwise damage will occur.
Before starting work on the pump, make sure that the
electricity supply has been switched off and that it
cannot be accidentally switched on.
iii) Wellhead
A robust sealed well head plate should
be fitted on the borehole top to
prevent borehole contamination, a
DAYLIFF well head assembly being
recomm e n d e d . The a s s e m b ly
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.
The electrical connection should be carried out by an
authorised electrician in accordance with local
regulations.
4
WARNING
Motors
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.
Correct earthing for all borehole pump installations is
essential for safety and pump motor protection. Consult a
licensed electrician for advice on requirements.
WARNING

45
ŸThe required voltage quality for DAYLIFF DSD 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 approximately 3X
maximum rated motor current.
ŸDSD3/7, 3/13 and 3/18 are supplied with control unit and should be installed
with a Dayliff AVS.
ŸDayliff SCM/SCT electronic pump controllers are recommended for
comprehensive pump protection of the other models.
ŸGenerally recommended unless water availability is assured is low level
protection to prevent the pump running dry. Conventionally this is provided by
a relay connected by cable to sensors in the borehole water, though wireless
electronic protection is also available.
ŸDSD 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.
Fig. 3 Wiring diagram
Black
Blue
Yellow/Green
Black
Blue
Yellow/Green
Brown
M
1~
C
CPE
A
M
NL

46
Fig. 4 Wiring diagram for SCT
Function
Switch
R
“Store” button
Check
Valve Valve
Upper
Probe
Lower
Probe
S T U V W 1 2 3 4 5 6
Com Probe
Water Well
5. INSTALLATION
i) Pump Application
ŸDifferent pump models are available and the pump selected must be matched
to the well output to provide optimal operating performance. Where
installation is in a borehole refer 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 -110mm.
ŸMaximum Pump Immersion Depth - 150m.
ŸPumped liquid should be clean, thin and non-explosive containing no solid
particles or fibres. Sand content should not exceed 0.25% or else pump life will
be reduced and any warranties will be invalidated.
0
ŸLiquid temperature should not exceed 35 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 according to
deration factors.

The immersion depth should not exceed 80m for the smaller
1phase pumps and 150m for larger pumps and be atleast 3m
above the borehole bottom
L1.Immersion depth below static water
level
Fig. 5 Borehole Measurements
L5
L4
L1
L2 L3
L6
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.
ŸIf the pump is installed in a well or in open water with no
water flow past the motor it is important that a flow
sleeve is fitted to enhance motor cooling.
Not
Allowed
Fig. 5 Pump Axis Limits
Allowed
WARNING
Never allow the pump to operate dry, without water.
If a plastic delivery pipe is used a steel or nylon rope to hook
the pump is required during lowering and lifting.
WARNING
ii) Pump Position
Borehole Measurement Parameters
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
47
NOTE

4
8
ŸWhen positioning the pump it is important to ensure adequate motor
cooling through water flow past the motor.
ŸIt is recommended that the complete pump is submerged at least 3m below
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.
iii) Pump Lowering
For shallow boreholes (less than 50m) a manual tripod arrangement can be
used while a more elaborate lowering mechanism may be required for
deeper boreholes. When moving the pump the following procedures should
be followed:-
ŸBefore pump lowering it is important to check well depth and straightness
to ensure there is unobstructed passage. The pump shall be carefully
lowered into the well and if an obstruction is encountered the pump
should be removed and the cause investigated to avoid pump or cable
damage.
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.
6. PUMP OPERATION
When the pump has been connected correctly and is submerged in water proceed
as follows:-
ŸThe pump should 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 it should be raised until it is in a position of
clear water availability. Alternatively a borehole problem is indicated and
the driller should be consulted.

9
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
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.
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.
Ÿ The controller should be connected by a qualified technician and the
pump must be connected according to the wiring diagram.
7. MAINTENANCE
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.
ŸInterpretations of various operating problems are given in the Trouble
shooting 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 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.

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
8. TROUBLE SHOOTING GUIDE
The protection relay has
tripped due to power Contact the power supply
provider
10

11
The pump
runs but
gives no
water
The non-return valve is stuck
in its shut position
The discharge 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
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 with
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 six months - The item will be replaced or repaired at no
charge.
• Over 6 months, less than one year - 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.

INS393B-02/20
www.davisandshirtliff.com